Referenzprojekt: Verdichterstation Waidhaus und Wildenranna

Auftraggeber: MEGAL / OGE
Objekt: Verdichterstation Waidhaus

The Waidhaus compressor station is a strategically important gas transport facility, equipped with an additional steam process for efficient heat recovery. Between 2021 and 2022, Elpro GmbH successfully carried out a comprehensive modernization project that brought the station up to state-of-the-art technology and optimized it for long-term performance.

The facility handles an impressive flow volume of 2.5 million standard cubic meters per hour (2.5 x 10⁶ Nm³) and features five high-performance transport units connected in series, with a total output of 91 MW. Three steam generators each produce up to 25 tons of steam per hour, which is used to drive a 14 MW steam turbine with turbo compressor. The turbine inlet pressure ranges from 35 to 50 bar, while the outlet pressure can be increased to as much as 78 bar.

The centerpiece of the modernization was the complete renewal of the control system. Elpro implemented a modern, virtualized station control system consisting of operator and engineering stations along with a high-performance archive server, all running on two redundant host computers. The existing redundant AS 417-4-2H controllers were replaced by the much more powerful AS 410-5H system.

The established SIMATIC PCS7 control system ensures reliable and safe operation. Redundant controllers for the station and steam turbine, a fully redundant Ethernet system bus, and Profibus-based remote I/O technology all ensure maximum system availability and fail-safety.

Thanks to Elpro GmbH’s modernization measures, system availability was significantly increased, while efficiency and energy savings were greatly improved. The project was completed on schedule and to the full satisfaction of the client, MEGAL / OGE.