Faced with significant process instabilities and inefficiencies at their gas plant, the customer contacted CCC for a comprehensive turbomachinery solution to improve production, ensure stability, and drive long-term operational success.
CCC set out to equip the manufacturer’s hydrogen cycle compressor with Prodigy — a turbomachinery control platform that leverages more than 50 years of specialized expertise to set a new standard for control innovation.
The Challenge
A Major petroleum company in Egypt was grappling with severe operational challenges as its gas plant. These challenges included high fluctuations feed flow rates and molecular weight, which were causing frequent offloading and flaring. These issues led to inefficiencies and safety concerns.
The existing control scheme, with anti-surge valves perpetually open, compromised plant efficiency and limited the operating range, creating a bottleneck that stifled production capacity and reliability.
The Solution
CCC was selected for its proven expertise in delivering robust turbomachinery solutions. Our team collaborated closely with the customer, from initial studies through implementation, to ensure a seamless upgrade. Key components of the solution included:
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Retrofit of Existing Controls
The existing anti-surge and performance controls were retrofitted, redesigning the scheme to separate anti-surge valves from performance control, enabling precise and effective machinery management.
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Installation of Suction Throttle Valve
A new suction throttle valve, absent from the original setup, was designed, sized, supplied, and installed. This valve played a pivotal role in stabilizing operations and optimizing the control scheme.
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Advanced Control Systems
Replacement of the old controllers with CCC's Prodigy® Control System for anti-surge and power control, and integration of a third-party controller for shutdown loops.
The Results
CCC’s intervention led to transformative results:
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Increased Production
The gas plant achieved stable operations with effectively managed anti-surge valves, resulting in a remarkable production increase of over 43 MMSCFD.
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Improved Process Stability
The new control algorithms enabled better handling of feed fluctuations, significantly extending the operating range and enhancing overall process reliability.
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Energy Savings
The new control scheme and suction throttle valve reduced energy consumption, yielding substantial cost savings.
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Enhanced Safety and Efficiency
The separation of control functions and advanced diagnostics improved both safety and operational efficiency.
The customer reported a substantial improvement in process stability and production capacity, affirming CCC's position as a trusted partner in turbomachinery optimization.
Conclusion
CCC's advanced turbomachinery solutions have transformed operations at the customer's gas plant, driving increased production, enhanced stability, and significant cost savings.
Contact CCC today to learn how our advanced turbomachinery solutions can drive your success.
