Success Story

Modernizing Hydrogen Recycle Compressor Controls for Safer, Smoother Operations

See how a leading petrochemical company overcame critical control limitations to improve system stability, safety, and reliability, without replacing field hardware

A global petrochemical manufacturer faced mounting issues with its hydrogen recycle compressor control system. Outdated logic and limited auxiliary control lacked integration, advanced surge protection, and fallback strategies, posing risks to performance and safety. The big challenge was to complete a full control system retrofit in just eight weeks, with minimal disruption to operations.

CCC delivered a fast-tracked retrofit using its Prodigy® control platform. Designed for flexibility, maintainability, and precision, Prodigy® enabled CCC to implement advanced antisurge and performance control, integrate auxiliary logics, and reuse the client’s existing infrastructure. Despite missing performance curves and outdated documentation, CCC completed the upgrade within the client’s 2.5-day shutdown window by executing blind surge testing and converting legacy Siemens logic into a more maintainable format.

Read the full story to see how CCC’s retrofit improved startup reliability, control availability, and process stability, without requiring new instruments or field wiring. The new control architecture also lays the foundation for future automation and constraint-based control.