Seven Ruston TB4000 Compressor Control Upgrades at the Apache Forties Field

Apache is one of the world’s top independent oil and gas exploration and development companies. Its goal is to provide oil and natural gas for the purpose of advancing the quality of human lives.

To support Apache in its mission, HPI upgraded the turbine and compressor controls for seven Ruston TB4000 gas turbines driving Dresser-Rand NGL compressors. The HSDE DIGICON® controllers were upgraded with HPI’s Replacement DIGICON Units (RDU™). These units are located on the Apache Forties Field Platform, which is located in the United Kingdom sector of the North Sea. The upgrade consisted of a replacement control panel with governing and turbine sequencing protection for the units. Compressor controls included anti-surge, load share, and valve sequencing. The new control panel was designed specifically to fit where the HSDE DIGICON equipment was located.

An HMI was located on the control panel door to provide the user with all the necessary control and monitoring functionality. This HMI was expanded to provide additional diagnostics to improve the fault finding and troubleshooting capabilities of the system.

The upgraded software is a FlexLogix system which provides a distributed approach to industrial control. This system is a member of the Logix Platforms, which is part of Rockwell Automation’s integrated architecture. This means that Apache will get the maximum in control integration, program reuse, communication flexibility, and overall ease of use. By using FlexLogix, Apache will spend less on setup, operation, and maintenance.

The software upgrade comes with a MicroLogix™ 1100 controller. This device is used to protect the system from overspeed and over temperature. Each controller comes with 10 digital inputs, 6 digital outputs, and 2 analog inputs.

HPI also provided a new enclosure for the power supply module. The new 19” enclosure provided recessed mounting for the MCBs and a new
Perspex hinged door on the front to provide better protection and prevent accidental operation of the MCBs. This enclosure was designed to fit into the same location as the old MCBs.