PT TRANSPORTASI GAS INDONESIA

TGI Operation Technical Sharing Forum 2012

Challenges & Perspective on Compressor Integrity

10 Years Compressor Operation (2002 2012)

Presented by PT Transportasi Gas Indonesia Regional Office-2 Belilas Compressor Station Pekanbaru, 21 November 2012

Presentation outline :

Compressor Operation in 2002 to 2012

Technical challenges

Perspective on Compressor Integrity

TGI Operation Technical Sharing Forum 2012

Compressor Operation in 2002 to 2012 Man Power

TGI Operation Technical Sharing Forum 2012

Compressor Operation in 2002 to 2012 Flow & Compressor Discharge Pressure

1080 1020 960 900 840 780 720 660 600 540 480 420 360 300 240 180 120 60 0 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Station Flow, Average

Station Discharge Pressure, Average

TGI Operation Technical Sharing Forum 2012

Technical Challenges :

1. Equipment Failure GTGC A, Engine Flame Out GTGC A, GP Over speed

2. Product Obsolete Gas & Detection System, Power Supply GTGC PLC product

TGI Operation Technical Sharing Forum 2012

Technical Challenges :

1. GTGC A, Engine Flame Out Downtime : Cause :

Often shutdown and re-start @11:30 am since Dec 2009 Feb 2010 1 of 10 units Battery 110VDC for Control Console GTGC A drop voltage
EGF

Batteries

Rectification:

TCS Panel

DC PUMP

Checking all batteries and perform battery replacement. TGI Operation Technical Sharing Forum 2012

Technical Challenges :

2. GTGC A, GP Over speed Downtime :

0.83Hrs unavailable unplanned on March 11, 2012 Often shutdown and re-start since Nov 2011 April 2012

Cause :

Spike at GP over speed probe sensor due grounding shield for GP Probe cable connection failure

Rectification:

Ensure grounding shield connection system are correct base on Electrical Schematic

TGI Operation Technical Sharing Forum 2012

Technical Challenges :
GD PANEL

1. Gas & Detection System, Product Obsolete Cause : Year of 2009 Siemens Cerberus GD System Power Supply 24VDC Fault Power Supply Parts PRODUCT OBSOLETE

GD PANEL POWER SUPPLY

TGI Operation Technical Sharing Forum 2012

Technical Challenges : Road Map Gas Warning System

PREVIOUS

CURRENT

Source:

TGI Operation Technical Sharing Forum 2012

Technical Challenges :

Rectification: Temporary Modified Power Supply 24VDC Source from UPS 24VDC

Siemens Cerberus Gas Detection Control System UPGRADING

TGI Operation Technical Sharing Forum 2012

Technical Challenges :

2. GTGC Control Net Product Obsolete Downtime : 583 Hours since May 1, 2009 to may 25, 2009 Cause : Module Flex I/O ZF 2080 Node 8 Error

TGI Operation Technical Sharing Forum 2012

Technical Challenges :

Rectification: Step 1. Replace Module Flex I/O ZF 2080 Node 8 (Last Spare Part)
Rockwell Automation Information :

Control Net 1.25 Protocol, PLC5 40C, Since 2003 PRODUCT OBSOLETE
http://www.ab.com/silver/communications/controlnet125.html:
The Silver Date for these ControlNet 1.25 products is December 31, 2003. As with any discontinued Rockwell Automation product, and depending on component availability, it is our goal to provide repair services and technical support for these products for at least seven years. If a migration path is required, Rockwell Automation offers upgrades and other new ControlNet 1.5 products with current functionality.

TGI Operation Technical Sharing Forum 2012

Technical Challenges :

Solar Turbines Product Information Letter (PIL 180) Turbotronic 3MX, since 2003 PRODUCT OBSOLETE

TGI Operation Technical Sharing Forum 2012

Technical Challenges :

Rectification: Step 2.

UPGRADING SYSTEM
CONTROL NET 1.25 PROTOCOL, PLC5 40C

CONTROL NET 1.5 PROTOCOL, PLC5 40C 1.5

RETROFIT TURBOTRONIC CONTROL SYSTEM

TGI Operation Technical Sharing Forum 2012

Perspective on Compressor Integrity :

COMPRESSOR INTEGRITY
Manage Spare Parts (Inventory) Predictive Maintenance Root Cause Failure Analysis Product Update and Upgrade

SPECIALIST TEAM

JCS

SCS

BCS

TGI Operation Technical Sharing Forum 2012