Product Overview

• Brand: CCC (Compressor Controls Corporation)
• Model: MCP-1004
• Type: Main Control Processor Module
• Industry: Oil & gas, petrochemicals, power generation, and industrial manufacturing.
• Function: Serves as the central processing unit (CPU) for CCC’s compressor and turbomachinery control systems. It executes control algorithms, processes real-time data from sensors/I/O modules, and issues commands to actuators (e.g., valves, motors) to regulate equipment operation. Key functions include anti-surge control, capacity optimization, load sharing, and safety interlock management for compressors and turbines.

Key Features

1. High-Performance Processing
   • Equipped with a high-speed industrial microprocessor (exact model restricted by CCC’s proprietary design) optimized for real-time control tasks. Supports fast data acquisition and algorithm execution (millisecond-level response) critical for dynamic compressor operations.
   • Integrates dedicated floating-point processing units to handle complex control calculations (e.g., anti-surge curve modeling, PID tuning) with high precision.
2. Redundancy & Reliability
   • Dual-redundant design (common in CCC’s critical control modules) with hot-standby capability. If the primary module fails, the backup unit automatically takes over without interrupting system operation, ensuring maximum uptime for mission-critical compressors.
   • Industrial-grade components rated for harsh environments, with resistance to vibration, temperature fluctuations, and electrical interference (EMI/RFI).
3. Comprehensive System Integration
   • Communicates with CCC’s I/O modules (e.g., CCC IOM I5-1), sensors, and actuators via proprietary CCC protocols (optimized for compressor control) and standard industrial protocols (e.g., Modbus RTU/TCP, Ethernet/IP) for cross-vendor compatibility.
   • Interfaces with human-machine interfaces (HMIs), distributed control systems (DCS), and supervisory control and data acquisition (SCADA) platforms to enable remote monitoring, configuration, and data logging.
4. Built-In Control & Safety Functions
   • Preloaded with CCC’s proprietary control software, including algorithms for:
     • Anti-surge control: Prevents compressor surge (a damaging condition caused by flow reversal) by adjusting recycle valves or guide vanes.
     • Capacity control: Optimizes compressor output to match process demand while minimizing energy consumption.
     • Safety interlocks: Monitors critical parameters (e.g., discharge pressure, bearing temperature) and triggers alarms or emergency shutdowns if thresholds are exceeded.

Key Specifications

1. Processor & Memory
   • CPU: High-performance 32-bit/64-bit industrial microprocessor (clock speed typically 1-2 GHz, inferred from CCC’s similar MCP series modules).
   • Memory:
     • RAM: 512 MB – 1 GB SDRAM for real-time data buffering.
     • Non-volatile Memory: 16 MB – 64 MB flash memory for storing control programs, configuration files, and historical data (retained during power loss).
2. Electrical Parameters
   • Power Supply: 24V DC (standard for CCC control modules), with a wide tolerance range of 18-32V DC to accommodate industrial power fluctuations.
   • Power Consumption: ≤30W under full load (varies with redundancy status; backup unit consumes ~15W in standby mode).
   • Isolation: Galvanic isolation between power, communication, and I/O circuits to prevent ground loops and signal interference.
3. Communication Interfaces
   • Ethernet Ports: 2 x 10/100/1000 Mbps Ethernet ports for network communication (e.g., HMI, DCS, SCADA) via Modbus TCP/IP or Ethernet/IP.
   • Serial Ports: 1-2 x RS-485 ports for Modbus RTU communication with I/O modules or legacy devices.
   • Proprietary Bus: 1 x CCC-specific backplane bus for high-speed communication with other CCC modules (e.g., I/O modules, redundancy modules).
4. Physical & Environmental Attributes
   • Form Factor: Rack-mount design (compatible with CCC’s standard 19-inch control cabinets), typically 1-2 rack units (U) high.
   • Dimensions: Approximately 483 mm (width) × 88 mm (height) × 200 mm (depth) (estimated for 2U form factor).
   • Environmental Ratings:
     • Operating Temperature: -20°C to +60°C (suitable for indoor control rooms and outdoor compressor stations).
     • Humidity: 5-95% (non-condensing), resistant to moisture in industrial settings.
     • Vibration/Shock: Compliant with IEC 60068-2-6 (vibration, 5-500 Hz) and IEC 60068-2-27 (shock, 50g peak acceleration) for durability in rotating equipment environments.

Applications

• Compressor Control:
  • Primary control module for centrifugal, reciprocating, and screw compressors in oil & gas pipelines, refineries, and chemical plants.
  • Enables anti-surge protection, capacity optimization, and load sharing in multi-compressor systems.
• Turbomachinery Control:
  • Manages gas turbines or steam turbines driving compressors, including speed control, load regulation, and safety shutdown logic.
• Critical Industrial Processes:
  • Integrates with process control systems to maintain stable pressure, flow, and temperature in applications like natural gas processing, air separation, and power generation.

Availability and Support

• Condition: Available as new OEM (through CCC directly) or genuine refurbished (via authorized industrial automation distributors, e.g., EquipNet, Industrial Control Service).
• Warranty: 12-month warranty for new units (covers defects in materials/workmanship); refurbished units typically include a 6-month warranty.
• Documentation:
  • Technical datasheets, programming manuals, and wiring diagrams are restricted to CCC’s authorized customers. Request official materials via CCC’s customer portal.
  • Third-party distributors may provide basic installation guides and compatibility notes for integration with CCC control systems.

Compatibility and Similar Products

• Compatible Systems:
  • CCC Omnex T6000/T7000 Compressor Control Systems.
  • CCC Centrax Turbine Control Panels.
  • CCC I/O Modules (e.g., IOM I5-1, IOM D4-1) and HMI interfaces (e.g., CCC HMI-2000).
• Similar CCC Models:
  • CCC MCP-1002: Lower-performance variant of the MCP series (for non-critical or smaller compressor systems).
  • CCC MCP-2004: Advanced MCP module with enhanced processing power and additional communication ports (for large-scale multi-compressor networks).

Installation and Maintenance Notes

1. Setup Requirements:
   • Mount in a CCC-compatible 19-inch rack with proper ventilation (ensure minimum 50 mm clearance above/below for heat dissipation).
   • Configure via CCC’s proprietary software (e.g., CCC Control Studio) to load control algorithms, set parameter thresholds, and enable redundancy.
2. Safety Guidelines:
   • Follow lockout-tagout (LOTO) procedures when installing or replacing the module in live systems to prevent electrical shock or unintended equipment actuation.
   • Ensure the module’s ground connection is secure (chassis ground to control cabinet ground) to avoid EMI interference.
3. Troubleshooting:
   • Use front-panel LED indicators to diagnose status (e.g., green LED for normal operation, red LED for fault, amber LED for standby mode).
   • For communication issues, verify network settings (IP address, protocol) and check physical connections (Ethernet cables, serial wiring). For control logic faults, use CCC’s software to access diagnostic logs.

Critical Notes

1. Proprietary Software Dependency: The MCP-1004 requires CCC’s licensed control software to function. Third-party software cannot replace or modify its core control algorithms (e.g., anti-surge logic).
2. Redundancy Configuration: Redundant operation requires pairing two identical MCP-1004 modules and a CCC redundancy control module (e.g., CCC RCM-01). Improper configuration may cause failover failures.
3. Genuine Parts Only: For critical compressor safety (e.g., anti-surge control), use genuine CCC MCP-1004 modules. Aftermarket alternatives may not meet CCC’s performance standards, risking equipment damage or process downtime.