Atyrau Oil & Gas
Advantek Engineering: A Full Cycle from Control System Design to Customer Personnel Training
Advantek is a dynamically developing company in Kazakhstan’s engineering services market. With extensive experience and deep expertise in industrial automation for the oil and gas industry, the company provides a full cycle of modern solutions, from the modernization and expansion of existing systems to the automation of new facilities of any complexity.
Over 30 Years of Experience and Expertise
Advantek has been successfully operating in the CIS market for over 30 years as a developer and supplier of industrial automation solutions. The company’s primary focus is the development of control and regulation systems for gas turbine engines, compressor units, and turboexpander systems.
The company’s history dates back to 1993, when it developed an automatic control and regulation system for gas turbine engines. This system successfully competed with foreign manufacturers, and through long-term operation in gas transportation applications, it earned a reputation as the most reliable control system.
At the heart of the system is a multi-loop software-based fuel regulator that incorporates a mathematical model of a gas turbine engine. It is the most stable, reliable, and fast regulator, featuring adaptive settings for various operational modes of gas and steam turbines.
Over 200 control systems using the software-based fuel regulator have been implemented at industrial facilities across Central Asia.
Moving Forward
Today, Advantek Engineering is a fast-growing engineering company specializing in industrial automation. The company’s core values include reliability, safety, and high efficiency in technological processes. Advantek’s key advantage lies in its team of highly qualified specialists who develop and deliver innovative solutions while continuously improving product and service quality.
Special attention is given to testing modern hardware and software solutions and collaborating with equipment manufacturers and automation solution providers.
Leveraging its extensive experience and achievements, the company offers:
- Engineering: Development of application software and complex regulation algorithms.
- Process Control System (PCS) Design: Development of systems of any complexity, from local equipment automation to large-scale PCS solutions for major technological facilities, including dispatch control systems.
- PCS Maintenance Services: Ensuring the long-term efficiency and reliability of customer systems.
- Personnel Training: Conducted through multiple training programs tailored to different skill levels, with the option to develop customized training courses.
Service Offerings:
- Comprehensive assessment of automation facilities;
- Development of documentation of any complexity (technical specifications, design documents, engineering documentation);
- Development of application software;
- Technical supervision and installation oversight;
- Commissioning services;
- Warranty services;
- Control system maintenance and personnel training.
Key Solutions
Advantek’s extensive experience in industrial automation has led to the development of several ready-made solutions for oil and gas enterprises, including:
- Automatic Control System (ACS) for gas turbine-based power units
- Software-based fuel regulator
- Control and protection system for centrifugal compressors, including the Anti-Surge Regulator (ASR)
- Group Power Regulation System (GPRS)
- Automated Power Supply Control System (APCS) for gas piston power plants
- Gas Detection System
- Automated Oil Depot Management System
- Automated Dispatch Control System for industrial facilities
All solutions are based on the expertise of highly skilled engineers and utilize state-of-the-art software and hardware from global manufacturers, including commercially available programmable logic controllers (PLCs) and SCADA software.
A particular point of pride for the company is the Fuel Regulator (FR)—a software-based mathematical system designed for controlling gas turbine engines (converted for ground use as mechanical drives). Developed using aviation engine control experience, it is protected by patent No. 2252329. The solutions embedded in the regulator are universal, enabling efficient control of all types of gas turbines for ground applications.
Structurally, the system is analogous to the latest software-based aircraft engine regulators, commonly called FADEC (Full Authority Digital Engine Control). These electronic control systems manage the engine across all flight stages and operating modes. The fuel regulator’s structure is illustrated in Figure 1.
Figure 1. Structural diagram of the fuel regulator software.
Advantages of the Software-Based Fuel Regulator:
- Minimal sensitivity to the thermophysical properties of fuel gas.
- Seamless switching when adjusting control and limitation parameters.
- High-speed response to accommodate 100% load drops.
- Comprehensive control across all operating modes, from startup to maximum power.
- Hardware-agnostic: functions effectively on various process control systems (PCS) with verified technical specifications.
The fuel regulator is compatible with gas turbine engines from different manufacturers, including LM2500 (General Electric).
Advantek has also developed a unique anti-surge protection and control system (ASPCS)—a software-based regulator that serves as a key component in the automatic control system for gas compressor units (ACS GCU).
Key Functions:
- Surge detection
- Execution of a control sequence to restore normal operation
- System recovery after a surge event
Advantages:
1. High-Speed Response.
Actions for surge detection and engine recovery must be performed within the minimum allowable time to ensure protection against damage to the flow path. Anti-surge protection parameters are configured based on the specific characteristics of each compressor.
Surge detection is performed based on the relative pressure drop behind the compressor for axial compressors or the relative airflow rate for centrifugal compressors, following OST 100932-88 recommendations. The algorithms detect loss of gas-dynamic stability (GDS) using two criteria:
- Drop in pressure or gas flow rate relative to the mean value;
- Relative amplitude of pulsation components.
Applying these criteria allows detecting GDS loss within a time frame of approximately ¼ of the surge oscillation period, ensuring activation of the engine recovery cycle, determining the moment of surge termination, and restoring nominal operating conditions.
2. Digital Filters.
The algorithm includes digital filters for processing compressor outlet pressure measurements:
- Band-pass filter for isolating the pulsation component;
- Low-frequency filter for extracting the mean value.
The filtered values are used in decision-making logic and surge recovery execution. The operating frequency bands of the filters are configured for each specific compressor, taking into account the connected pipeline volumes.
3. Advanced Diagnostics.
Real-time diagnostics tailored to customer requirements.
Trend-based diagnostics for early defect detection and/or determining the need for gas turbine engine maintenance.
The presented gas turbine engine and compressor station control solutions are outlined concisely, highlighting key advantages for improving efficiency, safety, and operational stability. For detailed information on implementation, customization for specific tasks, and technical specifications, you can always contact Advantek specialists.
Industrial automation in the oil and gas sector is a trend and a strategic necessity in today’s industrial landscape. The deployment of reliable automation solutions unlocks new growth opportunities and competitive advantages. Furthermore, control systems contribute to achieving Sustainable Development Goals. By selecting trusted industrial automation partners, companies invest in both efficiency and a sustainable future. Stay ahead of the curve, enhance productivity, and transition to an environmentally sustainable, technologically advanced production model!
Partner with Advantek
For a full range of Advantek solutions and services, visit:
https://advantek.io
For project references and case studies, please submit a request via the website.
To discuss potential collaboration, contact us in Almaty:
Mamayr Microdistrict, Afitsinao St., Bldg. 4, Apt. 1, Office 68.
Phone: +7 771 558 18 33