Project NameControl System SIL-2 Programming for Reciprocating Compressor Application
Case Study: Rotary Equipment Control
SIL-2 Compressor Control System for Reciprocating Compressor Application - Rockwell ControlLogix
SIL-2 rated PLC and SCADA solution for 4 reciprocating compressor units - Make-Up and Recycle service - delivered for Siemens Energy with end user YPF, USA.
Project Overview
Project Information
Hive Automation delivered a complete, SIL-2 rated control system automation solution for a Reciprocating Compressor application developed for Siemens Energy, with end user YPF, USA.
This project focused on ensuring precise, safe, and efficient control of four compressor units - two Make-Up service and two Recycle service - in a critical process environment.
Our scope covered end-to-end PLC, HMI, and SCADA software development, rigorous in-house testing, and successful site commissioning.
The system was built on a redundant SIL-2 Rockwell ControlLogix (1756-L72) architecture - providing hot-standby CPU redundancy, redundant I/O for critical signals, IPC-based operator workstations, and local HMIs at each compressor unit for on-site operation.
Project Details
Project Delivery Snapshot
Completion DateOctober 2022
Scope of WorkPLC | HMI | SCADA Programming | Testing | Site Commissioning
LocationUSA (engineered and tested in OEM Place)
System Architecture
Technical Architecture
Redundant SIL-2 Rockwell ControlLogix (CPU 1756-L72) with redundant I/O stations for critical safety signals across all four compressor units.
IPC-based operator workstations in the centralised control room, with FactoryTalk View used for SCADA and HMI development and plant-wide supervision.
Local HMIs at each of the four compressor units with Studio 5000 Logix Designer used for PLC programming, sequencing, interlocks, and shutdown logic.
Delivery Scope
Scope of Work & Key Deliverables
- Control system architecture design - SIL-2 redundancy scheme, panel GA, and wiring drawings
- PLC programming - Rockwell ControlLogix (Studio 5000) for all 4 compressor unit sequences
- HMI development - local panel HMIs for on-site compressor operation
- SCADA integration and deployment - FactoryTalk View centralised monitoring for all 4 units
- In-house Factory Acceptance Testing (FAT) and SIL verification activities
- On-site commissioning at the USA facility
Project Impact
Challenge & Outcome
Challenge
Engineering a unified SIL-2 control system for four independent compressor units - each with its own startup permissives, anti-surge sequences, vibration monitoring, and ESD logic - required careful cause-and-effect documentation, SIL verification, and a FAT that validated all shutdown functions against the safety requirements specification.
Outcome / Result
SIL-2 Rockwell ControlLogix compressor control system successfully commissioned for YPF, USA, in October 2022. All four compressor units - Make-Up and Recycle service - now operate under unified centralised SCADA with local HMI panels at each unit.
Process Coverage
Processes Automated
- Four reciprocating compressor units under one unified SIL-2 control architecture for Make-Up and Recycle service.
- Safety-critical functions including vibration trip, high-pressure shutdown, lube oil low-pressure, and ESD with cause-and-effect matrix programming and bypass management.
- Anti-surge sequences, startup permissives, shutdown logic, and alarm handling validated through FAT and SIL verification activities.
- Centralised SCADA visibility with local HMI panels at each compressor unit for on-site operation and diagnostics.
I/O Summary
I/O Capacity & Configuration
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Frequently Asked Questions
Rotary Equipment Control Automation Questions, Answered
SIL-2 (Safety Integrity Level 2) means the safety functions within the control system - such as high-pressure shutdown, vibration trip, and ESD activation - achieve a Probability of Failure on Demand between 10^-3 and 10^-2, as defined by IEC 61511 and IEC 62061. It requires redundant hardware, verified logic, and documented SIL assessment.
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