ABB Lummus Global B.V.

120.011 Dept./Sect.

04217 Project

E-15100-TN-5306-0001 Document Number

THIS DOCUMENT/DRAWING IS THE PROPERTY OF ABB LUMMUS GLOBAL B.V. INCLUDING ALL PATENTED AND PATENTABLE FEATURES AND/OR CONFIDENTIAL INFORMATION AND ITS USE IS CONDITIONED UPON THE USER’ S AGREEMENT NOT TO REPRODUCE THE DOCUMENT/DRAWING, IN WHOLE OR IN PART, NOR THE MATERIAL DESCRIBED THEREON, NOR TO USE THE DOCUMENT/DRAWING FOR ANY PURPOSE OTHER THAN AS SPECIFICALLY PERMITTED IN WRITING BY ABB LUMMUS GLOBAL B.V.

SHELL EASTERN PETROLEUM (PTE) LTD. SINGAPORE SHELL ECC PROJECT

STEAM PRODUCTION & DISTRIBUTION CONDENSATE COLLECTION DESALINATED WATER STORAGE DEMINERALISED WATER MAKE-UP SYSTEM

PROCESS CONTROL FUNCTIONAL SPECIFICATION UNIT 15100

2.00 1.00 0.00
REV.

2006-10-31 2006-05-31 2006-03-10
DATE

Revised Approved for Design Approved for Design ORIGINAL DOCUMENT
DESCRIPTION

RVO RVO RVO
PREPARED

GRI GRI GRI
CHECKED

GDS GDS GDS
APPROVED

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.DOT

PCFS NEM_R2.doc

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STEAM LOAD CONTROL PICA-070.3.3.2.00 Rev. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. Y-200.ABB Lummus Global B.3 1.DOT PCFS NEM_R2. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. 04217 Project E-15100-TN-5306-0001 Document Number 2./Sect.3. 1.1. UC-400.8 1.6 2.3 1.4 LGN SREP 04-3001-02.4 1.4 2.2.1 2. A-15101/2/3.1 1.1. 3.4.1.1.2.doc Page 2 of 92 .2 1.2.10 1.008 (Rev 0. HIC-200. 2. Y-100.3 1. HIC-300.5 BACKGROUND PROCESS INFORMATION PROCESS AND PROJECT STEAM AND POWER GENERATION / DISTRIBUTION SYSTEM Super High Pressure (SHP) Steam High Pressure (HP) Steam Medium Pressure Desuperheated (MPD) Steam Medium Pressure Desuperheated (MPD) Steam Low Pressure (LP) Steam Low Pressure Desuperheated (LPD) Steam Letdown Stations Steam Boilers Power Generation System Blowdown and Flash Drums CONDENSATE TREATMENT AND RECOVERY SYSTEMS Deaerators PCC NCC MP Condensate HP Condensate Condensate Treatment DESALINATED WATER DEMINERALISED WATER 4 4 6 6 6 6 6 6 6 6 7 7 7 7 7 8 8 8 8 8 9 10 2.4 DETAILED CONTROL NARRATIVES STEAM BOILERS.6 1.7 CONTROL DESCRIPTION STEAM SYSTEM General SHP Steam Header HP Steam Header MP Steam Header MPD Steam Header LP Steam Header LPD Steam Header 11 11 11 11 12 12 13 13 13 3.2.6 1.2 1.3.4 1.011 Dept.3 3.V.5 1.2.2.1 1.1 2.7 1.4.3 2.2.2 2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.1. HS-401. HS-098.3.1.4.1 3. Table of Contents 1. UC-401 Objective Functional Description Operational and Implementation Aspects History 14 14 14 14 14 14 15 16 3.3. PICA-071.2.5 2.2 3.1 1.1. Y-300.4.2.9 1.5 1.2 1.4 1. HIC-100.

LIC-401.7.4 3.1 3.3 3.8.7.13 LGN SREP 04-3001-02.2 3. V201 – FC172.2 3.11.9. HAH10AA424.1 3.V.10.4 3.1 3.PIC302.doc Page 3 of 92 .6. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.6.1 3. LBA10AA404.4 3.4 3.011 Dept. HS-023 Objective Functional Description Operational and Implementation Aspects History BOILER COMBUSTION AIR CONTROL HLA10AA001.1 3.3 3. GAC10AA011 .9 3. LAE10AA014 – TC205. PRESSURE CONTROL PICA-063. PICA-014. HAD10AA460 Objective Functional Description Operational and Implementation Aspects History DRAWINGS DOCUMENTS 47 47 47 48 49 52 53 53 53 53 54 58 59 59 59 59 61 64 91 91 3.9.6.10 3. HAD10AA470.3 3.12 3.11.9. TICA-005.ABB Lummus Global B.1 3.5.10. 3.4 3.1 3. TC206 Objective Functional Description Operational and Implementation Aspects History BOILER DRAIN AND BLOWDOWN CONTROL HAH10AA404. V502 – PDC182 Objective Functional Description Operational and Implementation Aspects History 17 17 17 17 18 19 24 24 24 24 25 30 31 31 31 31 33 39 BOILER STEAM DRUM LEVEL AND ECONOMIZER INLET TEMPERATURE CONTROL40 LAB10AA022 – FC101 LC101.11.3 3.6.3 3.7.TC401.5 3.4 3.2 3. FIC-502.8.2 3.2 3.11.2 3.8.10. XC504 Objective Functional Description Operational and Implementation Aspects History GAS/FUEL OIL CONTROL V102 – FC155. TIC301 Objective Functional Description Operational and Implementation Aspects History BOILER STEAM DESUPERHEATER TEMPERATURE CONTROL LAE10AA014 – TC203.11 SHP/HP STEAM DESUPERHEATER.8 3.8.4 3.DOT PCFS NEM_R2.5. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.00 Rev. V302 – PDC165./Sect.7 3.5. J-15101A/B.3 3. HAD10AA471 .3 3.6 3. 04217 Project E-15100-TN-5306-0001 Document Number 2.9. PY-014.008 (Rev 0. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.5.TIC-103 40 Objective 40 Functional Description 41 Operational and Implementation Aspects 42 History 46 BOILER START-UP PRESSURE CONTROL LBA10AA051 . LAB10AA032 .2 3.7. TC204.10.

MP steam is also used in the flare. Deaerators and for stripping purposes. which is used to drive large turbines. polished and used as BFW: • ECU • U & GF (except LPS users) • ECC Jets/Tracing • C4SHU LPD Steam Users • PHU • BEU-1 LPS Users LGN SREP 04-3001-02. and three Steam Boilers. MPD steam is required for several heat exchangers/reboilers in the PPS and LOP. In addition. in the LOP. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.V./Sect.DOT PCFS NEM_R2. pumps and fans. heating coils. The condensate treatment systems collects all the returned condensate streams and can be divided into four categories: • HP return condensate which is normally clean and not likely to be contaminated is recycled to the Deaerators via a HP condensate flash drum and via the MP condensate system without any further treatment. • Normally Clean Condensate (NCC) from surface condensers PCC is collected in the PCC Flash Drum from the following sources. 04217 Project E-15100-TN-5306-0001 Document Number 2. and by extraction from the C3-REF Compressor – K-11501. LP steam is produced by various backpressure turbines. for boiler soot blowing and to drive smaller turbines. Low Pressure Desuperheated (LPD) steam is produced by desuperheating of LPS steam. 1. MP steam is also used as atomizing steam. Medium Pressure (MP) steam is mainly extracted from the Power Generator and used for process heat exchangers in all the process units. 1.doc Page 4 of 92 . High Pressure (HP) steam is extracted from the Cracked Gas Compressor turbine and used for various heat exchangers. Medium Pressure Desuperheated (MPD) steam is produced by desuperheating MPS steam. LPD steam is required for several heat exchangers/reboilers in the LOP. LP steam is used in all process units and offsite systems in heat exchangers. will generate Super High Pressure (SHP) steam. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.1 BACKGROUND PROCESS INFORMATION PROCESS AND PROJECT The ten Cracking Heaters in the LOP. smaller turbines and a number of pumps.008 (Rev 0. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. Pressure letdown stations are provided from higher pressure to (the next) lower levels. • Potentially Contaminated Condensate (PCC) from condensed LP/MPD steam. pressure letdown is done as much as possible via the turbines and the amount of steam which is letdown via the letdown/desuperheater stations is minimized. and by the Quench Oil/LP Steam Exchangers E-11133 A/B.00 Rev. During normal operation. The remainder is produced via letdown of MPS.ABB Lummus Global B. • MP return condensate which is normally clean and not likely to be contaminated is recycled to the Deaerators via a MP condensate flash drum without any further treatment.011 Dept.

008 (Rev 0. Steam Condensate Cooler E-15613 • Charge Gas Compressor.011 Dept. 04217 Project E-15100-TN-5306-0001 Document Number 2. NCC is collected in the Condensate Surge Tank T-15101 from the following sources and used as BFW: • Turbine Steam Condenser E-151910 • Ethylene Refrig Compressor./Sect. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. It can also be sent to the Waste Water Equalisation Tank. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. The Demineralised Water is pumped from the tank to: • Continuous BD Drum Interchanger • Condensate Treatment Package • Waste Water Neutralisation Sump The regenerant waste streams from the PCC/NCC treatment are sent to the waste water neutralisation sump before being pumped to the Plant Outfall. Steam Condenser E-11212 • MP Condensate Trim Cooler E-15107 • Ethylene Refrig Compressor. Steam Condensate Cooler E-15513 • Treated PCC from Condensate Activated Carbon Filters V-15104A/B MP Condensate is collected in the MP Condensate Flash Drum V-15102 from the following sources and used as BFW: • PHU Users • BEU-1 Users • MP Condensate/Process Water Exchanger E-1132 • ECU Users HP Condensate is collected in the HP Condensate Flash Drum V-15103 from the following sources and is recycled to the MP Flash Drum: • E-13206 in the BEU-1 • Drier Regeneration Gas Heater E-11214 Desalinated water is imported from the Bukom Refinery’s desalination plant and stored in the Desalinated Water Storage Tank.ABB Lummus Global B. or it is sent to NCW. if required.00 Rev. LGN SREP 04-3001-02.DOT PCFS NEM_R2.V.doc Page 5 of 92 . The Desalinated Water is used to: • Supply Desalinated Water to the Demineralised Water Package • Supply Desalinated Water to Industrial Water Distribution (Not normal flow) • Supply Desalinated Water to the maintain Fire Water ring main pressure (Not normal flow) • Supply Desalinated Water to the Fire Water Pumps (Not normal flow) The feed to the Demineralised Water System consists of Desalinated Water. The Demineralised Water System sends Demineralised Water to the Demineralised Water Storage Tank.

/Sect.4 Medium Pressure Desuperheated (MPD) Steam MPD steam is extracted from the MP steam system and used: • for the MP condensate collection system.00 Rev. 1. • to drive an air compressor turbine. 1. • to support the LP steam system.7 Letdown Stations Pressure letdown stations are provided from each pressure level to the next lower level. equipment heating and storage tank heating. reboilers. reboilers.2. It is used to provide heating for various equipment. 1. • for export to the Bukom Refinery. MP. Deaerator. heat exchangers.011 Dept.2.3 Medium Pressure Desuperheated (MPD) Steam MP steam is extracted from the PG turbine and used: • for various equipment (e. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.2.g. 1.2. • to provide heating for the process water stripping in the LOP units. heat exchangers.ABB Lummus Global B. turbine drives) in all the process units.2. LP and LPD levels. in all the process units.DOT PCFS NEM_R2. • to support the MP steam system.2.g. 1.2 STEAM AND POWER GENERATION / DISTRIBUTION SYSTEM Steam is generated and used at six pressure/temperature levels. LGN SREP 04-3001-02.2.5 Low Pressure (LP) Steam Low Pressure (LP) steam is produced by various backpressure turbines and used to provide heating for all process units and offsite systems. e. • to drive backpressure turbines and produce LP steam. HP. 1.V. except for SHP.g. 04217 Project E-15100-TN-5306-0001 Document Number 2. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.1 Super High Pressure (SHP) Steam The LOP unit’s cracking heaters and the steam boilers generate the SHP steam. 1. From each pressure level steam can also be vented to the atmosphere.6 Low Pressure Desuperheated (LPD) Steam LPD steam is extracted from the LP steam system and also generated in the gasoline fractionator area. MPD.doc Page 6 of 92 . • for various process heat exchangers in the process units. • as dilution steam for the LOP cracking heaters.2 High Pressure (HP) Steam HP steam is extracted from the CGC turbine and used: • for various equipment in the LOP units.008 (Rev 0. The SHP steam is used to drive the following three turbines: • Cracked Gas Compressor (CGC) turbine K-11201 • Propylene Refrigeration Compressor (PRG) turbine K-11501 • Power Generation (PG) turbine GT-15190 All three turbines are designed as a combination of extraction/condensing type turbine to meet the needs of steam and power for the complex. 1. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. e. namely the SHP.

8 Steam Boilers Three steam boilers are provided to generate the required quantity of SHP steam during normal operation with all three boilers in operation. to atmosphere. One motor driven and steam turbine driven forced draft fan for each steam boiler supply the necessary combustion air. The flashed steam is re-used at a lower pressure level and the condensate is cooled and treated. 1. The collected water is cooled and re-used as wash water and dilution water. 1. LGN SREP 04-3001-02. Only one power turbine/generation set is provided. The BFW is pumped to the boilers by means of both turbine driven and motor driven pumps.008 (Rev 0.1 CONDENSATE TREATMENT AND RECOVERY SYSTEMS Deaerators Two Deaerators V-15120 A/B will be provided to produce all required BFW for the Cracking Heaters. a furnace box. an economizer. via the AOC system. before it is either re-used.10 Blowdown and Flash Drums A continuous blowdown drum V-15105 is provided to collect and flash the continuous blowdown from the three steam boilers and the twelve LOP cracking heaters. The remaining Deaerator is then operated at 100% of its design capacity. flue gas ducts and exhaust stack. The BFW is also treated by injecting various chemicals such as an oxygen scavenger. During normal operation. Desuperheaters and other steam generators. Each boiler system comprises a steam drum. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. collects the intermittent blowdown from the LOP cracking heaters.9 Power Generation System A power generator driven by an extracting/condensing steam turbine is provided to supply the electricity required. Several flash drums operating at different pressure levels are provided to receive the condensate streams from the various steam users. while the liquid is discharged to the LLOD. a superheater. Natural gas is used as primary back-up fuel for the boilers.doc Page 7 of 92 . which is produced by the LOP units as Ethylene Cracker Residue (ECR).2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. one FD fan. sent to the intermittent blowdown drum V-15104. This common intermittent blowdown drum.2. or in case of surplus. amine and phosphate.2. Steam Boilers. or disposed.ABB Lummus Global B.V.011 Dept. Any problem associated with the steam power generation will require the Cracker Complex to switch its power supply to the outside power source from the Bukom Refinery. the BFW capacity is decreased by exporting less steam to Bukom Refinery and stopping the production of electric power. 04217 Project E-15100-TN-5306-0001 Document Number 2.3 1. two Deaerators are available and are operating at about 77% of their design capacity each.00 Rev. The generator electricity produced will be integrated with the site electrical system. The flashed steam is vented. The steam boilers are normally fired with fuel oil. 1. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. In the event that one Deaerator is shutdown for maintenance and/or statutory inspection. 1. Two Deaerators are provided to produce the necessary boiler feed water (BFW).3./Sect.DOT PCFS NEM_R2. Cracked Gas Oil (CGO) is used as secondary back-up fuel and can also be blended with ECR.

/Sect.00 Rev. Due to its low pressure. 1.3.3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. driving the big compressors and the power generator. Contaminated Condensate is sent to the Emergency Basin. Contaminated Condensate is sent to the Emergency Basin via HP Condensate Emergency Cooler E-15108 where it exchanges heat with the MP Flash Drum bottoms exiting E-15106. which is sent to the Deaerators for BFW make-up. The cooled down condensate without polishing. The stream is further cooled in the PCC Trim Cooler E-15104 using Cooling Water.4 MP Condensate MP Condensate is collected in the MP Condensate Flash Drum V-15102. then discharges to ASL. The flashed steam is sent to the MP Steam header and the condensate is sent to the MP Flash Drum. operating at LPS and LPD level.doc Page 8 of 92 . reboilers.011 Dept. The cooled. 04217 Project E-15100-TN-5306-0001 Document Number 2. The Condensate Transfer Pumps P-15101A/B/C pump the tank inventory to the Condensate Treatment Package A-15140. The stream leaves the filters and goes through the Condensate Activated Carbon Filters V-15140A/B before entering the Condensate Surge Tank T-15101. installed on top of the vessel. The flashed steam is sent to the LP Steam header and the condensate is sent to the Process Water Stripper C-11105 and to the Condensate Surge Tank T-15101. flashed steam.008 (Rev 0. In this way the flashed steam is recovered and its energy is used to heat-up demin water.3. the condensate is cooled down via the MP Condensate Cooler E-15106 and the MP Condensate Trim Cooler E-15107. before being sent to the PCC Cartridge Filters S-15135A/B. The PCC bottoms.DOT PCFS NEM_R2. a TOC-analyser is installed downstream the Activated Carbon Filter. The PCC is sent to the PCC Cartridge Filter S-15135 A/B and the Activated Carbon Filters V-15140 A/B.ABB Lummus Global B. In order to minimize ingress of O2 and CO2 in the PCC/NCC. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. Flashed-off steam is condensed in the PCC Flash Drum Vent Condenser E-15101. it can be contaminated by inorganics in the case of cooling water leakage in the surface condensers. the return condensate is more susceptible to hydrocarbon contamination. heating coils etc. T-15101 is provided with nitrogen blanketing. is the feed for the Deaerators V-15120 A/B.3. LGN SREP 04-3001-02.6 Condensate Treatment Pre-treatment All rust. from the PCC Flash Drum V-15101 are pumped by the PCC Pumps P-15109A/B through the PCC/Condensate Interchanger E-15102 where heat is exchanged with Polished Condensate from A-15140.3 NCC NCC is the LP condensate returned from the surface condensers of the steam turbines. 1. Consequently. debris and hydrocarbons are removed from PCC in the pre-treatment section. 1. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.V.3. Before reaching the Surge Tank. However. Contaminated PCC can be sent to the PCC Emergency Basin. The tank material will be epoxy-coated CS. NCC is normally clean and contains no hydrocarbons. E-11214 HP Condensate is collected in the HP Condensate Flash Drum V-15103. In order to detect any hydrocarbon breakthrough. 1.2 PCC PCC is the LP condensate returned from the heat exchangers. the tank type is a Low Pressure Cone Roof storage tank. 1.5 HP Condensate HP Condensate is collected in the HP Condensate Flash Drum V-15103 from the following sources: • E-13206 in the BEU-1 • Drier Regeneration Gas Heater.

the pressure is maintained by circulating the water over the tank using the pump’s minimum flow. followed by backwashing with demin water. other inorganic compounds and humic acids are removed in the Condensate Cation Exchangers V-15151A/B and the Mixed Bed Polishers V-15151A/B. Polishing The PCC is sent through the Cation Exchangers and Mixed Bed Polishers where all hardness. the sump pump discharge valve remains closed and the water is recirculated back into the sump.00 Rev./Sect. 1. At the end of the regeneration cycle water is pumped out of the sump.5 and 9. the stream is goes to the Deaerators as BFW. and are backwashed with demin water.5 and 9.DOT PCFS NEM_R2. In order to minimise ingress of O2 and CO2 to the Desalinated Water Tank T-15105 is provided with nitrogen blanketing.008 (Rev 0. The Desalinated Water System also serves as a backup water source for the industrial water distribution system. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. In order to monitor any breakthrough of compounds which shall be adsorbed by the Polishers. LGN SREP 04-3001-02. before being sent to the Plant Outfall. The Mixed Bed Polishers are regenerated by diluted caustic / diluted acid. In the event that the downstream Desalinated Water Package is not operating. The regeneration waste is discharged and neutralised in the Waste Neutralisation Sump A-15110. A sodium-analyser is installed downstream the Cation Exchangers in order to monitor whether the cationic resin is still active. the tank type is a Low Pressure Cone Roof Storage Tank and the tank material is epoxy-coated CS. Diluted acid is made on-line by mixing demin water and 98% Sulphuric acid coming from P-16104 A/B. Consequently. The Mixed Bed Polisher exit stream is heated in PCC/Condensate Interchanger E-15102 and the MP Condensate Cooler E-15106. Diluted caustic is made on-line by mixing demin water and 50% caustic coming from P-16103 A/B.4 DESALINATED WATER This tank contains hold-up for Demineralised Water production as well as firewater storage. conductivity-analyser and a pH-analyser are installed downstream the Mixed Bed Polishers. Backwash & Regeneration Regeneration of the Cation Exchangers is done by diluted acid. or has to be regenerated. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. The pH is then adjusted and when it is between 6. Two Desalinated Water Distribution Pumps P-15105 A/B are used to transfer desalinated water to the Demineralised Water Package. After being heated. If the pH at the pump discharge is not between 6. alkalinity.doc Page 9 of 92 .V. In the event of a low pressure in the fire water system. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.011 Dept. it is pumped to the plant outfall. The Desalinated Water Distribution Pumps also keep the firewater ring main under pressure. an auto-start signal will start the standby pump. 04217 Project E-15100-TN-5306-0001 Document Number 2. a silica-analyser.ABB Lummus Global B. One pump is the operating duty pump and the other pump is the operator selected standby pump.

• Waste Water Neutralisation Sump A-15110.doc Page 10 of 92 . The dilute Acid stream and the dilute Caustic stream are sent to both the Condensate Treatment Package and the Waste Water Neutralisation Sump. one is mixed with 98% Sulphuric Acid and the other is mixed with 50% Caustic. Two streams are taken from the pumps discharge line. A stack comprises a number of dual-chambered cells. The tank type is a Low Pressure Cone Roof storage tank. Demin water is stored in the Demin Water Storage Tank T-15103. • Neutralised Waste Transfer Pump P-15108. The Demin Water Package A-15165 consists of a large number of ‘stacks’ in parallel.5 DEMINERALISED WATER The Demineralised Water System consists of: • Demineralised Water Package A-15165. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. by using pumps P-15105A/B./Sect. LGN SREP 04-3001-02. where it is neutralised by mixing with a dilute Acid and Dilute Caustic. at constant liquid level. Two of the three pumps are running and one is spare.DOT PCFS NEM_R2. • Demin Water Transfer Pumps P-15103A/B/C • Regeneration and Backwash Pumps P-15106A/B.008 (Rev 0. 04217 Project E-15100-TN-5306-0001 Document Number 2. In the event of an NCC and/or PCC/NCC failure. by the Regeneration and Backwash Pumps P-15106A/B as Backwash Water. Desalinated water is pumped from the Desalinated Water Tank to the Demin Water Package A-15165. 1. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. Within each cell there are two different chambers: a dilute (“D”) chamber through which the desalinated water is fed for de-ionisation and a concentrate (“C”) chamber used to collect and remove the extracted ions. before being pumped to the plant outfall by the Neutralised Waste Transfer Pump P-15108. the tank is operated full.011 Dept. the third demin water pump must/can be switched on to maintain sufficient make-up to the Deaerators The Demin Water is also pumped. During normal operation. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.ABB Lummus Global B. The regenerant waste streams from the PCC/NCC treatment are sent to the waste water neutralisation sump A-15110. to the Condensate Treatment Package A-15140. • Low pressure demin water storage tank T-15103.V. sandwiched between two electrodes. The tank material will be epoxy-coated CS Demin Water from the Storage Tank is pumped by the Demin Water Transfer Pumps P-15103A/B/C to the Continuous Blowdown Drum Interchanger E-15103.00 Rev.

the surplus of steam can be letdown to a lower pressure level also via a letdown station.1. LP and LPD) is controlled in each header by means of a set of pressure controllers. • Ratio control of fuel and combustion air with lead/lag function (by steam boiler vendor).DOT PCFS NEM_R2.1 General The pressure in each of the five steam headers (SHP. • On the lower side. Demin Water and returned Condensate. This makes it possible to split the operating window for each header into various pressure ranges and for each range to take specific control actions. The MPD steam header is only temperature controlled./Sect. For each steam header this approach will be described in more detail in the next paragraphs. • Neutralization control of regeneration waste from Demin and Polisher Unit prior to discharging to sea.1 CONTROL DESCRIPTION STEAM SYSTEM The main control objectives for the Steam/BFW/Condensate and Power Generation System can be summarized as follows: • Maintain the pressure/temperature in all six steam headers (SHP.008 (Rev 0.00 Rev. • On the higher side. 04217 Project E-15100-TN-5306-0001 Document Number 2. when the steam pressure is increasing too much. • Low and high pressure protective control of the fuel supply (by steam boiler vendor). except for SHP. 2. • Provide a boiler feed water control system for the steam boilers A-15101/2/3 and Cracking Heaters F-10100-11000 where the supply of water matches the steam production rate such that the level in the steam drums is maintained around midpoint.and temperature control.011 Dept. LP and LPD). HP. 2. • Provide MP Steam Export flow. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. • Provide an electrical system for the turbine-generator controls. • Adequate removal/re-use of the condensate from the blowdown drums and condensate flash vessels V-15101/2/3/4/5. when the steam pressure in the header is decreasing. 2.ABB Lummus Global B.1. MPD.2 SHP Steam Header The pressure in the Primary SHP steam header is maintained under normal operating conditions by adjusting the load of one of the steam boilers A-15101/2/3. • Provide a burner management system that includes: • Load control on steam pressure (by steam boiler vendor). Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. The general setup for the control actions is as follows: • Under normal operating conditions. when the steam pressure in the header is increasing. • Provide sufficient storage capacity for Newater. steam is vented to the atmosphere. HP. LGN SREP 04-3001-02. additional steam can be taken in via a letdown station from the higher pressure level. whereby two of them run on a fixed load approximately 75%. MP. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. MP. 2. All three boilers will be in operation. the SHP Steam header pressure is controlled by adjusting the load of the steam boilers. MP Steam and LP Steam headers are controlled by adjusting the steam extraction flows from the steam turbines and the pressure in the MPD Steam and LPD Steam is controlled by steam letdown via the desuperheaters. • Provide a control system to maintain the level and pressure in the Deaerator V15120A/B during boiler load variations. the pressure in the HP Steam. while the third boiler reacts on the pressure variations as set by the pressure controller.doc Page 11 of 92 . • On the higher side.V.

Natural gas flow rate. by manipulating the amount of BFW added to the SHP/HP Steam Desuperheater. SHP Steam is then letdown from the SHP Steam Header to the HP Steam Header via high signal selector PY-014. via high signal selector PY-022. along with the ECR/CGO flow rate. 2.doc Page 12 of 92 . The signal from the pressure controller is therefore sent to the control system of the Steam Turbine/Generator Package. Shall the pressure continue to fall in the HP Steam Header. The PV for all pressure controllers is derived from a MOO3 configuration with three pressure tappings. At the other hand in the event that the pressure in the HP Steam Header increases. LGN SREP 04-3001-02. the load of the second and third boiler is adjusted. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. which manipulates the steam extraction control valve of the Cracked Gas Compressor (CGC) Steam Turbine KT-11201. The PV for all pressure controllers is derived from a MOO3 configuration with three pressure tappings. In the event that the pressure in the HP Steam Header decreases.DOT PCFS NEM_R2. a third pressure controller PICA-069 will open the SHP/HP steam desuperheater/letdown valve J-15101A or B and SHP steam is letdown to the HP steam header.1.3 HP Steam Header There are five pressure controllers PICA-013 until PICA-017 on the HP Steam Header./Sect. If the pressure.00 Rev. the air flow rate and the stack Oxygen content.011 Dept. In the event that the capacity of the boiler under pressure control reaches a constraint (for example the boiler is at its minimum turndown or the boiler is at 100% MCR). The signal from a pressure controller PICA-070 (or PICA-071) is sent to the burner management system of the relevant boiler. in the SHP steam header becomes high. A continued increase in pressure in the HP Steam Header will result in PICA-013 opening a vent control valve to ASL. PICA-015 will open via high signal selector PY-015 SHP/HP Steam Desuperheater/letdown valve J-15109A or B and more SHP steam is then letdown from the SHP Steam Header to the HP Steam Header. TICA-006 is used to control the exit temperature of SHP/HP Steam Desuperheater J-15109A or B.ABB Lummus Global B. 04217 Project E-15100-TN-5306-0001 Document Number 2. PICA-014 will open the SHP/HP Steam Desuperheater/letdown valve J-15101A or B.008 (Rev 0. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. The temperature controller TICA-005 is used to control the exit temperature of the SHP/HP Steam Desuperheaters J-15101A or B.1. The pressure in the HP Steam Header is normally controlled by pressure controller PICA-017. reducing the steam demand on the Power Generation (PG) turbine.4 MP Steam Header There are five pressure controllers PICA-021 until PICA-025 on the MP Steam Header. PICA-016 will send a singal to high signal selector 151PY-022 in order to open HP/MP Steam Desuperheater/letdown valve J-15102A or B and HP steam is then letdown to the MP steam header.V. 2. A further decrease in the Primary SHP steam header pressure will result in the second pressure controller PICA-068.

1. TICA-011 is used to control the exit temperature of MP/LP Steam Desuperheater J-15110A or B. LGN SREP 04-3001-02. A continued increase in pressure in the MP Steam Header will result in PICA-021 opening a vent control valve to ASL. by manipulating the amount of MBFW added to the MP/LP Steam Desuperheater.6 LP Steam Header There are three pressure controllers PICA-030. The PV for each pressure controller is derived from a MOO3 configuration with three pressure tappings. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. In the event that the pressure in the LP Steam Header decreases PICA-031 will open the control valve upstream of the MP/LP Steam Desuperheater J-15103 via high signal selector PY-031./Sect. to the MP Steam Header. The pressure in the MP Steam Header is normally controlled by pressure controller PICA-025 which manipulates the steam extraction control valve of the Power Generation Steam Turbine GT-15190. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. MP steam is then letdown to the LP Steam Header. More HP steam is then letdown from the HP Steam Header.00 Rev. HP Steam is then letdown from the HP Steam Header to the MP Steam Header. PICA-031 and PICA-032 on the LP Steam Header. PICA-022 will open the HP/MP Steam Desuperheater/letdown valve J-15102A or B.DOT PCFS NEM_R2. pressure controller PICA-024 will open the control valve PICA-031CV (via high signal selector PY-031). The temperature controller TICA-015 is used to control the exit temperature of the MP/LP Steam Desuperheater J-15103.1. MP Steam is then letdown from the MP Steam Header to the LP Steam Header. 2. The PV for each pressure controller is derived from a MOO3 configuration with three pressure tappings. 04217 Project E-15100-TN-5306-0001 Document Number 2. 2. Shall the pressure continue to fall in the MP Steam Header. At the other hand in the event the pressure in the MP steam Header increases.doc Page 13 of 92 . The temperature controller TICA-010 is used to control the exit temperature of the HP/MP Steam Desuperheaters J-15102A or B.ABB Lummus Global B. via high signal selector PY-022.5 MPD Steam Header The temperature controller TICA-014 is used to control the exit temperature of the MP/MPD Steam Desuperheater J-15105. by manipulating the amount of MBFW added to the HP/MP Steam Desuperheater.1. by manipulating the amount of MBFW added to the MP/MPD Steam Desuperheater. PICA-023 will open HP/MP Steam Desuperheater/letdown valve J-15110A or B. In the event that the pressure in the MP Steam Header decreases.008 (Rev 0. The pressure in the MP Steam Header is normally controlled by PICA-030 which manipulates the steam extraction control valve of the Propylene Refrigeration Compressor Steam Turbine KT-11501. 2.011 Dept.7 LPD Steam Header There are two pressure controllers PICA-036 and PICA-037 on the LP Steam Header. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.V. A high increase in pressure in the LP Steam Header will result in PICA-032 opening a vent control valve to ASL. installed upstream the MP/LP Steam Desuperheater J-15103.

Upon increasing pressure in the LP Steam Header. The 3 boiler. The load of the boilers is maintained between 72 ton/h and 180 ton/h steam per steam boiler. 3.2 Functional Description Two of the three boilers operate at an operator set fixed steam production rate. as a percentage of MCR. and rd HIC-300 (boiler A-15103). 3. is in balancing mode. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. by manipulating the amount of MBFW added to the LP/LPD Steam Desuperheater. by controlling the SHP Steam Header pressure with the firing rate and by distributing the load over the three boilers.011 Dept. One of the two boilers at fixed rate will be set as backup balancing boiler by the operator through HS-401. The signals from HIC-100. pressure controller PICA-037 will opening a vent control valve to ASL. HIC-300. A-15101/2/3. Y-300.4 DETAILED CONTROL NARRATIVES STEAM BOILERS. 04217 Project E-15100-TN-5306-0001 Document Number 2. PICA-071 is only used when the primary SHP Steam Header controller PICA-070 is out of service due to maintenance and/or inspection. Additional provisions guarantee steam production during upsets. selected by the operator through HS-401.008 (Rev 0. HIC-200.ABB Lummus Global B. Y-200 (boiler A-15102).DOT PCFS NEM_R2. Above 180 ton/h is not allowed as this is above 100 % MCR of the steam boiler. This control scheme determines the set point for the boiler firing control scheme. The operator selects the active pressure controller.4. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. HIC-200 and HIC-300 are sent to the boiler load calculation blocks Y-100.doc Page 14 of 92 . HS-401. set by HIC-100 (boiler A-15101). Y-200 and Y-300 respectively. Y-300 (boiler A-15103) and to the Steam Generation Load Control 151UC-400 ???????? LGN SREP 04-3001-02. PICA-071. Y-200. HIC-100. HS-098. LP steam is then letdown to the LPD steam header. Below 72 ton/h (40 % MCR) is not allowed as this is the minimum stable turndown of the steam boiler. pressure controller PICA-036 will open the control valve upstream the LP/LPD Steam Desuperheater J-15104. UC-400. HIC-200 (boiler A-15102). STEAM LOAD CONTROL PICA-070. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. 3. The SHP steam pressure controller switch HS-098 receives a measurement from either PICA-070 (normally active) or PICA-071. Upon decreasing pressure in the LPD steam Header.00 Rev. UC-401 UFS E-00000-TN-2366-0026 E-15100-TN-2396-0001 UEFS E-00000-TN-2395-0075 E-15100-TN-2395-0004 Deaerator and SHP Steam Production BFW and SHPS Distribution – Sheet 10 SHP Steam Boilers 3. Y-100.V.4. The output of switch HS-098 is sent to the calculation blocks Y-100 (boiler A-15101). The temperature controller TICA-017 is used to control the exit temperature of the LP/LPD Steam Desuperheater J-15104.1 Objective The objective is to balance the steam production with the steam demand./Sect.

HIC-200 and HIC-300. The output of the direct acting. LGN SREP 04-3001-02.4.DOT PCFS NEM_R2. the boiler at fixed production will be set to backup balancing mode automatically. Y-200 and Y-300. The signal from HS-401 determines the position of the calculation blocks Y-100.3 3./Sect.00 Rev. through HS-401.3. HS-401 will switch the backup balancing boiler to balancing mode. In case that the balancing boiler trips.V. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. depending on the position of the hand switch HS-098.011 Dept. or falls below the fixed low value. proportional only controller UC-401 is sent as a bias signal to HIC-100. the controller will be made active with the setpoint having the value of the fixed high value or the fixed low value respectively. The boiler in balancing mode selects the signal from HS-098. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. The signal from the Primary SHPS Header pressure controller PICA-070 or the Secondary SHPS Header pressure controller PICA-071 is sent to the proportional-only controller UC-401.1 Operational and Implementation Aspects Operational Modes Each of the three boilers can be in either balancing mode. the controller will not be active. The boiler in fixed production mode switches in this case automatically to backup balancing mode through HS-401. The boiler in backup balancing mode operates as it is in fixed production mode. When this signal is higher than the fixed low value. the other boilers select the signal from their respective HIC.4.doc Page 15 of 92 . Selection is made by the operator through switch HS-401. PV Tracking will make the setpoint equal to the measurement. Y-200 and Y-300 is sent to the burner management system of respectively boiler A-15101. HS-401 will switch the boiler at fixed rate to backup balancing mode. The output of the three calculation blocks Y-100. In case that the boiler in backup balancing mode trips. A-15102 and A-15103. When the measurement exceeds the fixed high value. backup balancing mode. or falls below a fixed low value. but switches to balancing mode when the boiler in balancing mode trips. Control Alg Action PID Reverse PID Reverse MAN-SEL MAN-SEL PID Direct ??? ??? Valve Name - Tag Name PICA-070 PICA-071 HS-098 HS-401 HIC-100 HIC-200 HIC-300 Y-100 Y-200 Y-300 UC-401 UC-400 PV-Tracking Yes Yes Yes ??? NEM comment: Controller UC-400 to add?????? 3. 151UZ-xx2 and 151UZ-xx3 respectively. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. 04217 Project E-15100-TN-5306-0001 Document Number 2. or fixed production mode. Trip signals from the three boilers A-15101. The steam production rate of the two boilers at fixed load will automatically be adjusted in parallel when the MCR of the balancing boiler exceeds a fixed high value. A-15102 and A-15103 are sent to HS-401 through 151UZ-xx1. In case that the backup balancing boiler trips.008 (Rev 0.ABB Lummus Global B. and lower than the fixed high value.

3. 3.9 Operator Interfaces The operator can access UC-401. HIC-200 and HIC-300 only through the normal DCS interface.4.4.5 Shutdown When a trip signal from the boiler in balancing mode is received. The boiler in fixed production mode shall be switched to backup balancing mode. Y-200 or Y-300) shall be switched to select the input from the manual input station. 3. A-15102. the controller shall be set to MAN with its last good output value.doc Page 16 of 92 LGN SREP 04-3001-02.10 Special Considerations The manual input stations HIC-100.3.3.ABB Lummus Global B.3 Normal Steady State The manual input stations HIC-100.4.1. and controller UC-401 shall have high and low output limits at 180 ton/h steam and 72 ton/h steam respectively.00 Rev.4. and the switch HS-401 will always be in AUTO. The calculation blocks Y-100. the boiler in fixed production mode shall be switched to backup balancing mode through HS-401. A-15103 respectively) shall be set to 0%.7 Initialisations When the switch Y-100.011 Dept. HIC-200 or HIC-300 for boilers A-15101. The respective switch (Y-100. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.3. 3. HIC-200 and HIC-300.4. the HIC shall absorb any difference to ensure bumpless transfer.3. 3. HIC-100. 3. 04217 Project E-15100-TN-5306-0001 Document Number 2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.3. Y-200. When a boiler trip signal is received.008 (Rev 0. See for further functional requirements paragraph 3.4. HIC-200 and HIC-300. the output of the respective manual input station (HIC-100. 3. or Y-300 switches from UC-401 to the corresponding manual input station (HIC-100. the boiler in backup balancing mode will be switched to balancing mode through HS-401.4.4 Crippled Mode Operation When PICA-070 or PICA-071 becomes BAD.3.V. Y-200. 3.2 Start up N/A.3. 3.3.6 Calculations N/A. When a trip signal from the boiler in backup balancing mode is received.4.DOT . 3. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. trip signal 151UZ-HOLD from boiler A-15102 and trip signal 151UZ-HOLD from boiler A-15103 shall be connected to switch HS-401.4.8 Interfaces Trip signal 151UZ-HOLD from boiler A-15101. Operational modes.4 History Date Author Description PCFS NEM_R2.3./Sect. Y-300 will always be in CAS.4. HIC-200 or HIC-300 respectively). Controller UC-401 shall have a proportional only PID algorithm.4. Controller UC-401 cannot be switched to MAN. 3.

V.008 (Rev 0. With manual selector swith HS-023 the operator is able to select the right control valves. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. PRESSURE CONTROL PICA-063. When for low pressure protection this line of defence is not sufficient a separate pressure controller activates a second SHP to HP steam letdown through the SHP/HP Steam Desuperheater J-15109. 04217 Project E-15100-TN-5306-0001 Document Number 2. J-15101A/B. the high signal selector PY-014 sends a signal to control valve PICA-014CVB and temperature controller TICA-005 sends a signal to control valve TICA-005CVB.011 Dept. Control Action Direct Reverse Valve Name - Tag Name PICA-069 1 PICA-014 PY-014 Alg PID PID H-SEL PV-Tracking No No - LGN SREP 04-3001-02.5. 09-05-2006 GRI Original Document 3. 3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. which in turn selects one controller to operate one of the control valves PICA-014CVA/B.1 Objective To protect SHP steam header against high pressure and to protect HP steam header against low pressure.ABB Lummus Global B.00 Rev. Otherwise when manual selection switch HS-023 is in position “J-15101B”. HS-023 UFS E-15100-TN-2396-0001 E-15100-TN-2396-0003 UEFS E-15100-TN-2395-0006 Deaerator and SHP Steam Production HP Steam Distribution SHP/HP Steam Desuperheaters 3.11. corrresponding to the SHP/HP Steam Desuperheater J-15101A or J-15101B in operation. Both the controllers PICA-069 and PICA-014 send the output signal to the high signal selector PY-014. Both objectives are achieved by SHP to HP steam letdown through the SHP/HP Steam Desuperheater J-15101.5. For detail specification see section 3. regardless of the Desuperheater load. the high signal selector PY-014 sends a signal to control valve PICA-014CVA and temperature controller TICA-005 sends a signal to control valve TICA-005CVA. which manipulates the HBFW flow to the SHP/HP Steam Desuperheater J-15101A/B. PICA-014. PY-014. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.doc Page 17 of 92 . TICA-005. Pressure controller PICA-014 also operates one of the control valves PICA-014CVA/B. The protective pressure controller PICA-014 protects the HP steam header against low pressure. which manipulates the SHP/HP steam letdown flow through the SHP/HP Steam Desuperheater J-15101A/B.2 Functional Description The protective pressure controller PICA-069 protects the SHP steam header against high pressure. The objective for TICA-005 is to maintain a steady temperature for the desuperheated steam./Sect. Pressure controller PICA-069 operates one of the control valves PICA-014CVA/B. The temperature controller TICA-005 operates one of the control valves TICA-005CVA/B.5 SHP/HP STEAM DESUPERHEATER.DOT PCFS NEM_R2. In case manual selection HS-032 switch is in position “J-15101A”.

1 Operational and Implementation Aspects Operational Modes This control scheme is required to be operational during start up and normal operation.3.3. apply external reset feedback from the output of low signal selector PY-014. the mode of the pressure controller PICA-069 shall be set to MAN and its output shall be frozen.008 (Rev 0.5.5. The temperature controller TICA-005 shall be in AUTO. LGN SREP 04-3001-02.3 3.5. 04217 Project E-15100-TN-5306-0001 Document Number 2.3.5. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. 3.3. 3. 3.5.9 Operator Interfaces Operator can access tags on the DCS. 3: Describes control with manual selection switch in position “J-15101B”. If all HP steam header pressure measurements PI-012A/B/C are BAD.5.7 Initialisations To prevent the protective pressure controllers PICA-069 and PICA-014 from winding-up.3.ABB Lummus Global B.00 Rev. 3.4 Crippled Mode Operation If the SHP steam header pressure measurement PI-069 is BAD. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.011 Dept.3. TICA-005 2 HS-023 HS-023 3 PID - Direct - Yes - TICA-005CVA/ PICA-014CVA TICA-005CVB/ PICA-014CVB NOTE: 1: The pressure controller uses the output (OP) of Moo3 PY-012 as PV.3. 3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.doc Page 18 of 92 . 3.3.6 Calculations N/A.3 Normal Steady State During normal operation the pressure controllers PICA-069 and PICA-014 and the calculation block PY-014 shall be in AUTO.V.3. 3. If the HP steam header temperature measurement TI-005 is BAD the mode of the temperature controller TICA-005 shall be set to MAN and its output shall be frozen./Sect.5.DOT PCFS NEM_R2. 2: Describes control with manual selection switch in position “J-15101A”.5.5 Shutdown 3.5.8 Interfaces N/A. the mode of the pressure controller PICA-014 shall be set to MAN and its output shall be frozen.5.2 Start up 3. when not selected.

DOT PCFS NEM_R2. The mode of these protective controllers shall always be AUTO.doc Page 19 of 92 .00 Rev.5. 04217 Project E-15100-TN-5306-0001 Document Number 2.10 Special Considerations The setpoint of the protective controllers PICA-069 and PICA-014 cannot be changed by the operator.008 (Rev 0.3. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.5./Sect.4 History Date 10-03-2006 Author RVO Description Original Document LGN SREP 04-3001-02.V.011 Dept. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.ABB Lummus Global B. 3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. 3.

We will send you our “Shellified” P&ID’s so that you know how we understand and interpret your intended control and safeguarding.doc Page 20 of 92 . ‘Control Description’. Please also provide input for Section 2. Add a separate section for the Cooling Air Fans Automatic take-over 6. i. We have checked this document towards your ‘Process Control Diagrams’ (PCD’s). The configuration of the DCS (by Yokogawa) will be done via the NEM logics and the “Shellified” P&ID’s made by J. 04217 Project E-15100-TN-5306-0001 Document Number 2. Add a separate section for the sootblowing sequence control. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. Please give a (brief) description of all calculation blocks/functions.DOT PCFS NEM_R2.008 (Rev 0. 5.e.V. including: • Steam Turbine KT-15161 • Lube Oil System • Automatic “clutch” system.011 Dept. in DCS 4. NO. We assume that selection of the atomizing medium is done in/via the Burner Management System (BMS).V. NEM General comments: 1.00 Rev. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. 3./Sect. Many calculation blocks/functions are not described in this document. 2. LGN SREP 04-3001-02. switch-over system from steam turbine to electric motor and vice versa 7.ABB Lummus Global B. Add a separate section for the control and safeguarding of the FD Fan K15161.

04217 Project E-15100-TN-5306-0001 Document Number 2. This SHP steam is fed to the steam header of the plant at the following normal operating conditions: Flow: 72 ./Sect. The operation of the boiler and its associated equipment is carried out by the following systems: System Boiler Fuels/Burners/atomizing FD fan (incl. and operation of the burners can be found in the following documents: Burner System Description: 36005-824-04-148 Logic Diagrams: 36005-824-04-304-001 Cause and Effect Diagram: 36005-824-04-307 Logbook The boiler is operated through a DCS. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. which are mentioned as reference documents. 3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. See also process control diagrams 36005-646-01. The safeguarding with interlocks is integrated in the plant ESDS (including BMS). boiler steam conditions. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.00 Rev. It also supplies trends of process values and stores a database of previous operating conditions and boiler status. At the boiler and FD Fan local panel only start-stop of the burners and FD fan unit is possible.doc Page 21 of 92 . ST) Motor drive FD fan Seal and cooling air fan Sootblower DCS control/start/stop control/start/stop control/start/stop start/stop start/stop start/stop Local panel emergency stop start/stop start/stop start/stop The boiler is designed for operation from the plant CCR.DOT PCFS NEM_R2. fuel and air flow conditions. The document describes the controls. This DCS is capable to supply interactive communication between the operators and the installation. boiler load.008 (Rev 0. boiler start/stop. The owner of the boiler is obliged to register all relevant data of the boiler in a logbook. system protection.6 BOILER OPERATION AND CONTROL INTRODUCTION This document describes the fired steam boiler for the Ethylene Cracker Complex (ECC) to be installed at Shell Eastern Petroleum Plant. All instrument tag numbers will have prefix ‘151’.180 t/h (40 – 100% MCR) Pressure: 120 – 125 bar(g) Temperature: 515 – 525 ° C The boiler operates at single pressure with natural circulation and is fed by FW pumps.ABB Lummus Global B. The detailed procedure on the start-up and shutdown. All relevant signals in the ESDS are also monitored in the DCS. (The Logic Diagrams and Loop Diagrams shall describe these in detail and are always leading above this document). Control and monitoring of the boiler is performed by the DCS.011 Dept. malfunctioning of systems/equipment and other process conditions. It should be read in conjunction with the piping and instrumentation diagrams (P&ID's). in general for items within the responsibility and scope of NEM. As a minimum the different operating situations are noted: HP steam header conditions. settings etc.V. LGN SREP 04-3001-02. The boiler forms an integral part of the plant and produces SHP superheated steam for the plant by firing different fuels.

Note: 1) In this document reference is made to equipment or parts of the plant not in NEM scope.00 Rev. Here it has the purpose to explain the functionality of the NEM scope integrated in the total plant.ABB Lummus Global B. This logbook will be very helpful also in case of malfunctioning of a part to assure fast and adequate NEM response.DOT PCFS NEM_R2. 04217 Project E-15100-TN-5306-0001 Document Number 2. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.008 (Rev 0. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.doc Page 22 of 92 . The NEM scope is also defined in the P&ID’s (see reference documents) LGN SREP 04-3001-02. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. This document does not change NEM’s scope.011 Dept./Sect.V.

030-C LGN SREP 04-3001-02. guarantee) and ECR (70% MCR.ABB Lummus Global B. At MCR the steam production of each boiler is 180 t/hr. ASME VIII Edition 2004. Operation The boiler is designed for a life time of 20 years.00 Rev.008 (Rev 0. Degree of Automation The degree of automation is described in more detail in the chapters below. including addenda 2005 3.20.DOT PCFS NEM_R2. the boiler pressure and temperature gradients may never exceed the allowable values. Dynamic Characteristics The boiler is designed to follow boiler load fluctuations during normal operation. Reference documents DEP 32. In case one of the boilers is out of service the remaining boilers will operate at 100%MCR. The boiler plant consists out of three (3) boilers operating simultaneously. OPERATION AND DESIGN CRITERIA Regulations and Design Codes The system is designed and fabricated according to the applicable rules: 1. 04217 Project E-15100-TN-5306-0001 Document Number 2.V.24. ASME I Edition 2004. ASME B31. For these documents it is referred especially to the cases ECR (100% MCR. However. Control System Requirements The control of the boiler shall be realized with a control system. Protection Concept Dangerous situations shall be avoided by safety relief valves and by the safety oriented protection system. NFPA85 Edition 2004 Supervision The system is designed for constant supervision from a CCR in the vicinity of the boiler.38-Gen Standard drawing S24./Sect. The operating schedule for each unit is 8760 hr of service per year. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. The boiler turn down range is 40 – 100% MCR load. normal). May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. Environmental Conditions The boiler is located outdoors.3 Edition 2004 5.011 Dept.doc Page 23 of 92 . ASME B31. including addenda 2005 2. The steam temperature is controlled for 40 – 100% MCR load. Within the life time of the boiler the number of start-up/shutdowns are based on cold conditions and limited to: Type of cycle Cold start-up and shut down Number 2000 Definition of cycle boiler at ambient conditions Performance The boiler is designed to meet the performance as noted in NEM’s Performance Table documents 36005-103-01/36005-103-38. which is commonly used in power plants. The control system shall be capable of handling the dynamics of the system without limiting the performance. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.1 Edition 2004 4.

Depending on boiler load (firing rate) measured air and fuel flows are used for this control with the O2 content measured at the stack inlet as correction parameter. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.2 Functional Description The desired boiler load is compared with the total measured fuel and air flow load in a minimum respectively maximum value selector. When firing oil and gas together the required air/fuel ratio for oil will be used to determine the required air flow. The min/max selection takes care for having under all load conditions. and during load increase and decrease that the air/fuel ratio is held on a predefined value to assure proper and complete burning. 3. 04217 Project E-15100-TN-5306-0001 Document Number 2. The air flow is controlled by the IGV of the FD Fan using the air flow measured in the FD Fan suction duct.008 (Rev 0./Sect. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. To control the air/fuel ratio under all operating situations in a correct manner the following corrections are incorporated: • Boiler load • Number of burners in operation • Number of air doors not closed opened • Fuel temperature (HOLD) • Igniter in operation (HOLD) • Variations in heating value (HOLD) • Natural Gas density (HOLD) LGN SREP 04-3001-02.00 Rev.ABB Lummus Global B. one fuel in control mode or both fuels in control mode and atomization medium (if applicable).doc Page 24 of 92 . Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.7. FC-202B (Combustion Air).7.011 Dept.V. 3.7 BOILER COMBUSTION AIR CONTROL HLA10AA001 (IGV FD Fan). QC-021 (Oxygen) P&ID 36005-105-02 PCD UEFS E-15100-TN-2395-0031 Fluegas System 111 Steam Boiler Package A-15101 – Flue Gas System 3.DOT PCFS NEM_R2. When firing fuel oil the total fuel load is composed from the measured ECR/CGO flow and atomizing gas flow. The operator has to select the control mode for the fuels (one fuel in fixed load mode. This is achieved during load increase by determination of the desired fuel flow via the measured air flow and during load decrease by determination of the desired air flow via the measured fuel flow.1 Objective The air flow and air/fuel ratio control take care for an optimal and safe combustion of fuel oil (ECR/CGO). During dual fuel firing the measured total fuel load is composed from the measured ECR/CGO flow and added with the measured NG flow and atomizing gas flow. Natural gas (NG) or a combination of fuels.

227 are on AUTO Action Operator Valve/Controller PDIC-216 or PDIC-227 NOTE: IPS . 04217 Project E-15100-TN-5306-0001 Document Number 2. etc. switches. the controllers FC-202B and QC-021 will be switched to AUTO and receive their set points from the overall load control.V.3 Normal Steady State During normal operation controllers FC-202B and QC-021 shall be in AUTO.Discrete Control Service Limit Switch to gas or steam PDICatomising.008 (Rev 0.7.19 3.ABB Lummus Global B.3.3. DCS – Analogue Control Service Action PID Direct PID Direct Automatic start up function Valve Name FICA-202 - Tag name FC-202B QC-021 Y-202A NOTE: PV-Tracking No No No Tag name HS-204 DCS .Discrete Control Service Combustion Air flow Tag name FZA-201 1) Limit LL Action Boiler trip Valve/Controller Natural gas Fuel Oil Atomising valves NOTE: IPS (SIL1) 3. Please briefly describe all calculation blocks. 216/PC216 or Calculation to Combustion air PDICequivalent is dependant on 227/PCatomisation.doc Page 25 of 92 . Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. output 0%. 3.3 3.1 Operational and Implementation Aspects Operational Modes This control scheme is required to be operational during start up and normal operation and shutdown.011 Dept.DOT PCFS NEM_R2.7.2 Start up At starting of the boiler the controllers FC-202B and QC-021 are in MAN mode. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.00 Rev. LGN SREP 04-3001-02. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. See also section 3./Sect. When all the burners are started and on AUTO.7. High or Low Selectors.7.3.

x2.7.00 Rev.3.3. The air will forcibly cool down the boiler in a rapid time.4 Crippled Mode Operation Instrument Tag Name Output Controller 1) FZA-201 BAD IPS FICA-202 BAD FC-202B TI-201 BAD PIA-203 BAD TI-202 BAD PIA-202 BAD TIA-203 BAD TIA-204 BAD 2) QICA-021 BAD QC-021 PI-204 BAD 1) NOTE: IPS 2) In JVN Scope Action Boiler trip Mode to MAN Mode to MAN - Output Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze 3. 3.7.ABB Lummus Global B.3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. may be too fast with respect to temperature gradients in the steamdrum and superheater headers.x3) TAG Y-202 x1 Y-100 Boiler load % MCR value HLA10CF001 1) N/m2 HLA10CF002 1) N/m2 NG burner in operation Number of air doors Number of NG/CO burners in operation x2 TC-202 Steam temp. gradient x3 y = CY −202 ∗ x1 or x 2 Low SEL and SP Calculation stochiometric air equivalent [kg/h] FZA-201 FICA-202 HY-261A y = C 201 ∗ x1 Conversion to kg/h y = C 202 ∗ x1 Conversion to kg/h n = ∑1 (x1 + x 2) n burners in operation 6 CO burner in operation Air doors not closed Air doors not closed Correction value C261B Correction value C261C HY-261B y = ( x1 − x 2) ∗ C 261B Air flow leakage correction for n air doors closed HY-261C y = ( x1 − x 2) ∗ C 261C Air flow leakage correction for n air doors not closed and n burners in operation LGN SREP 04-3001-02.5 Shutdown It is only for a limited time (maximum 60 seconds) allowed keeping the combustion air flow through the boiler when the boiler is not in operation anymore.7. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.V.008 (Rev 0.doc Page 26 of 92 . See also section 3. 04217 Project E-15100-TN-5306-0001 Document Number 2.19 3.6 Calculations Output (y) Calculation Input (x1.011 Dept./Sect.DOT PCFS NEM_R2. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.

04217 Project E-15100-TN-5306-0001 Document Number 2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.011 Dept. HY-261D y = x1 + x 2 + x3 Total air flow leakage correction for n air doors not closed and n burners in operation HY-261A HY-261B HY-261C HY-261E y = x1 / x 2 HY-261D HY-261A Air flow leakage correction factor for n air doors not closed and n burners in operation HY-260A y = C1260 A ∗ x1 + C 2 260 A Excess air depending on boiler load [%MCR] High SEL in case of combined fuel firing Y-202 Boiler load % MCR value Minimum excess air factor for NG HY-260A HY-260C Minimum excess air factor for CO HY-260B Maximum Excess air factor QY-021C FY-502D HY-261E HY-260B HY-260C HY-260D High SEL excess air factor Low SEL excess air factor HY-260E FY-202A HY-202B High SEL excess air factor y = x1 / x 2 Calculation Air/Fuel Ratio HY-260D FICA-202 HY-260 y = x1 * x 2 Calculation total excess air factor FY-202B y = x1 / x 2 Calculation stochiometric air requirement FY-202C FY-211A FY-211B FY-205A FICA-202 kg/h HY-202B Y-202 kg/h Y-202 kg/h FI-207 kg/h HY-202B y = x1 * x 2 SP calculation air requirement Low SEL or SP and PV combustion air equivalent High SEL or SP and PV of total combustion air equivalent FY-211B kg/h FY-202B kg/h FY-205D kg/h HC-205B CNG y = x1 * C NG * (C COG .DOT PCFS NEM_R2.doc Page 27 of 92 . Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.008 (Rev 0.ABB Lummus Global B.00 Rev. steam or no atomising HC206C/D/E CCOG. CCOS or CNO FY-205B FY-205D y = C NG ∗ x1 ∗ 1000 Combustion air equivalent NG If firing mode is COMBINED: FIC-205 t/h FY-205B kg/h HC-205B CNG FY-206B kg/h y = x1 + x 2 if firing mode is NOT COMBINED: burners FY-206B y = High SEL( x1. x 2). # FIC-206 kg/h HC-206B CCO y = C CO ∗ x1 Combustion air equivalent CO LGN SREP 04-3001-02./Sect. C COS or C NO ) Combustion air equivalent atomizing gas.V. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.

May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.DOT PCFS NEM_R2. FY-212A FY-212B y = x1 − x 2 Combustion air equivalent CO FY-211A kg/h FY-212A kg/h FY-212G kg/h FY-212B kg/h FY-212C kg/h FY-212E kg/h FI-207 kg/h Y-202 Boiler load % MCR value QC-021 QC-021B HC182 HC182 FY-205B kg/h FY-205A kg/h FY-206B kg/h HC-206 CCO HC-205 CNG FY-206A kg/h HC-206C/D COG or COS y = x1 − x 2 y = x1 − x 2 Combustion air equivalent correction for atomizing gas FY-212C FY-212D Combustion air equivalent NG y = x1 / C CO Calculation stochiometric air flow to CO flow in kg/h FY-212E y = x1 / C NG Calculation stochiometric air flow to NG flow in kg/h FY-212F y = ( x1 − x 2) / 1000 NG flow correction for atomizing gas flow in t/h FY-206A QY-021 y = x1 ∗ (C OG or C OS ) Contribution atomizing medium y = C1021 ∗ x1 + C 2 021 O2 vol % depending on boiler load [%MCR] Low SEL excess air factor High SEL excess air factor QY-021B QY-021C HY182n HY182g Maximum excess air HY-260B y = C CON .011 Dept.doc Page 28 of 92 .7.3.V./Sect.ABB Lummus Global B. Air [kg/h] NOTE: LGN SREP 04-3001-02. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. f COG ( x1) 1) Please consider to use the output of flowmeter installed in gas atomizing line NOTE: 3.00 Rev.7 1) Square root operation in DCS Initialisations Ranges Description Combustion air Controller Oxygen outlet boiler controller Calculation block combustion air TAG FC-202B QC-021 Y-202 Range 30 . f CON ( x1) 1) y = C COG .008 (Rev 0. 04217 Project E-15100-TN-5306-0001 Document Number 2.100 0-2 0 – 216000 Units % Excess Air Equivalent comb.

00 Rev.HOLD Z-- Trips Level IPS – SIL1 IPS – SIL1 ?????????? Value 90000 108000 1.1 1. TAG FICA-202 PIA-203 PIA-202 PIA-202 TIA-203 TIA-204 QICA-021 FA-202A FA-202A NOTE: Description AA+ A+ AA+ A+ AA+ A- Alarms Level Indication Indication Indication Indication Indication Indication Indication Indication Indication Value 108000 90 30 -10 390 To follow 1.ABB Lummus Global B.1 1.0137 - LGN SREP 04-3001-02.0 1 0 0 0.6 1.008 (Rev 0.1 Units MJ/kg kg/h Kg/s/√(bar) HOLD Kg/s/√(bar) HOLD - C1260A -0./Sect.011 Dept. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. 04217 Project E-15100-TN-5306-0001 Document Number 2.0 Units kg/h kg/h - TAG HC182 CY-202 C201 C202 HC-205B CNG HC-206B CCO HC-206C CCOG HC-206D CCOS HC-206E CNO C261B C261C Settings Description Lower Heating Value common Oil Conversion from MCR value to CA equivalent flow Conversion from ∆p measurement to flow in kg/h Conversion from ∆p measurement to flow in kg/h CNG Stochiometric air flow factor CCO Stochiometric air flow factor CCOG Calculation factor for gas atomization CCOS Calculation factor for steam atomization CNO Calculation factor for no atomization Air flow factor for cooling when air door is closed (leakage) Air flow correction factor for air door is not closed but burner out of operation (flame front resistance) Conversion for excess air depending on boiler load [%MCR] Value By JVN 2016 To follow To follow 16.4 13.DOT PCFS NEM_R2.05 Units kg/h mBar(g) mBar(g) mBar(g) ° C ° C % - TAG FZA-201 FZA-201 FZA-202A NOTE: Description Z-A. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.V.doc Page 29 of 92 .

00 Rev.7. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.1 (min. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.3. 0% output.011 Dept.20.doc Page 30 of 92 . 3.24.9 Operator Interfaces Operator can access tags on the DCS.0 (max) To follow To follow % (vol) % - NOTE: 3. 04217 Project E-15100-TN-5306-0001 Document Number 2.38). The control system and air/fuel ratio computation counts for the number of burners in operation and number of air doors NOT closed. 2.7.ABB Lummus Global B.7. If oxygen controller QC-021 is forced to MAN it shall retain its last output setting unless manually changed by the operator.8 Interfaces With SHP steam load controller Y100 3.3. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.V.10 Special Considerations During purge. C2260A C1021 C2021 HS-021 C502b CCOG Conversion for excess air depending on boiler load [%MCR] Conversion for O2 % depending on boiler load [%MCR] Conversion for O2 % depending on boiler load [%MCR] O2 vol % Influence of firing mode on excess air Conversion factor from PV CO flow to required CO flow (with gas atomization) Please consider to use the output of the flowmeter.7.008 (Rev 0.DOT PCFS NEM_R2. start up and shutdown the air flow through the FD Fan will be limited by means of a mechanical minimum stop.3.4 History Date 20-07-2007 Author HuR/WiH Description Original Document LGN SREP 04-3001-02. which is installed in the gas atomizing line./Sect.) 7.05 - -0.16 12. Counting for the burners will be based on “oil flame on” or “gas flame on” or both signals healthy for individual burner (see also DEP 32.7 1. In case one or more burners are out of operation the oxygen controller (QC-021) is put to MAN. 3.

At low loads (below 30% MCR) the atomizing medium pressure will be kept on a minimum fixed value. 3. The amount of atomizing steam or atomizing gas depends on the nozzle characteristic and medium pressure above the fuel oil pressure.2 Functional Description The measured fuel flow will be compared with the required fuel flow as determined by the combustion air control system and the output signal will be used to control the fuel by the control valves PICA-209 and/or PICA-214.8.DOT PCFS NEM_R2.1 Objective The fuel flow control takes care for an optimal and safe combustion of fuel oil (ECR/CGO). LGN SREP 04-3001-02. 04217 Project E-15100-TN-5306-0001 Document Number 2. The atomizing medium amount is controlled by a pressure difference controller. Similarly. High or Low Selectors. In case the fuel pressure becomes too low the master control will be override by the slave controller and the fuel is controlled at a minimum pressure. Before starting on fuel oil the atomizing medium differential pressure control should be on AUTO.008 (Rev 0.V. steam or NG atomizing) and fuel ratio. Please briefly describe all calculation blocks. Natural gas (NG) or a combination of fuels. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. The atomizing gas flow will be used for monitoring and will be used in the fuel/air control of the total flow of the different fuels.8. selection for fuel and atomizing medium can also be made at the local burner panel.1.00 Rev. PDIC-227 / PC-227 (Atomizing Steam). switches. Always one fuel shall be in the AUTO control mode.011 Dept. 3./Sect.ABB Lummus Global B. In the DCS the operator has to select the control mode for the dual fuel firing (one fuel in fixed load mode. Atomizing gas or steam will be supplied at a pressure just above the fuel oil pressure. PC-214A / PC214B / FC206 (CO). The atomizing medium pressure follows the oil pressure with a pressure difference of about 1 . Depending on the fuel(s) to be fired the operator has also to select from DCS the atomizing medium (no atomizing. The control system will count for the number of burners in operation and the number of air doors open. Depending on boiler load the measured fuel flow is used for this control. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. The controller compares the fuel and atomizing medium pressure and the output signal will adjust the position of control valves PDIC-216 or PDIC-227.5 bar. etc. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. one fuel in control mode or both fuels in control mode).8 GAS/FUEL OIL CONTROL PC-209A / PC209B / FC-205 (NG).doc Page 31 of 92 . when the fuel pressure becomes too high the fuel is controlled at maximum pressure. PDIC-216 / PC216 (Atomizing Gas) P&ID 36005-105-17 P&ID Piping burner system 36005-824-04-151-002/003/004 P&ID Common skid 36005-824-04-151-005/006/007 P&ID Local burner fuel system PCD UEFS E-15100-TN-2395-0039 Reference document 36005-824-04-148 112 Steam Boiler Package A-15101 – Fuel Control System Burner system description 3. Selection to start/stop each burner.

A. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.Analogue Control Service Action PID Direct PID Indirect PID Indirect PID Direct PID Indirect PID Indirect PID Indirect PID Indirect PID Indirect PID Indirect PV-Tracking Yes Yes Yes Yes Yes Yes No No Yes Yes Valve Name PICA-209 PICA-209 PICA-209 PICA-214 PICA-214 PICA-214 PDIC-216 PDIC-227 PDIC-216 PDIC-227 Tag name HS-270 HS-269 HS-227 See general note 3 Y-209 NOTE: DCS .00 Rev.V. 04217 Project E-15100-TN-5306-0001 Document Number 2. Action Operator Operator Operator Valve/Controller PICA-209/ FC-205 PICA-214/ FC206 PDIC-216/ PDIC-227 PICA-209 Automatic set point adjustment for start up Start program IPS .A.011 Dept. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. N.Discrete Control Service Switch NG to AUTO or MAN SP Switch CO to AUTO or MAN SP Switch to gas or steam atomising Limit N.A.ABB Lummus Global B./Sect.DOT PCFS NEM_R2. N.doc Page 32 of 92 .Discrete Control Tag name 1) PZA-210 PZA-212 PIA-211 1) Service NG pressure too low NG pressure too high NG pressure low NG pressure high NG pressure low NG pressure high Limit LL HH L H L H Action NG trip NG trip NG trip if Leak test failed Atomising Gas trip if Leak test failed CO trip 2) Valve/Controller NG TSO Block valves NG TSO Block valves NG TSO Block valves NG TSO Block valves PIA-232 2) PZA-213 1) CO pressure too low LL PZA-215 2) Atomizing steam pressure too low LL CO trip PZA-217 2) Atomizing gas pressure too low LL CO trip CO + atomizing TSO block valves CO + atomizing TSO block valves CO + atomizing TSO block valves NOTE: 1) 2) IPS IPS (SIL1) LGN SREP 04-3001-02. Tag name FC-205 PC-209A PC-209B FC-206 PC-214A PC-214B PDIC-216 PDIC-227 PC-216 PC-227 NOTE: DCS .008 (Rev 0.

Normal operation is based on ECR with natural gas as atomizing medium. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. To meet the required viscosity range ECR may be mixed with CGO. the control system accounts for the number of burners in operation and the number of not closed air doors.3 CSt @ 100° C Air/fuel ratio for NG Air/fuel ratio for ECR/CGO Air/fuel ratio for dual fuel firing minimum 1.34 MWth NG 26. Atomizing medium When firing ECR. 3. Viscosity for CGO within 0. In case a burner is tripped or taken out of operation the operator can decide to close the air door of the specific burner.8. Either all burners have gas atomizing or steam atomizing. To operate safely.3 3. ECR/NG or NG/CGO.075 minimum 1.45 MWth Viscosity for ECR within 8 – 10 CSt @ 190° C. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. Air doors The burners are equipped with manually operated air doors with limit switches.1 Operational and Implementation Aspects Operational Modes This control scheme is required to be operational during start up and normal operation and shutdown.1 Viscosity When firing ECR the fuel must heated to 190°C to me et the required viscosity range of 8 – 10 CSt. Remote or local operation (preliminary) Following operator limitations are applicable: • Controls AUTO/MAN only from DCS • Priority concerning local or remote start/stop is at DCS • Fuel ratio adjustment only possible from DCS • Set point adjustments only possible from DCS LGN SREP 04-3001-02. Prior to start up all airs doors must be proven open to allow a start up. Atomizing steam will be available as back up for NG atomization. For the normal start up with Natural Gas an automatic start up procedure is incorporated.doc Page 33 of 92 .DOT PCFS NEM_R2.8 – 1.7/5.8./Sect. however manual start up with ECR or CGO is possible. Natural gas and/or CGO will be used as back up fuel in case no ECR is available.00 Rev. General operation aspects: Operation modes The boiler is able to operate with different fuels in a load range of 40 – 100% with all six burners in operation.7/4. It is also possible to fire the fuel combinations ECR/CGO.008 (Rev 0.1 minimum 1. CGO or a mixture of ECR/CGO atomizing steam or NG must be available. Operating limits The turndown ratio of the burner system with six burners in operation is: ECR/CGO 5:1 NG 6:1 The maximum/minimum Heat Input per burner is: ECR/CGO 26.3.011 Dept. To ensure a proper combustion the viscosity of the ECR must stay within the mentioned viscosity range.V. 04217 Project E-15100-TN-5306-0001 Document Number 2.ABB Lummus Global B.

one on oil/gas etc. With all the required burners in dual fuel mode When the second fuel flow set point is > minimum. simultaneous on the same burner 2) • Dual fuel. When firing NG only the fuel oil gun has to be cooled by steam (steam tip cooling). This means that the oil gun must be purged with steam at the end of the stop/trip sequence of each burner. the operator can start the second fuel from DCS or local panel. 2) Fuel changeover (main to secondary): Boiler load control mode The boiler can be operated in load control mode.011 Dept. By increasing the fuel flow set point of the second fuel changing the fuel ratio (NG/OIL) the second fuel will be increased while the main fuel is automatically decreased. the burners have to be taken into operation one by one with sufficient time delay to let the system accommodate to the new situation. fixed load mode or balancing mode. Firing mixed fuels Following mixed fuel firing modes can be distinguished: • Fuel combinations: ECR/CGO in any proportion. CGO) always atomizing gas or steam is required.DOT PCFS NEM_R2. one on oil. 1) In case of dual fuel firing the air flow and air/fuel ratio will be based on the air/fuel ratio requirements for fuel oil. However this operation mode is not recommended. When the main fuel is at minimum load the fuel AUTO mode control has to be switched-over to the second fuel. The flow controller (FC-205 or FC-206) of the second fuel is in MAN mode 0% output at a flow set point just above minimum burner load. one on gas. Fuels: When firing fuel oil (ECR. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.ABB Lummus Global B.doc Page 34 of 92 . The main fuel supply to each burner can be stopped and the changeover is completed. operating mode per burner (oil or gas) and control mode (AUTO/MAN). Also the fuel ratio has to be selected which can be adjusted manually in the DCS. When adding the second fuel the load of the main fuel is automatically decreased by the combustion air control boiler load controller. The burners will be able to fire mixtures of fuels across the boiler (i. The second fuel must be started at minimum load per burner. Starting a burner on fuel oil must always be done with a clean (purged) oil gun. For dual fuel firing mode this mode of operation the operator has to select in the DCS the fuels. the second fuel control will be changed from pressure to switched to manual flow control mode by increasing the pressure control set point for the maximum pressure controller of PC-209B or PC214B to its normal value. When taking the second fuel in operation the During start up of the second fuel is on pressure control. • Dual fuel: ECR/CGO/NG or ECR/NG or CGO/NG. In three operation modes the air and fuel systems are in AUTO mode.e. To start the changeover.008 (Rev 0. In this case the main fuel flow will be controlled by the boiler load controller.V. Further./Sect. simultaneous on different burners 1) For dual fuel firing on the same burner both fuels (oil and gas) one fuel will can be in AUTO control mode simultaneously or with and one fuel is at in MAN mode at a fixed load. Therefore the set point of the maximum pressure controller (PC209B or PC214B) is lowered to the value required for start up. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. Boiler fixed flow control LGN SREP 04-3001-02. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.00 Rev. 04217 Project E-15100-TN-5306-0001 Document Number 2.

ABB Lummus Global B. The start up with fuel oil will be done manually./Sect. causing flame instabilities and potential flame out situation.008 (Rev 0. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. the burners have to be taken into operation one by one with sufficient time delay to let the system accommodate to the new situation.v. Atomizing medium changeover: Changeover from NG to steam atomising and v. When the second fuel flow set point is > minimum. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. After the combustion air control system has been accommodated to the new heat input the air/fuel ratio is corrected to the required value. 04217 Project E-15100-TN-5306-0001 Document Number 2.00 Rev. Start up To discuss: fuel temperature control (for ECR. Further.2 Note: When UZ-507 should be closed than a safety relief valve is required.DOT PCFS NEM_R2. HOLD: LGN SREP 04-3001-02. is not permitted during operation with fuel oil due to the timing to open and close valves. If a changeover is required the next the general procedure should be followed: • Changeover the fuel to single firing of NG • When operate at NG select required atomizing medium • Changeover to oil or dual fuel firing Steam Tracing: Steam tracing will be used to compensate for heat loss of the oil system or avoid clogging of the oil system when fuel oil is not in service. See conference notes April 3.doc Page 35 of 92 . When adding the second fuel the load of the main fuel is automatically decreased by the boiler load controller. 2007 (mechanical) and several e-mails about this subject decision by JV Basically the start up with NG will follow an automatic sequence. the second fuel will be switched to pressure control for the maximum pressure controller.8. During start up of the second fuel is on pressure control. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. In this case the main fuel flow will be controlled by the boiler steam flow controller set to a fixed value.3.V. ECR/CGO and CGO) prior to start up. Note: (HOLD) After a burner is taken into operation with the second fuel at minimum load the excess air amount will temporally decrease. When steam tracing is taken into operation following manual actions is required: • Open shut off valves in oil system • Open shut off valve in steam line To allow for thermal expansion of the oil system with steam tracing in operation the manual operated valves are locked open and pneumatic operated stop valves (UZ-502 and UZ-507) must be opened by the operator. The second fuel must be started at minimum load per burner.011 Dept. By changing the fuel ratio (NG/OIL) the second fuel will be increased while the main fuel is automatically decreased. Sub-stochiometric conditions however will not occur due to the limited fuel flow of the added second fuel. the operator can start the second fuel from DCS or local panel. To start the changeover. HOLD 3. When the main fuel is at minimum load the fuel supply to each burner can be stopped and the changeover is completed.

The NG vent valve UZ-506 is open to create flow to be able to control the NG on pressure. When three (3) burners are in operation at the required load the set point of PC-209B will be gradually increased to its normal set point (maximum pressure set point).011 Dept.3. When the oil conditions are good the first burner can be started. Start up with NG When starting the boiler the pressure controllers PC-209A and PC-209B are in AUTO. This valve will be closed after the first burner is in operation. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. When the boiler is connected to the steam grid the load controller will be switched to AUTO (pressure or flow) and receive their set points from the overall load control. During start phase air controller FC-202B will be switched to AUTO when all burners are in operation (HOLD). When starting the first burner the minimum stop at the fuel control valve will ensure sufficient NG to light-off the burner.DOT PCFS NEM_R2. When the boiler is connected to the steam grid the load controller will be switched to AUTO (pressure or flow) and receive their set points from the overall load control. 04217 Project E-15100-TN-5306-0001 Document Number 2. See also section 3.3 Normal Steady State During normal operation one the fuel controller shall be in AUTO. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. When starting the first burner the minimum stop at the fuel control valve will ensure sufficient fuel oil to light-off the burner. Start up with fuel oil Prior to start up with oil the supply temperature and viscosity must be correct. This valve will be closed after the first burner is in operation. When starting the boiler the pressure controllers PC-214A and PC-214B are in AUTO./Sect. The set point of controller PC-209B is set to a low value (by the start program) corresponding with the required burner start load. When three (3) burners are in operation at the required load the set point of PC-214B will be gradually increased to its normal set point (maximum pressure set point). To achieve the required conditions for starting the burners the supplied oil is circulated via UZ-502 and UZ-507. Flow controller FC-205 is in MAN mode output 0%.ABB Lummus Global B. Flow controller FC-206 is in MAN mode output 0%. The oil to the burners will be branched off from the common circulation system (JV-scope). Therefore the oil system will be circulated. The selected atomization controller is on AUTO in case atomization is effective. At the same time flow controller FC-206 is put in AUTO and FC-206 controls the flow at the predefined boiler load. Controllers PC-227 and PDIC-227 or PC-216 and PDIC-216 are in AUTO (depending on selection atomizing medium).19 3.008 (Rev 0. At the same time flow controller FC-205 is put in AUTO and FC-205 controls the flow at the predefined boiler load (given by the start sequence program). The set point of controller PC-214B is set to a low value corresponding with the required burner start load. The NG control valve is positioned by the start sequence program (or when in manual mode by the operator). The fuel oil control valve is positioned by the operator.8.doc Page 36 of 92 . PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.V. During start phase the air controller FC-202B will be switched to AUTO when all burners are in operation (HOLD).00 Rev. The fuel oil return line with valve UZ-507 is open to create flow to be able to control the fuel oil pressure. LGN SREP 04-3001-02.

008 (Rev 0. When firing in dual fuel mode first the fuel at fixed load must be taken out of operation prior to boiler load decrease.V. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.8.doc Page 37 of 92 . PDIC-227.19 3. 3.5 Shutdown Basically shutdown of the boiler has to be done manually by decreasing the boiler load to 20% MCR.3.4 Crippled Mode Operation Instrument Output Controller BAD FC-205 BAD PC209A/B BAD IPS BAD IPS Tag Name FIC-205 PICA-209 PZA-210 PIA-211 Action Mode to MAN Mode to MAN NG trip Abort Leakage Proofing / NG trip NG trip Mode to MAN Mode to MAN Output Freeze Freeze Freeze Freeze PZA-212 FIC-206 TIA-222 PICA-214 BAD BAD BAD BAD PZA-213 PICA-227 PZA-215 PICA-216 PZA-217 PIA-232 BAD BAD BAD BAD BAD BAD IPS FC-206 PC214A/B.8.011 Dept.ABB Lummus Global B. 04217 Project E-15100-TN-5306-0001 Document Number 2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.00 Rev.DOT PCFS NEM_R2. PDIC-216 IPS PDIC-227 PC-217 IPS PDIC-216 PC-216 IPS IPS Freeze Freeze Freeze Freeze CO + Atomising trip Mode to MAN CO + Atomising trip Mode to MAN CO + Atomising trip Abort Leakage Proofing / CO + Atomising trip Freeze Freeze Freeze Freeze Freeze Freeze NOTE: 3.x2. As soon as the boiler load is < 20% MCR first the top burners and finally the bottom burners are stopped consecutively.x3) TAG FY-205 FY-206 PY-209A x1 FY-212F FY-212D FC-205 x2 HIC-272 HIC-271 PC-209A x3 HC205A HC206A LGN SREP 04-3001-02.6 Calculations Output (y) Calculation Low SEL Limits the maximum flow for NG Low SEL Limits the maximum flow for CO High SEL Limits the minimum flow for NG Input (x1.3.8. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. See also section 3./Sect.3.

100 HOLD Units % % % % % % % % % % Bar(g) TAG TIA-222 PICA-209 PIA-211 PICA-214 PICA-227 PICA-216 PIA-232 NOTE: Description AA+ / AA+ / AA+ / AAAA+ / A- Alarms Level Indication Indication Indication Indication Indication Indication Indication Value 180 To follow To follow To follow To follow To follow To follow Units ° C Bar(g) Bar(g) Bar(g) Bar(g) Bar(g) Bar(g) LGN SREP 04-3001-02.100 0 . pressure controller Atomizing steam pressure controller Atomizing steam minimum pressure controller Atomizing gas pressure controller Atomising gas minimum pressure controller Automatic set point adjustment for start up Range 0 – 100 0 .3.100 0 – 100 0 .00 Rev.DOT PCFS NEM_R2. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.V.100 0 . pressure controller CO Controller CO min. pressure controller CO max.100 0 .100 0 . 04217 Project E-15100-TN-5306-0001 Document Number 2.008 (Rev 0.100 0 .doc Page 38 of 92 . PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. PY-209B PY-214A PY-214B PY-216 Low SEL Limits the maximum flow for NG High SEL Limits the minimum flow for CO Low SEL Limits the maximum flow for CO High SEL Limits the minimum atomising gas pressure PY-209A FC-206 PY-214A PDIC-216 PC-209B PC-214A PC-214B PC-216 PY-216A PY-227 y = x1 − x 2 PICA-216 PDIC-227 PICA-214 PC-227 High SEL Limits the minimum atomising steam pressure PY-227A NOTE: 3./Sect.ABB Lummus Global B.8. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. pressure controller NG max.100 0 .7 Initialisations y = x1 − x 2 PICA-227 PICA-214 TAG FC-205 PC-209A PC-209B FC-206 PC-214A PC-214B PDIC-227 PC-227 PDIC-216 PC-216 Y-209 NOTE: Ranges Description NG Controller NG min.011 Dept.

TAG PI163 PZA-210 PZA-212 PIA-211 PZA-213 PZA-215 PZA-217 PIA-232 NOTE: PZA-213: Description Z++ Z-Z++ A+ / AZ-Z-Z-A+ / A- Trips Level IPS – SIL1 IPS – SIL1 IPS – SIL1 IPS – SILa IPS – SIL HOLD IPS – SILa IPS – SILa IPS – SILa Value To follow To follow To follow To follow To follow To follow To follow To follow Units Bar(g) Bar(g) Bar(g) Bar(g) Bar(g) Bar(g) Bar(g) Bar(g) SIL classification to be defined by JV Settings Description NG flow per ignition burner SP NG maximum load SP NG when in MAN mode SP min. atom.3.4 History Date 20-07-2007 Author HuR/WiH Description Original Document PCFS NEM_R2.8. Gas pressure TAG C402 HC-205A HIC-272 HC-209A HC-209B HC-206A HIC-271 HC-214A HC-214B HC-227A HC-227 HC-216A HC-216 NOTE: 3. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.doc Page 39 of 92 LGN SREP 04-3001-02.5 To follow 1.DOT . pressure CO SP steam atomization ∆p SP min. 04217 Project E-15100-TN-5306-0001 Document Number 2.8. pressure NG SP CO maximum load SP CO when in MAN mode SP min.ABB Lummus Global B. 3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. NG atomising gas control valve 4.8.5 To follow Units Kg/s t/h t/h Bar(g) Bar(g) kg/h kg/h Bar(g) Bar(g) Bar Bar(g) Bar Bar(g) Operator Interfaces Operator can access tags on the DCS. Natural Gas control valve 2.008 (Rev 0. steam pressure SP gas atomization ∆p SP min. Atomising steam control valve 3./Sect.8.8 Interfaces N/A.011 Dept.10 Special Considerations During start up and shutdown the position of the following valves will be limited by means of a mechanical minimum stop (based on one burner at minimum load): 1.3. atom.9 Value To follow To follow By operator To follow To follow To follow By operator To follow To follow 1. 3.00 Rev.3. ECR/CGO fuel oil control valve 3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. pressure NG SP max.V. pressure CO SP max.

008 (Rev 0. this control block receives a signal from the BMS which equals the steam boiler load at that time. This is to avoid evaporator damage due to a lack of water or steam system damage due to water carry over. OK 2. 3. Steady Operation OK 5.011 Dept. Warm Start-up 3.9.V.DOT PCFS NEM_R2. Economizer inlet temperature Due to the firing of sulphur containing fuels the flue gas leaving the boiler can cause corrosion to the ducting and tubes if the flue gas temperature becomes too low. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. Can “Heat Input On” – LY101d (Y-202) – be taken as a signal from the BMS? NEM expect the signal from DCS Does flowmeter LAB10 CF101 (BFW supply) have a local read-out? (DELETED) We have added a “Steam Boiler Start-up & Shutdown Block”. Hot Start-up 4. NEM expect the signal from DCS Note: This control block will send the following signals: 1. LGN SREP 04-3001-02.TC-207B HAD15AA001 (US-532) – HAD15AA002 (US-531) P&ID 36005-105-03 36005-105-04 PCD UEFS E-15100-TN-2395-0032 E-15100-TN-2395-0033 Economizer System Evaporator System 113 Steam Boiler Package A-15101 – Economiser System Steam Boiler Package A-15101 – Evaporator System Note: • • 1.00 Rev.doc Page 40 of 92 . Cold Start-up OK 2. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. Signal to FS-103. By raising the feedwater temperature the flue gas temperature to the stack will also increase which avoid sulphur dew point corrosion.9 BOILER STEAM DRUM LEVEL AND ECONOMIZER INLET TEMPERATURE CONTROL LAB10AA022 (TIC-207A) – FICA-203 – LICSA-202 LAB10AA032 (TIC-207B) . 3. Signal to temperature controller LAB10 CT003 (TIC-207) OK 4. Therefore the feedwater temperature at the inlet of the external economizer is controlled at minimum level by mixing hot and cold feedwater.1 Objective Drum level The drum level control has the objective to maintain the required drum water level within the specified limits./Sect. Signal to drum level controller to inform wether the boiler load is above or below 10% MCR (i. 04217 Project E-15100-TN-5306-0001 Document Number 2. Shutdown Furthermore. This block is configured in the DCS.e. Via a selector switch the operator can select the following modes: 1. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. Signal to pressure controller LBA10 CP001 (PC-207) (SHP Steam line) OK 3. Excessive boiler water shall be dumped with the blow off valve HAD10 AA471 (LICS202A) to the intermittent blowdown drum. P-control or P&I–control). irrespective of load fluctuation and during start-up and shutdown procedures. The mixed temperature will be controlled at a set point of 150° C.ABB Lummus Global B. which opens/closes ON/OFF valves HAD15 AA001 and HAD15 AA002.

When the steam flow is higher than 10 % of MCR the controller is changed over to Proportional and Integral control (P+I). Changeovers from start level to normal level and from normal level to start level. when the boiler is taken out of operation. The flows will be joined upstream of the external economizer to get a uniform mixed temperature. For fast response and more stable operation of the control loop. the difference between steam and feedwater flow is used as feed forward signal in the drum level controller. occurs. From this block. are part of the start-up or shutdown procedure. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.2 Functional Description Drum level The drum level controller is designed as a three-element controller using the drum level as the primary control variable. Automatic set point adjustment to be incorporated by JV During start of the boiler when no steam is leaving the drum. signal from BMS is send to Control Block 151US-230 “Steam Boiler Start-up & Shutdown”. controller FICA-203 to MAN. Swell compensation to be incorporated by JV Once the start-up swell is over the set point of the level controller is brought to normal level (NL) of the drum and stays here as long as the boiler is in operation. To avoid instability at low flows this feed forward signal is activated at steam/feedwater flows higher than 20% MCR. but is compensated by the feedforward and/or drum level control. LGN SREP 04-3001-02.ABB Lummus Global B. NOT CLEAR When the drum level exceeds the highest allowable level the feedwater supply will be shut-off by closing valve LAB10 AA010 (LZA-201).doc Page 41 of 92 . Economizer inlet temperature To control the feedwater temperature at the economizer inlet the total flow coming from the feedwater system is divided into two flows. This effect will C change the total feedwater flow and drum level.011 Dept. drum level control should be proportional to avoid too high levels as a result of the integrator action. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.9.008 (Rev 0. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. Variations of the drum level will cause a change of the feedwater flow through LAB10 AA022 (TIC-207A). Feed forward at loads > 20% MCR to be incorporated by JV When starting the boiler the water level and set point of the controller will be set to start level (SL) to allow level swell when boiler starts to produce steam. Interaction between both control loops Variations of drum pressure and drum level will have effect on both control valves. 04217 Project E-15100-TN-5306-0001 Document Number 2. caused by pressure changes in the drum./Sect. The drum level will be controlled by regulating the feedwater flow to the boiler with feedwater control valve LAB10 AA022 (TIC-207A). One part will pass through the feedwater control valve LAB10 AA022 (TIC-207A) while the other (smaller) part flows through control valve LAB10 AA032 (TIC-207B) which is heated in the feedwater pre-heater LAD10 AC001 in the drum. The steam and feedwater flows are used as feed forward. Upon trip by LZA-201 High High.00 Rev. 3.DOT PCFS NEM_R2. a signal is send to LY101c. Drum level swell compensation is incorporated to avoid wrong actions of the feedwater control valve if swell or shrink. Variation of the drum pressure will cause a variation in drum temperature and consequently also the feedwater temperature at the outlet of pre-heater LAD10 AC001. In this situation no feedwater is supplied to the drum.V. output to 0%. This will also influence the controlled feedwater temperature for the economizer inlet and hence the flow through LAB10 AA032 (TIC-207B) will also change. To keep the control loops stable a deviation of the drum level is also forwarded to control valve LAB10 AA032 (TIC207B). Hereto the differentiated steam flow is added to the output of the level controller. To control the feedwater temperature at 150° the flow through LAB10 AA032 (TIC-207B) will change.

9.V.008 (Rev 0. 3. High or Low Selectors.2 Start up During start up of the boiler control valve LAB10 AA032 (TIC-207B) will be forced to close.9.Discrete Control Service Switch to activate feedforward control if load > 35 t/h Close eco circulation valves if BFW flow is high enough during start-up Close eco circulation valves if BFW flow is high enough during start-up Open eco circulation valves if BFW flow becomes too low during shutdown Limit HH H L Action Switch Close Open Valve/Controller US-531 US-532 US-531 US-532 NOTE: IPS . May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.011 Dept.3. 04217 Project E-15100-TN-5306-0001 Document Number 2. Please briefly describe all calculation blocks. DCS . output 0% We have put it on the P&ID as follows: • In Control Block 151US-230 “Steam Boiler Start-up & Shutdown”. When the boiler load < 15% the output of temperature controller TC-207B and control valve TIC207B is in MAN mode.DOT .1 Operational and Implementation Aspects Operational Modes This control scheme is required to be operational during start up and normal operation.3 3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.Discrete Control Service Steam drum level too high Tag name 1) LZA-201A 1) LZA-201B 1) LZA-201C 2) LZA-201A 2) LZA-201B 2) LZA-201C NOTE: 1) 2) Limit HH Action Close Valve/Controller LZA-201 Steam drum level too low LL Boiler Trip Natural gas. Fuel Oil and Atomising TSO valves SIL 1 SIL 2 3. then: PCFS NEM_R2. In case of start-up.9. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.Analogue Control Service Action PID Indirect PID Direct PID Indirect FF balance BFW CV correction Valve Name TIC-207A LZA-201 - Tag name LICSA-202 FICA-203 TC-207B LY-101b TY-103a NOTE: PV-Tracking Yes Yes Yes Yes Yes Tag name XS-203 FS-213 FS-213 FS-213 DCS . a signal is send from control block 151US230 to temperature controller LAB10 CT003.00 Rev./Sect. etc.doc Page 42 of 92 LGN SREP 04-3001-02. When boiler load < 15%. the steam boiler mode is selected by operator. switches.ABB Lummus Global B.3.

FICA-203 and TC-207B shall be in AUTO.00 Rev.9.19 3.9.19 LGN SREP 04-3001-02. See also section 3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.doc Page 43 of 92 . See also section 3.9.Temperature controller and control valve LAB10 AA032: AUTO-mode When the boiler load > 15%.V.3 Normal Steady State During normal operation the temperature controllers LICSA-202. then: .008 (Rev 0.3.5 Shutdown Action Mode to MAN Mode to MAN 3oo3: Mode to MAN Mode to MAN - Output Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze When the boiler is shutdown and burners are out operation the drum level set point has to be gradually decreased from NL to SL.DOT PCFS NEM_R2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.Output of control valve LAB10 AA032: 0% When boiler load > 15%. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.ABB Lummus Global B. 04217 Project E-15100-TN-5306-0001 Document Number 2. .Output temperature controller LAB10 CT003: 0% .3.4 Crippled Mode Operation Instrument Output Controller BAD FICA-203 BAD BAD BAD TC-207B BAD BAD BAD BAD LICSA-202 BAD BAD BAD LICSA-202 BAD BAD BAD FICA-203 BAD - Tag Name FT-203 TI-205 TI-206 TICA-207 1) LZA-201A 1) LZA-201B 1) LZA-201C LT-202A LT-202B LT-202C PIA-206 1) PT-205 PICA-207 FI-204 TICA-217 1) NOTE: IPS 3. then the temperature controller TC-207B and control valve TI-207B are put in AUTO mode During start up phase the drum level set point has to be raised gradually from SL to NL.011 Dept. 3.3./Sect.

3.6 Calculations Output (y) Calculation Input (x1.doc Page 44 of 92 . During shutdown from NL to SL. p d ) 2) 3) LT-202A mmwc PIA-206 Bar(g) HEAT INPUT ON LY-202B t/h FT-203 t/h LZA-201A mmwc PT-205 Bar(g) FY-210 t/h FICA-203 % FICA-203 % HC-207C % FY-204 t/h LT-202B mmwc LY-202 mmwc LT-202C mmwc - FY-204A t/h TI-205 Temperature correction for feedwater 4) flow LZA-201 LZA-201 LY-206 TY-207A TY-207B TY-207C FY-210 NOTE: 1) 2) 3) y = 2oo3( x1.100 0 – 100 Units t/h t/h % % LGN SREP 04-3001-02. x3) / ρ design Pressure and temperature correction for steam flow LY-202 LY-202A LY-202B LY-202C FY-203 y = MeanValue( x1.ABB Lummus Global B. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. 3. x3) y = LevelCorrection( x1.011 Dept. x 2) y = x1 + x 2 y = x1 − x 2 y = x1 + x 2 y = x1 − x 2 y = x1 + x 2 2) LZA-201B mmwc LZA-201 mmwc LICSA-202 t/h TC-207B % TC-207B % TC-207B % FI-210 t/h LZA-201C mmwc - 4) Square root operation in DCS Calculation is drum connection layout dependant. During start-up the set point is raised from SL to NL.x2.008 (Rev 0.9. 3. x 2./Sect. x 2) y = Setpo int Level ( x1) y = x1 + x 2 y = x1 ∗ ρ ( x 2 . Controller TAG FY-204A LICSA-202 FICA-203 TC-207B NOTE: Range HOLD 0 – 180 0 . x3) y = LevelCorrection( x1.V.7 Initialisations Ranges Description D-action anti swell compensation Level Controller BFW flow controller Temp. During normal operation the level set point is at NL. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.x3) TAG FY-204 x1 FI-204 t/h 1) x2 PICA-207 x3 TICA-217 y = C 204 ∗ x1 ∗ ρ ( x 2. 04217 Project E-15100-TN-5306-0001 Document Number 2. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. x 2. p d ) / ρ (t d . Uncorrected flow (t/h) is calculated in vortex transmitter.3.00 Rev.DOT PCFS NEM_R2.9. Will be supplied on separate sheet If burners are out of operation the level set point is at (low) start level (SL).

doc Page 45 of 92 .V.00 Rev./Sect. 04217 Project E-15100-TN-5306-0001 Document Number 2.DOT PCFS NEM_R2. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.008 (Rev 0. TAG FY-203 LZA-201A LZA-201B LZA-201C LT-202A LT-202B LT-202C LT-202A LT-202B LT-202C LZA-201A LZA-201B LZA-201C PIA-206 PIA-206 NOTE: Description A+ AAAAAAA+ A+ A+ A+ A+ A+ A+ A- Alarms Level Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Value 190 -150 -150 -150 -150 -150 -150 +150 +150 +150 +150 +150 +150 135 0 Units t/h mm mm mm mm mm mm mm mm mm mm mm mm Bar(g) Bar(g) TAG LZA-201A LZA-201B LZA-201C LZA-201A LZA-201B LZA-201C NOTE: Description Z-Z-Z-Z++ Z++ Z++ Trips Level SIL2 SIL2 SIL2 SIL1 SIL1 SIL1 Value -525 -525 -525 +295 +295 +295 Units mm mm mm mm mm mm TAG C204 Settings Description Flow constant for conversion to t/h ρdesign Density at design parameters flow element pd td FS-213 (HH) FS-213 (H) FS-213 (L) Boiler feedwater pressure in design case Boiler feedwater temperature in design case BFW flow high enough to switch over to feedforward control BFW flow high enough to close eco circulation valves BFW flow low enough to open eco circulation valves Value To follow Type flow measuremen t not decided yet To follow Type Flow measuremen t not decided yet 158 117 35 15 12 1) Units - Kg/m3 Bar(a) ° C t/h t/h t/h 2) LGN SREP 04-3001-02.ABB Lummus Global B.011 Dept.

3. When the measured feedwater flow comes above a predefined value the valves have to be closed.9.9.3. 3. In case of a shutdown the valves have to be opened when the measures feedwater flow falls below the predefined value.9.ABB Lummus Global B. eco 1) NOTE: Flow > 15 t/h for at least 60 seconds 2) Flow < 12 t/h for at least 60 seconds HOLD HOLD HOLD -25 -400 150 mm mm ° C 3.9. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.9 Operator Interfaces Operator can access tags on the DCS.011 Dept.V./Sect. Opening of the valves makes the economizer part of the evaporator system and so temperature differences between economizer and evaporator will be negligible.doc Page 46 of 92 . 04217 Project E-15100-TN-5306-0001 Document Number 2.10 Special Considerations During start up and shutdown of the boiler the economizer circulations valves HAD15 AA001/002 have to be opened and closed. This function is defined via Steam Boiler Start-up & Shutdown Block 151US-530.4 History Date 20-07-2007 Author HuR/WiH Description Original Document LGN SREP 04-3001-02. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.00 Rev. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. 3.3. before ext.008 (Rev 0.DOT PCFS NEM_R2.8 Interfaces N/A.3. FY-203A Gain for TIC-207A FY-207D Gain for TIC-207B FY-207E Gain for TIC-207A LY-202B Normal level (from centerline) LY-202B Start level (from centerline) HC-207B SP BFW temp.

04217 Project E-15100-TN-5306-0001 Document Number 2. This is achieved by controlling the valve position LBA10 AA051 (PICA-207) with pressure controller PC-207. PC-207. temperature and flow during start-up independently from the conditions of the common steam grid. Hot start-up (conditions after a shutdown of 2 hours. 3.10 BOILER START-UP PRESSURE CONTROL LBA10AA051 (PICA-207). Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.10. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. pressure at which the vent valve opens in order to avoid too quickly open of the safety releief valve(s) • Intended pressure when Steam Boiler is connected with the SHP Steam grid LGN SREP 04-3001-02.e.doc Page 47 of 92 .1 Objective Pressure control is required to gradually increase boiler pressure. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.DOT PCFS NEM_R2. Normal operation is considered if the following conditions are met: • Normal operating pressure is reached • Normal operating temperature is reached • Boiler load between 40 and 100% MCR • Boiler connected to the SHP steam grid Furthermore the Operator has to input the: • ‘Pre-safety pressure’ (i.008 (Rev 0. t_drum > 300° C) The Operator can select the above the above mentioned modes in the “Steam Boiler Startup & Shutdown” control block 151US-530 via selector switch 151HS-265: • Start up • Normal operation (connected to steam grid) This selector switch is represented by PY-265A and PY-265B shown at PCD115 Incoming signals to this control block are: • Operation mode (selector switch 151HS-265) • Boiler load (% MCR) from BMS 151UZ-500 FROM DCS? JV TO CHECK • Operating pressure ‘Main Steam Line’ – 151PICA-207 JV TO CHECK • Operating temperature ‘Main’ Steam ‘Line’ – 151TICA-217 JV TO CHECK Signals from this control block are sent to: • Pressure controller 151PICA-207 • Level controller 151LICSA-202/calculation block 151LY-202B • BFW Flow Switch FS103 (151FS-xxx) • BFW Temperature controller 151TIC-207 Furthermore. Warm start-up (conditions after a shutdown of more than 2 hours.V./Sect. TC-254 P&ID 36005-105-06 PCD UEFS E-15100-TN-2395-0035 Main Steam Line System 115 Steam Boiler Package A-15101 – Main Steam Line 3. but t_drum > 100° C) 3. For start-up following situations are distinguished: 1.011 Dept.00 Rev. Cold start-up (boiler at atmospheric conditions) 2. an indication is given when the boiler is (still) in start-up mode or is at normal operation.ABB Lummus Global B.

doc Page 48 of 92 . Pressure controller PC-207 is put in AUTO mode after a certain time and then controls the pressure at normal the operating value. (HOLD) • Limiting too low pressure when the boiler is shutdown (prevent vacuum conditions) (HOLD) 3. 04217 Project E-15100-TN-5306-0001 Document Number 2.Start up valve controls steam pressure at set point (normally 120 bar(g)) After or during start-up phase the main steam line and common grid can be pressurized and pre-heated by opening of valve LBA10 AA005 (manually). • Pre-safety function in case of too high steam pressure.Normal operating pressure is reached . Additional to the main function of the pressure control system following functions are incorporated: • Limiting too high pressure/temperature gradients in the drum and superheaters during start up.00 Rev. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.V. produce steam and pressure will rise.10. At the moment that the pressure difference over main steam valve LBA10 AA003 (MOV-201) is lower than 2 bar the main steam valve will be released to be opened (manually by the operator). Valve PICA-207 will stay in this position until the steam pressure reaches normal operating set point. 0%. When valve MOV-201 is open and start up valve (PICA-207) is closed the master control system has to be released to control the boiler load (boiler steam pressure or flow control) and output of controller PC-207 is put to MAN.DOT PCFS NEM_R2. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.Normal operating temperature is reached . The start-up sequence is ended when all of the following conditions are met: . When LBA10 AA051 is closed the set point will be increased to a value of Y bar above the actual set point of the main steam pressure. During Heat Input by the burners the boiler will be heated.2 Functional Description Depending on the pressure in the boiler the pressure the set point will be put in memory has to be set to at the actual pressure via an automatic switch when the first burner is started with a minimum of 2 bar(g). After the set point of the controller is reached the startup valve will be opened and pressure is controlled until an opening position for LBA10 AA051 (PICA-207) of 30% is reached. When there is a steam demand of the grid the boiler steam pressure tends to decrease but will be kept constant by further closing of the start up valve./Sect.Boiler load at 40% MCR .008 (Rev 0.ABB Lummus Global B. The start up valve controls the boiler steam pressure through pressure controller PC-207. DCS – Analogue Control Service Action PID Indirect PID Direct Temperature Low output gradient steam limitation 1) drum too steep Ramp-up High output pressure too limitation 1) slow See explanation at section start up Valve Name PICA-207 PICA-207 Tag name TC-254 PC-207 PV-Tracking No Yes Yes Yes PICA-207 NOTE: 1) LGN SREP 04-3001-02.011 Dept. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. When the steam pressure has reached the normal set point pressure controller PC-207 is switched to MAN mode and at the same time the opening limit of PICA-207 is removed.

2 Start up At starting of the boiler the set point of the pressure controller PC-207 is set switched to an appropriate value depending on the remaining pressure in the boiler the mode which is selcted by the Operator in Steam Boiler Start-up & Shutdown block 151US-530 (i. 04217 Project E-15100-TN-5306-0001 Document Number 2. The heat input will cause steam production and a pressure/temperature raise in the boiler. On the other side opening of the start-up valve must be not too much to keep the start-up time limited.Discrete Control Tag name N. Controller TC-254 will force open or limiting the start up valve position and so prohibiting controller PC-207 to close the start up valve under a certain value.10.3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE./Sect. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. At the moment this limitation is reached the set point of PC-207 is switched to that pressure value at which the boiler needs to be connected to the steam grid. CHECK).3.3 3. Cold Start-up.10.A.3. SH) steam temperature gradient.1 Operational and Implementation Aspects Operational Modes This control scheme is required to be operational during start up and normal operation. Controller PC-207 will be switched to MAN.11 For start up see also section 3.008 (Rev 0.V.00 Rev.ABB Lummus Global B. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. Warm Start-up or Hot Start-up. This raise is limited by the allowable steam drum water/steam temperature gradient and superheater (outlet Sec.e. The maximum opening restriction HY-264 is switched-off when the steam pressure has reached the set point value.3 Normal Steady State During normal operation pressure controller PC-207 shall be in MAN.011 Dept. Tag name HS-201 XY-207 HS-265 HS-098 NOTE: DCS – Discrete Control Service Limit Permission to open main steam L block valve MOV-201 if pressure difference is low enough Automatic set point switch-over See settings for start-up with timer Switch set point during start-up See section sequence initializations Switch input signal to PDS-204 See JVN from PICA-070 or PICA-071 section Action Permission Valve/Controller MOV-201 Switch + timer SP change PC-207 PICA-207 IPS . output 0% AUTO at a value of Y bar above normal operating pressure. LGN SREP 04-3001-02.10. Temperature controller TC-254 shall be in AUTO.doc Page 49 of 92 .19 3.10. 0% output when: • Valve PICA-207 is closed and • Valve MOV-201 is open For steam temperature gradient see section 3. 3. NOTE: Service Limit Action Valve/Controller 3.DOT PCFS NEM_R2.

10.V.4 Crippled Mode Operation Instrument Output Controller BAD TC-254 BAD PC-207 BAD Y-100 Tag Name PIA-206 PICA-207 PICA-070/ PICA-071 NOTE: 3. 04217 Project E-15100-TN-5306-0001 Document Number 2. The check valve will keep the line shut in boiler direction. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.19 3.7 Initialisations Ranges TAG PC-207 TC-254 NOTE: Description Boiler pressure Controller Steamdrum temp.011 Dept.3.3. TY-251B ° C/min TY-251C ° C/min PICA-070/ PICA-071 HC-265B HY-264 TC-254 PY265A/B PY-264 3. 2) Sampling time may be up to one minute.6 Calculations Output (y) Calculation Input (x1. 3.5 Action Mode to MAN Mode to MAN Mode to MAN Output Freeze Freeze Freeze Shutdown It is not necessary to close the MOV-201 when taking the boiler out of operation.10.ABB Lummus Global B.x2. gradient controller Range 0 – 100 0 – 100 Units % % LGN SREP 04-3001-02.3.00 Rev.008 (Rev 0.DOT PCFS NEM_R2. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.3.10.10. See also section 3./Sect.doc Page 50 of 92 . May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.x3) TAG TY-251A TY-251B TY-251C TYA-254 (H) TYA-254 (L) PDS-204 PY-265A x1 TY-251 PIA-206 Bar(g) PIA-206 Bar(g) TY-251A ° C/min TY-251A ° C/min PICA-207 HC-265A PC-207 PY-207A PICA-207 x2 x3 d ( x1) 2) y= dt y ≤ f max ∗ x1 + c max 1) y ≥ f min ∗ x1 − c min 1) x1 ≥ x 2 1) x1 ≥ x 2 1) x1 − x 2 ≤ dP 1) High SEL Start up steam pressure PY-207A Low SEL Start up valve opening limited PY-207B High SEL Start up valve opening limited PY-264 High SEL SP reached then start up valve opening limiter removed HY-264 Start up valve opening limiter 1) NOTE: See settings.

V.doc Page 51 of 92 .0577 8 2 Units ° C/min ° C/min Bar 2 120 30 0 .DOT PCFS NEM_R2. Boiler Steam outlet pressure at start-up (PICA-207) Intended boiler steam outlet pressure to connect with steam grid Pre-safety pressure Maximum valve opening during start-up Value 0. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.008 (Rev 0. SP steam pressure at cold start-up (PICA-207) SP steam pressure start-up (PICA-207) Timer to switch PC-207 from MAN to AUTO SP steam pressure at start up Automatic switch puts the measured pressure (PICA-207) in memory (set point) when the first burner is started.00 Rev.0538 7 0.125 Bar(g) Bar(g) seconds Bar(g) Actual pressure 120 Bar(g) Bar(g) 125 (HOLD) 30 Bar(g) % LGN SREP 04-3001-02.A. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.ABB Lummus Global B./Sect. NOTE: Description Trips Level Value Units TAG fmax cmax fmin cmin dP HC-265A HC-207 XY207timer AC-265B PY-265A PY-265B PY302c HY-264 NOTE: Settings Description Gradient for drum temperature increase (start up) Gradient for drum temperature increase (start up) Gradient for drum temperature decrease (shutdown) Gradient for drum temperature decrease (shutdown) Permission to open main steam valve (MOV-201) if pressure drop across valve is low enough Min. TAG PICA-207 PICA-207 TYA-254 High TYA-254 Low NOTE: Description A+ AA+ Load increase ALoad decrease Alarms Level Indication Indication Indication Value 130 115 See calculations See calculations Units Bar(g) Bar(g) ° C/min Indication ° C/min TAG N. 04217 Project E-15100-TN-5306-0001 Document Number 2. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.011 Dept.

4 History Date 20-07-2007 Author HuR/WiH Description Original Document LGN SREP 04-3001-02.3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.3.9 Operator Interfaces Operator can access tags on the DCS.doc Page 52 of 92 .10.00 Rev.10. 3.3.DOT PCFS NEM_R2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.ABB Lummus Global B./Sect.10. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.V.011 Dept.11) • Steam flow through the superheater to cool the superheater tubes (CHECK) • Pressure gradient at boiler outlet to limit the start-up time 3.008 (Rev 0.8 Interfaces N/A. 3. 04217 Project E-15100-TN-5306-0001 Document Number 2. 3.10 Special Considerations During start-up following critical process parameters must be kept within allowable limits: • Steamdrum water/steam temperature gradient • Steam temperature gradient (see also section 3.10.

DOT PCFS NEM_R2. To avoid entrance of not evaporated water into the superheater sections behind the desuperheater the set point of both controllers is limited such that the steam temperature will not become lower then a predefined value above saturation temperature. 3. TC-215.1 Objective The steam temperature control has the objective to control the final superheater temperature and to limit the superheater tube wall temperatures. 3. TC-214 LAE20AA014 (TICA-215). 04217 Project E-15100-TN-5306-0001 Document Number 2. The set point to control the steam temperature at outlet of the secondary superheater will be load dependent./Sect. Both control loops are controlling the steam temperature in such a way that the total spray water flow to control valves LAE10 AA014 (TICA-214) and LAE20 AA014 (TICA-215) is as much as possible divided equally over both control valves. TC-215B TC-202 P&ID 36005-105-05 PCD UEFS E-15100-TN-2395-0034 Superheater System 116 Steam Boiler Package A-15101 – Superheater System 3.008 (Rev 0. TC-212. Upon a trip of UZ-550 and/or UZ-560 also controller TC-214 and/or TC-215 will be put to MAN. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. The firing/steam unbalance occurs during load variations where the fuel input is not corresponding with the steam pressure. The firing/steam unbalance will be used as a feed forward signal to both control valves to anticipate on load variations. The second controller is controlling the steam temperature at the outlet of the secondary superheater by means of control valve LAE10 AA0014 (TICA-214). This is to avoid lifetime reduction and/or damage to the steam system. The boiler is designed to control the steam temperature at the superheater outlet at a constant value within the boiler load range of 40% . The normal set point is 525°C. This spray water is taken from the feedwater line to the boiler upstream of the feedwater control valve.doc Page 53 of 92 . The effect of the firing/steam unbalance can be adjusted by the gains TY-253A and TY253B.11.00 Rev.11 BOILER STEAM DESUPERHEATER TEMPERATURE CONTROL LAE10AA014 (TICA-214).100% MCR.11.011 Dept. The first controller controls the final steam temperature at the outlet of the tertiary superheater by means of control valve LAE20 AA0014 (TICA-215). Also when the steam temperature at the outlet of both desuperheaters becomes too high the steam temperature will be limited.ABB Lummus Global B. In case the final steam temperature becomes too high the boiler will be tripped. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. LGN SREP 04-3001-02. In case the steam temperature falls below its minimum the spray water supply will be shutoff by closing valves LAE10 AA011 (UZ-552) and/or LAE20 AA011 (UZ-562).2 Functional Description For steam temperature control two cascade control loops are used. Steam temperature control is achieved by regulating the spray water flow to two (2) inter-stage desuperheaters.V. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. output to 0%.

V.3 3.ABB Lummus Global B.doc . May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. This controller limits the heat input to the burners during start up.3.3.0% Boiler trip Valve/Controller UZ-552 UZ-562 LAE10AA011 LAE20AA011 TC205 Natural gas Fuel Oil Atomising valves TZA-218 1) 1) Steam Temperature too high HH NOTE: 3. Tag name TC-212 TC-214 TY204a.b TC-202 NOTE: DCS .2 Start up See also section 3./Sect. The steam temperature at the outlet of the secondary superheater is controlled by the slave controller but has also a steam temperature gradient controller (TC-202). 3.Discrete Control Service Steam Temperature too close to saturation.Analogue Control Service Action PID Direct PID Direct FF & SEL PID Direct PID Direct FF & SEL PID Indirect PV-Tracking Yes Yes Yes Yes Yes Yes Yes Valve Name TICA-214 TICA-215 - Tag name 1) TZA-211 TZA-213 1) IPS . Steam Temperature too close to saturation. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.19 3.00 Rev.11.b TC-215B TC-215 TY206a.1 IPS (SIL1) Operational and Implementation Aspects Operational Modes This control scheme is required to be operational during start up and normal operation.3. No BFW supply Limit LL LL LL Action Close Close Close Close MAN . 3. normal operation and shutdown if the steam temperature gradient exceeds allowable limits.008 (Rev 0. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. TC-215/TC-215B and TC-202 shall be in AUTO.11.3.011 Dept.3 Normal Steady State During normal operation the temperature controllers TC-212/TC-214.DOT PCFS NEM_R2.11. 04217 Project E-15100-TN-5306-0001 Document Number 2.4 Crippled Mode Operation Instrument Output Controller BAD BAD TC-214 BAD BAD TC-212 Tag Name TIA-210 TICA-214 1) TZA-211 TIA-212 Action Mode to MAN - Output Freeze Freeze Freeze Freeze Page 54 of 92 LGN SREP 04-3001-02.11.11.

doc Page 55 of 92 .ABB Lummus Global B.011 Dept.11. 04217 Project E-15100-TN-5306-0001 Document Number 2.00 Rev.V. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.11. TICA-215 1) TZA-213 TICA-217 1) TZA-218 1) NOTE: IPS 3. x 2 + ∆TSAT ) High SEL TY-202B TY-202C PV Fuel flow (in %) TY-251 ° C TY-253B ° C HC-214D TY-214A TY-214B TY-214C TY-253A TY-253B TY-215A TY-215B y = x1 − x 2 y = MAX ( x1.6 Calculations Output (y) Calculation Input (x1.008 (Rev 0.x3) TAG TY-202A TY-202B (H) TY-202C (L) TYA-202 High TYA-202 Low TY-252 TY-251 TY-253 x1 TIA-212 PIA-206 PIA-206 TY-202A TY-202A PT-205 PIA-206 PV SHP steam flow (in %) TY-214B ° C TC-212 ° C TY-214A TY-253 TY-253 TY-215B ° C TC-215B ° C x2 x3 y= d ( x1) 2) dt y ≤ hmax ∗ x1 + k max 1) y ≥ hmin ∗ x1 − k min 1) y = x1 − x 2 y = x1 − x 2 y = SaturationTemperature(x1) y = SaturationTemperature(x1) ( x 2 − x1) y= x1 y = MAX ( x1. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.DOT PCFS NEM_R2.x2. x 2) For NG only y = x1 ∗ G253 A y = x1 ∗ G253 B y = MAX ( x1./Sect.19 3. x 2 + ∆TSAT ) High SEL TY-251 ° C TY-253A ° C y = x1 − x 2 LGN SREP 04-3001-02. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.3.5 Shutdown BAD BAD BAD BAD TC-215 TC-215B - Mode to MAN Mode to MAN - Freeze Freeze Freeze Freeze See also section 3.3.

Sampling time may be up to one minute.00 Rev. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.ABB Lummus Global B.100 0 . TY-212 y = T (x1) PV SHP steam (t/h) y = M ST 1 ∗ x1 + TST 1 . 3.doc Page 56 of 92 .3.7 Initialisations Ranges TAG TC-212 TC-214 TC-215B TC-215 TC-202 NOTE: Description Master Sec. Inlet temperature controller Sec.011 Dept. 482 478 495 TZA-211 TZA-213 TY-252 TY-252 y = CLOSE if ( x1 < x 2 + ∆TSAT ) y = CLOSE if ( x1 < x 2 + ∆TSAT ) See settings. 04217 Project E-15100-TN-5306-0001 Document Number 2. Inlet temperature controller Slave Sec. if ( x1 ≤ 126 t / h) y = M ST 2 ∗ x1 + TST 2 . Superh./Sect.100 440 – 480 0 .V.DOT PCFS NEM_R2. if ( x1 > 126 t / h) Load(%) 40 70 100 UZ-550 UZ-560 NOTE: 1) 2) Steam(t/h) 72 126 180 Temp. Superh. Inlet temperature controller Slave Tert. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.11.100 Units ° C % ° C % % TAG TIA-210 TICA-214 TICA-214 TZA-211 TIA-212 TICA-215 TICA-215 TZA-213 TICA-217 TICA-217 TZA-218 TYA-202 (H) TYA-202 (L) NOTE: Description A+ AA+ AA+ AA+ AAA+ A+ A+ A- Alarms Level Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Value 440 360 395 360 505 360 475 360 510 535 535 See calculation See calculation Units ° C ° C ° C ° C ° C ° C ° C ° C ° C ° C ° C ° C/min ° C/min LGN SREP 04-3001-02. Superh. Superh. Gradient controller Range 370 – 400 0 .008 (Rev 0. Superh. Inlet temperature controller Master Tert.

/Sect.4098 Units ° C/min - 55 ° C/min ∆TSAT TMAX LHV205 LHV206 G253A G253B MST 1 TST 1 MST 2 TST 2 HC-215B HC-214D 30 500 47. Maximum temperature outlet secondary superheater Lower heating value NG Lower heating value CO Gain for feedforward signal to temperature control Gain for feedforward signal to temperature control Flow constant for load dependent set point Temperature constant for load dependent set point Flow constant for load dependent set point Temperature constant for load dependent set point Set point SHP steam temperature outlet boiler Low SEL (Maximum temperature in case of NG firing) Value 0.008 (Rev 0.08 488 0.DOT PCFS NEM_R2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.525 380 ° C ° C kJ/t kJ/kg ° C ° C NOTE: LGN SREP 04-3001-02.doc Page 57 of 92 .6 39500 HOLD HOLD -0.011 Dept. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.00 Rev. TAG TZA-211 TZA-213 TZA-218 NOTE: Description Z-Z-Z++ Trips Level SIL1 SIL1 SIL1 Value 330 330 540 Units ° C ° C ° C Settings TAG hmax kmax hmin kmin Description Gradient for superheater temperature increase (start up) Gradient for superheater temperature increase (start up) Gradient for superheater temperature decrease (shutdown) Gradient for superheater temperature decrease (shutdown) Required temperature difference above saturation. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. 04217 Project E-15100-TN-5306-0001 Document Number 2.ABB Lummus Global B.3 440 515 .V.4344 22 0.

3.V.9 Operator Interfaces Operator can access tags on the DCS. 3.11. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120./Sect.3.11.8 Interfaces N/A. 04217 Project E-15100-TN-5306-0001 Document Number 2.ABB Lummus Global B.10 Special Considerations The setpoint of the controller TC-215B may be changed.3.doc Page 58 of 92 . Closing the block valves LAE10 AA011 (UZ-552) and LAE20 AA0011 (UZ-562) upstream the desuperheaters is a SIL 1 application. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.11.011 Dept.3. 3. C. but only to a temperature between 515 and 525 ° by the operator.008 (Rev 0.00 Rev. 3.11. The mode of this cont roller shall always be AUTO.4 History Date 20-07-2007 Author HuR/WiH Description Original Document LGN SREP 04-3001-02.DOT PCFS NEM_R2.

/Sect. To avoid a too high blow down flow when the drum is pressurized the output to the control valve (HAD10 AA471. 3.LICS-202A) is limited based on the square root of the drum pressure in LGN SREP 04-3001-02.2 Functional Description Condensate: As condensate can occur during different start up conditions the control valve opening position is pressure depended. To assure that all condensate is removed the main steam drain valve LBA10 AA404 (TICA-217) will be closed if superheated conditions have been reached. 3. The drain valves HAH10 AA404 (FIC-204A) and HAH10 AA424 (FIC-204B) will be closed when the boiler steam flow becomes > HC-202 t/h (see setting list below) According to PCD117 these valves close at a certain steam flow. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. Industrial water (GAC10 BR010) is supplied to the water outlet of the intermittent blowdown drum to reduce the water temperate to the sewer. HAD10AA470 (LICS-202).12.1 Objective Condensate will be formed in the superheaters and connecting piping if the boiler is shutdown and during start-up. The boiler intermittent blowdown (HAD10 BR470) might be opened during start up (swell) and is also opened during normal operation upon a high level in the steam drum. HAD10AA471 (LICS-202A).doc Page 59 of 92 .V. Steam flow is measured and is pressure and temperature compensated.ABB Lummus Global B. The boiler drain control has the objective to discharge this condensate to the intermittent blowdown drum during start up of the boiler. TS404 gets a signal from FY102 which is P.00 Rev. GAC10AA011 (TICA-219). HAD10AA460 (QISA-202) P&ID 36005-105-04 36005-105-07 36005-105-08 36005-105-09 PCD UEFS E-15100-TN-2395-0036 E-15100-TN-2395-0043 Evaporator System Drain System Blow Down System Sample unit 117 Steam Boiler Package A-15101 – Blowdown & Drain System Steam Boiler Package A-15101 – Sample Unit 3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. Intermittent blowdown: Intermittent blow down control is used during start-up and in normal operation if the water level in the drum becomes too high and is carried out by means of a proportional controller. LBA10AA404 (TICA-217).DOT PCFS NEM_R2.12 BOILER DRAIN AND BLOWDOWN CONTROL HAH10AA404 (FIC-204A).011 Dept. The Gain for the controller can be set to 100% divided by the difference between NWL drum level and drum level H alarm setting HOLD. 04217 Project E-15100-TN-5306-0001 Document Number 2. The intermittent blow down control is normally designed to allow sufficient blow down when the drum is at low pressure. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. A continuous blowdown (HAD10 BR460) is provided to control the quality of the drum water and to avoid scaling on the heat transfer areas of the drum. to avoid foaming and to assure the quality of the produced SHP Steam.12. The set point for this controller is adjusted to the same value as for the drum level high alarm. HAH10AA424 (FIC-204B).T compensated.008 (Rev 0.

008 (Rev 0.doc Page 60 of 92 . Pdrum In this formula the constant Cvalve is the drum pressure where the control valve is allowed to open fully at controller output of 100% (Cvalve see setting list below)./Sect. The HP intermittent blow down valve LICS-202B is on AUTO after valve LICS-202B is opened (ZS = 100%). The HP intermittent blow down valve LICS-202B is closed after control valve LICS-202A is closed (ZS = 0%) for a certain time (tclose see setting list below). The amount depends on the water quality in the drum. also when the blow down control is in MAN mode. Continuous blowdown At normal operation boiler water from the drum will be discharged via the continuous blowdown valve to an external system. Blowdown water temperature: Blowdown water of 100° will be mixed with industri al water to limit the temperature to the C sewer system to 50° Temperature control of the mi xed flows is achieved by temperature C. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. accordance with the formula C valve . This limitation shall always be present to avoid damage to the blow down tank.V.011 Dept. PENDING Decision by JV Tag name LC-207 TC-219 FC-202 TC-217 DCS .00 Rev. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. 04217 Project E-15100-TN-5306-0001 Document Number 2. Valve HAD10 AA460 (QISA-202) will be opened/closed by the measured conductivity.Discrete Control Tag name ZS-202B ZS-202A TS-403 Service LC-207 in AUTO if LICS-202B is open LICS-202B to close if LICS-202A is closed for tIBD-valve Close main steam line drain valve if steam flow is enough superheated during start-up Close superheater drain valves if steam flow is during start-up Open Close IBD block valve LICS202B in case the level becomes too high is low enough Limit 100% 0% H Action AUTO Close Close Valve/Controller LC-207 LICS-202B LBA10AA404 TS-404 LS-207 H H Close Open Close HAH10AA404 HAH10AA424 LICS-202B LGN SREP 04-3001-02. The design blowdown capacity will be < 2% of the maximum economizer flow and is measured by HAD10 CF101 (FI-210). The flow has to be manually adjusted by valve HAD10 AA461. controller TC-219. A too high temperature will be alarmed. Based on the results of the water quality samples the operator can choose to adjust the valve opening of HAD10 AA461.DOT PCFS NEM_R2.ABB Lummus Global B.Analogue Control Service Action PID Direct PID Direct PID Direct PID Direct PV-Tracking No No No No Valve Name LICS-202A TICA-219 FIC-204A/B TICA-217 DCS . The HP intermittent blow down control valve LICS-202A is set to –10% opening (MAN 0% output) as soon as drum level is at NWL for a certain time (tclose see setting list below).

ABB Lummus Global B.V.

Client Subject

SHELL EASTERN PETROLEUM (PTE) LTD. PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011 Dept./Sect.

04217 Project

E-15100-TN-5306-0001 Document Number

2.00 Rev.

QIS-202

Open CBD valve QISA-202 for t202 minutes if the conductivity in the drum is too high Close CBD valve if conductivity after timer t202 is elapsed. This CBD valve is working “discontinuously”. Please consider to install a “continuously” working CBD valve. If this is not possible or not preferred by NEM, please explain. PENDING (decision by JV see conference notes 2007-04-03)

H

Open

QISA-202

t202

Close

QISA-202

NOTE: IPS - Discrete Control Tag name N.A. NOTE: Service Limit Action Valve/Controller

3.12.3 3.12.3.1

Operational and Implementation Aspects Operational Modes This control scheme is required to be operational during start up and normal operation.

3.12.3.2

Start up See also section 3.19

3.12.3.3

Normal Steady State During normal operation the controllers LC-207, TC-219, FC-202 and TC-217 shall be in AUTO.

3.12.3.4

Crippled Mode Operation Instrument Output Controller BAD BAD TC-219 BAD BAD LC-207 BAD BAD BAD BAD -

Tag Name LIA-203 TICA-219 FI-210 LY-202A QIA-202 QIA-203 QIA-204 QIA-205 NOTE:

Action Mode to MAN Mode to MAN -

Output Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.DOT

PCFS NEM_R2.doc

Page 61 of 92

ABB Lummus Global B.V.

Client Subject

SHELL EASTERN PETROLEUM (PTE) LTD. PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011 Dept./Sect.

04217 Project

E-15100-TN-5306-0001 Document Number

2.00 Rev.

3.12.3.5

Shutdown See also section 3.19

3.12.3.6

Calculations Output (y) Calculation Input (x1,x2,x3)

TAG TS-403

x1
CT001

x2
LBA10 CP001

x3

y = 0% if ( x1 > TSAT ( x 2) + ∆TSAT LBA10 else y = 100%
DELETED

TY-217

y = Tsat ( x1) + ∆TSAT )
SP for temperature controller at which valve TICA-217 is closed

PICA-207

TY-217A TY-217B TS-404

y=

C 217 A

PICA-207 TC-217 FY-102 TY-217A

x1 y = MIN ( x1 (digital ), x 2 (digital ))

Low SEL

y = 0% if ( x1 > x%) else y = 100%

DELETED FY-202A

y=

C 202 A x1

PIA-206

HOLD FY-202B LY-206A Explain function TS-404

y = MIN ( x1 (digital ), x 2 (digital ))

FS-202 LICSA-202

FY-202A

Output limiter

y = x1 + ∆L206 A
Signal to open IBD control valve if drum level exceeds ∆L mm above SP

y = 100% if ( x1 > x 2 + ∆L401b ) else y = 0%
DELETED

FY102

PY-207

y=

C 207 x1

PIA-206

HOLD LY-207 QIS-202

y = MIN ( x1 , x 2 ) y = 100% ( for t 202 min)

LC-207 QIA-202

PY-207

Low SEL

if x1 > K 202 else y = 0%
PENDING (decision by JV see conference notes 2007-04-03) NOTE:

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.DOT

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Page 62 of 92

ABB Lummus Global B.V.

Client Subject

SHELL EASTERN PETROLEUM (PTE) LTD. PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011 Dept./Sect.

04217 Project

E-15100-TN-5306-0001 Document Number

2.00 Rev.

Please describe: TY403b Low Selector? NO, is output limiter TY404b Low Selector? NO, is output limiter

YES, Low SEL YES, Low SEL

3.12.3.7

Initialisations

Ranges TAG TY-403 TY-404 FC-202 TC-217 TC-219 LC-207 NOTE: Description Switch close/open Switch close/open Steam flow controller drain valves FIC-204A/B Steam tempeprature controller drain valve TICA-217 Industrial water temperature controller IBD level controller Range 0/100 0/100 0 - 100 0 - 100 0 - 100 0 - 100 Units % % % % % %

TAG LIA-203 QIA-202 QIA-203 QIA-203 QIA-204 QIA-205 TICA-219 NOTE:

Description A+ A+ AA+ A+ A+ A+

Alarms Level Indication Indication Indication Indication Indication Indication Indication

Value 1400 50 9.8 10.2 0.15 0.15 55

Units mm (above bottom TL) µs pH pH µs µs ° C

TAG N.A. NOTE:

Description

Trips Level

Value

Units

Settings TAG HC-202 Description Set point flow controller at which drain valves FIC-204A/B will be closed Constant Cvalve is the drum pressure where the control valve LICS-202A is allowed to open fully at controller output of 100% Timer for set point -10% (MAN 0% output) opening IBD control valve LICS-202A after NWL is reached Value 15 Units t/h

Cvalve

0.2

Bar(g)

tclose

60

seconds

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.DOT

PCFS NEM_R2.doc

Page 63 of 92

011 Dept.12.12.3.67 HOLD As alarm from transmitter 50 ° C √(Bar) √(Bar) mm mm √(Bar) hours LC-207 K202 Gain for LC-207 (100%/150mm) HOLD Maximum allowable conductivity µs HC-219 NOTE: SP temperature controller ° C 3.ABB Lummus Global B.10 Special Considerations A too high level in the intermittent blowdown drum will give an alarm. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE./Sect. to be finalized during operation 0.doc Page 64 of 92 .9 Operator Interfaces Operator can access tags on the DCS. 3. 04217 Project E-15100-TN-5306-0001 Document Number 2.DOT PCFS NEM_R2.12.3. 3.4 History Date 20-07-2007 Author HuR/WiH Description Original Document LGN SREP 04-3001-02.3. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. 3.008 (Rev 0.12.8 Interfaces N/A. tIBD-valve ∆TSAT C217A C202A ∆L206 A ∆L401a C207 t202 Timer for to close valve LICS202B after IBD control valve LICS-202A is closed Required temperature difference above saturation. Constant which limits opening of the valve at higher pressures Constant which limits opening of the valve at higher pressures Level margin to open IBD block valve LICS-202B Level margin to close IBO valve Constant which limits opening of the valve at higher pressures Timer for opening CBD valve QISA-202 PENDING (decision by JV see conference notes 2007-04-03) 60 seconds 30 To follow To follow 150 160 To follow 4 Initial. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.00 Rev.V.

13. KT-15161 Woodward Governor 151UC-xxx (start/stop turbine/motor & turb. 3.DOT PCFS NEM_R2. turbine and fan Lube oil temperature in tank Valve Name UC-581 PIC-225 Tag name UC-580 PIC-225 Tag name PISA-222 UC-580 ST-206 TA-258 Limit L 0 H Action Start aux. 2.011 Dept.008 (Rev 0. The lube oil is supplied by the shaft driven oil pump to the bearings of the whole FD Fan train. oil pump Stop aux. The speed controller (UC-580) of the steam turbine controls the position of the steam governor valve.13. oil pump Switch heater off Valve/Controller LGN SREP 04-3001-02. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. 3./Sect.p.doc Page 65 of 92 . which receive its signal for the required air flow from the combustion air flow controller FC-202B.1 Objective The objective for the dual driven FD Fan is to supply combustion air to the boiler in a controlled manner.V.00 Rev. Following control/safeguarding blocks: 1.13 DUAL DRIVEN FD FAN P&ID 36005-560-04-151 36005-560-04-151-002 36005-105-13 PCD UEFS E-15100-TN-2395-0041 E-15100-TN-2395-0044 Reference documents 36005-560-04-148 36005-560-04-148-001 Steam Boiler Package A-15101 – Dual Driven FD Fan Steam Boiler Package A-15101 – Lube Oil System Operating procedure Control Narratives 3. control) KT-15161 Bentley Nevada 151UZ-xxx (monitoring/safeguarding) KT-15161 FD Fan Operation 151US-xxx (driver selection) DCS . The speed of the FD Fan and steam turbine will be kept constant over the operating range by control of the steam flow through the steam turbine.m.ABB Lummus Global B.Discrete Control Service Lube oil pressure to bearings R. 3. 04217 Project E-15100-TN-5306-0001 Document Number 2.2 Functional Description The FD fan capacity is controlled with the IGV damper. The fan will be driven by a steam turbine as main driver and in case the steam turbine is not available or tripped the driving function is taken over by an electric motor.Analogue Control Service Action PV-Tracking PID Direct Yes PID Direct Yes DCS . May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. The oil pressure to the bearings is controlled by pressure controller PIC-225.

Normal operation: The FD Fan is dual driven by a steam turbine or electric motor. Automatic clutches will engage the driver with the highest speed and disengage the driver with the lower speed. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. When the steam turbine is in operation the electric motor is decoupled and v. Start up/shutdown: Start up and shutdown of the FD Fan unit can be done automatically from the DCS and manually from a local panel (see also section start up below).3 3.doc Page 66 of 92 . In general the driver with the highest speed will drive the FD Fan. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. High temperature is a SILa classification Decision by JV 3. The steam turbine outlet is connected to the LP steam system.13. and take-over.1 Operational and Implementation Aspects Operational Modes This control scheme is required to be operational during start up./Sect. At steam turbine trip the steam to the turbine is immediately shut off. The FD Fan is normally driven by the steam turbine.V.ABB Lummus Global B.011 Dept. LGN SREP 04-3001-02. The FD Fan train runs at the following speeds: • Steam turbine: 4762 rpm • FD Fan: 1500 rpm • Electric motor: 1500 rpm Steam for the steam turbine is coming from the HP steam system. The steam turbine will keep the speed constant over the load range by admit more or less steam to the turbine. 04217 Project E-15100-TN-5306-0001 Document Number 2.Discrete Control Service Steam turbine speed Steam turbine inlet temperature FD Fan bearings Lube oil pressure to bearings Lube oil pressure to bearings Limit H S HH LL HH PZA-223 NOTE: Note: Action Trip turbine Trip turbine Trip Fan Trip Fan Trip Fan Valve/Controller UC-581 UC-??? UC-581 UC-??? Trip steam turbine TISA-249 HOLD.DOT PCFS NEM_R2.13. TA-258 NOTE: Lube oil temperature in tank L Switch heater on Tag name UC-580 TISA-249 IPS . The FD Fan operation is continued by automatic start of the electric motor (starting time approximately 17 seconds). The trip signal will ramp down the speed set point of the turbine to zero.3. Automatic take-over: With the steam turbine in operation an automatic take-over takes place in case of a steam turbine trip. shutdown.00 Rev. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. normal operation. When the turbine speed indicates no speed (for x seconds HOLD) the steam governor switches to shutdown and the steam governor valve (UC-581) will than be closed.008 (Rev 0. The electric motor serves as a back up.v.

008 (Rev 0.13.V.ABB Lummus Global B.011 Dept. 3. For take over from electric motor to steam turbine start up procedure (see 3. lube oil system ready.3. LGN SREP 04-3001-02.3. Manual take-over: A planned take-over from steam turbine to electric motor or from electric-motor to steam turbine has to be done manually (from DCS or local panel). A manual takeover takes to much time and in this case a boiler start up procedure has to be initiated. Steam turbine/Gearbox permissive • Verify steam turbine/gearbox bearing temperatures are within operating range./Sect. General permissive • Verify steam conditions are within operating range • Steam lines pre-heated.2 Start up Start up and preparations prior to start up have to be done manually with local actions and supervision of the operator (i.2) has to be followed: Trip/stop electric motor A trip or stop of the electric motor leads to a shutdown or trip of the boiler. The steam turbine will be started according the normal start up procedure and when the steam turbine reaches his normal speed the electric motor can be switched off. During take-over. generally the driver with the highest speed will drive the FD Fan.00 Rev.13. From steam turbine to electric motor (Preliminary) For take over from steam turbine to electric motor next procedure has to be followed: • Start permissive when electric motor temperatures is within operating range • Start electric motor to full speed 1) • Auxiliary lube oil pump will start automatically if PISA-222 is LOW • Speed set point is ramped to zero (slow rate) • When set point is zero.DOT PCFS NEM_R2. manual actions (preheating steam lines to and from steam turbine.doc Page 67 of 92 . PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.). • Valves in correct position • Lube oil system ready 2) • Verify steam turbine doesn’t accelerate/run if steam inlet/outlet valves are opened • Emergency cooling water system in circulation Note: 2) If turbine starts running close steam valve LBG10 AA010/015 FD Fan permissive • Verify IGV FD Fan closed to minimum stop • Verify impeller is not rotating • Verify FD Fan bearing temperatures are within operating range. 04217 Project E-15100-TN-5306-0001 Document Number 2. steam systems available.e valves in correct position. etc). • Verify Woodward governor is shutdown (governor valve closed) • Emergency trip is reset (if required) (DCS or LOCAL) • Steam turbine housing preheated (preferred but not required). Prior to start up a selection has to be made which driver should be started. emergency cooling water available. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. valve limiter is stepped to zero 1) Manual start from local panel also possible From electric motor to steam turbine (preliminary) The take-over from E-motor to steam turbine needs additional local. valves in correct position etc.

noise). • Lube oil system is in operation and conditions are verified.10). • Electric motor permissive and lube oil permissive are fulfilled.00 Rev./Sect. • Check differential temperature between steam turbine inlet and outlet (dT < 177° C) • Check oil temperature outlet oil/water cooler E-15163 (Toil < 49° C) Ramp up of the steam turbine to nominal speed will be done according a programmed sequence. FD Fan operation After steam turbine or electric motor is in stable operation the FD Fan runs with IGV’s in minimum opening position. • Verify steam turbine. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.011 Dept. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. start can be released when: • Electric motor temperatures within temperature range.e.008 (Rev 0.V. E-motor permissive • Verify bearing temperatures are within operating range. 04217 Project E-15100-TN-5306-0001 Document Number 2. The governor valve position will be controlled by the speed controller.doc Page 68 of 92 . LGN SREP 04-3001-02. If excessive conditions occur the steam turbine must be shutdown. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. • Verify lube oil pressure when running with main pump (shaft driven) • Verify gearbox vibration is within operating range Start electric motor operation When the electric motor is selected. During start up conditions of steam turbine and FD Fan need to be checked (i.3.ABB Lummus Global B. • Verify is FD Fan speed is 0 rpm or 1500 rpm Lube oil unit permissive • Verify emergency cooling water conditions (press/temp) are within operating range • Lube oil reservoir level > LOW Start lube oil unit (DCS or LOCAL) • Lube oil system to be started with the auxiliary lube oil pump (motor driven). oil temperatures. Note: The number of starts with the E-motor is limited (see section 3. pressures.13. meanwhile checking conditions of the FD Fan unit Steam turbine in normal operation • Governor at will ramp up speed to nominal speed (4762 rpm) • When the oil pressure of main pump PISA-222 is within operating limits the auxiliary lube oil pump can be switched off manually. • Verify lube oil pressure (PISA-222) within operating range • Verify differential pressure (PDIA-226) lube oil filter < HIGH • Verify water content (QIA-206) < HIGH • Verify bearing and gearbox temperatures are within operating range Start steam turbine operation (DCS or LOCAL) • Put governor in start function • Start steam turbine • Governor will ramp up turbine to nominal speed to minimum operating speed (500 rpm HOLD). vibrations. The turbine runs for (15 minutes at 500 rpm HOLD). FD Fan and lube oil temperature is within operating range.DOT PCFS NEM_R2.

4 Crippled Mode Operation Instrument Controller Action 1) Manual Stop steam turbine Manual Stop steam turbine Manual Stop steam turbine Manual Stop steam turbine Manual Stop steam turbine 1) Tag Name TIA-231A & TIA-231B TIA-232A & TIA-232B TIA-233A & TIA-233B TIA-234A & TIA234B TIA-235A & TIA-235B & TIA-235C TIA-236A & TIA-236B TIA-237A & TIA-237B TIA-238A & TIA-238B & TIA-238C TIA-239 TIA-240 TIA-241 TIA-243 XIA-201 ST-202A & ST-202B ST-204 TI-201 Output BAD BAD BAD BAD BAD Output Freeze Freeze Freeze Freeze Freeze 1) 1) 1) BAD BAD BAD - Manual Stop steam turbine Manual Stop steam turbine Manual Stop steam turbine 2) 1) Freeze Freeze Freeze 1) 1) BAD BAD BAD BAD BAD BAD BAD BAD UC-580 - Manual Stop FD-Fan 2) Manual Stop FD-Fan 3) Manual Stop E-motor 3) Manual Stop E-motor 4) Manual Stop steam turbine Mode to MAN PCFS NEM_R2.DOT . 04217 Project E-15100-TN-5306-0001 Document Number 2.011 Dept. See also section 3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. The pressure controller PIC-225 in the lube oil system will always be on AUTO.3 Normal Steady State During normal operation the steam turbine speed controller (UC-580).3.13. Controls Steam turbine/motor/lube oil unit At starting of the steam turbine the turbine speed controller (UC-580) is in start up mode.V. FD Fan At starting of the boiler the controllers FC-202B and QC-021 are in MAN mode.doc Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Page 69 of 92 LGN SREP 04-3001-02. 3. When the speed reaches normal set point the controller will be switched to AUTO.008 (Rev 0.19 3. oil pressure controller (PIC-225) and controllers FC-202B and QC-021 shall be in AUTO.13.00 Rev. Both controllers can be put on AUTO when: • All burners are in operation HOLD • FD Fan unit is in stable operation The controllers FC-202B and QC-021 receive their set points from the overall load control./Sect.3. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.ABB Lummus Global B. output 0%.

Shutdown with electric motor • IGV FD Fan to minimum position • Activate E-motor stop • When the electric motor is switched off and the speed of FD Fan = 0 rpm stop the auxiliary lube oil pump after 60 seconds Note It is only for a limited time allowed to keep a combustion air flow through the boiler when the boiler is not in operation anymore.5 Shutdown Shutdown with steam turbine The normal shutdown procedure of the turbine has to be followed.008 (Rev 0. 5) 04217 Project E-15100-TN-5306-0001 Document Number 2. The air will forcibly cool down the boiler in a rapid time. During shutdown the auxiliary lube oil pump is started if the lube oil pressure (PISA – 222 or PIS – 227/327/427) is < L.DOT PCFS NEM_R2. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. lube oil pump 11) Check/adjust control valve PIC-225 3.3. • When the speed of Steam Turbine and FD Fan = 0 rpm stop the auxiliary lube oil pump after 60 seconds • Close steam valves LBG10 AA010 and AA015 3) Manual start from local panel also possible.ABB Lummus Global B.00 Rev./Sect. governor is shutdown and governor valve closes.13. LISA-204 BAD Note Freeze 6/7) TA-258 BAD Note Freeze 8) PDIA-226 BAD Note Freeze 9) QIA-206 BAD Note Freeze 10) PISA-222 BAD Note Freeze 11) PZA-223 BAD Note Freeze PT-225 BAD PIC-225 Mode to MAN Freeze 1) NOTE: When two/three signals are BAD stop turbine manually and start E-motor if possible 2) Steam turbine and E-motor must be stopped 3) Start steam turbine if possible 4) When signal is BAD stop turbine manually and start E-motor if possible 5) Shut off heater and check oil level 6) When HIGH switch heater off 7) When LOW switch heater on 8) Switch-over to other filter 9) Check oil system and replace oil content 10) Automatic start aux. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. may be too fast with respect to temperature gradients in the steamdrum and superheater headers.19 LGN SREP 04-3001-02.V.011 Dept. valve limiter is stepped to zero • If steam turbine speed is zero.doc Page 70 of 92 . See also section 3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. • IGV FD Fan to minimum position • Activate steam turbine stop • Speed set point is ramped to zero (slow rate) 3) • Auxiliary lube oil pump will start automatically if PISA-222 is LOW • When set point is zero.

Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. 3.5 100 2.x2. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.75 Units rpm ° C ° C ° C ° C ° C ° C ° C ° C ° C ° C ° C ° C ° C 2 mm/s or G mm ° C ° C Bar(a) ppm Bar(g) Bar(g) LGN SREP 04-3001-02.25 1./Sect.6 Calculations Output (y) Calculation Input (x1.100 0 .doc Page 71 of 92 .3.DOT PCFS NEM_R2.13. lub e oil pump if ( x1 & x 2 = 0 rpm for t stop sec onds ) x1 UC-580 x2 ST-204 x3 NOTE: 3.008 (Rev 0.7 Initialisations Ranges Description Lube oil pressure controller Speed controller TAG PIC-225 UC-580 NOTE: Range 0 .011 Dept. 04217 Project E-15100-TN-5306-0001 Document Number 2.13.100 Units % % TAG ST-204 TISA-249 TIA-231A/B TIA-232A/B TIA-233A/B TIA-234A/B TIA-235A/B/C TIA-236A/B TIA-237A/B TIA-238A/B/C TIA-239 TIA-240 TIA-241 TIA-243 XIA-201 LISA-204 TA-258 TA-258 PDIA-226 QIA-206 PISA-222 PISA-222 Description A+ A+ A+ A+ A+ A+ A+ A+ A+ A+ A+ A+ A+ A+ A+ AA+ AA+ A+ A+ A- Alarms Level Indication Indication 1) Indication 1) Indication 1) Indication 1) Indication 1) Indication 1) Indication 1) Indication 1) Indication 2) Indication 2) Indication 3) Indication 3) Indication 4) Indication Indication Indication Indication Indication Indication Indication Indication 5) 6) 7) 8) 9) 10) 11) Value 1550 400 110 110 105 105 105 105 105 105 80 80 80 80 58840 or 6 250 70 5 1.x3) TAG ????? y = stop aux.ABB Lummus Global B.00 Rev. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.3.V.

lube oil pump 11) Check/adjust control valve PIC-225 Trips Level SILa SIL1 - 1) TAG Description UC-580/ Z+ UZ-571 1) SS-207 Z+ TISA-249 S 2) PZA-223 Z-3) PZA-??? Z1) NOTE: Mechanical trip 2) Trip FD Fan and driver 3) Mechanical trip Note: Value 5450 5500 430 1. Following functions/signals are present: 151HS-xxx 151HS-xxx 151HS-xxx 151HS-xxx 151HS-xxx 151HS-xxx Switch in DCS Switch in DCS Switch on local panel Switch in DCS Switch on local panel Switch on local To select type of driver: steam turbine or motor To start/stop KT-15161 To start/stop KT-15161 To start/stop KM-15161 To start/stop KM-15161 To start/stop KT-15161 PCFS NEM_R2.62 Units rpm rpm ° C Bar(g) Bar(g) Trip steam turbine TISA-249 HOLD High temperature is a SILa classification Decision by JV Settings Description Timer to stop auxiliary lube oil pump Fan speed for permissive to start E-motor TAG tstop ST-204 NOTE: Value 60 0 or 1500 Units seconds rpm 3.13.3.V. NOTE: When two/three signals are BAD stop turbine manually and start E-motor if possible 2) Steam turbine and E-motor must be stopped 3) Start steam turbine if possible 4) When signal is BAD stop turbine manually and start E-motor if possible 5) Shut off heater and check oil level 6) When HIGH switch heater off 7) When LOW switch heater on 8) Switch-over to other filter 9) Check oil system and replace oil content 10) Automatic start aux.00 Rev.9 Operator Interfaces Operator can access tags on the DCS.008 (Rev 0. 04217 Project E-15100-TN-5306-0001 Document Number 2.13.011 Dept.5 0.doc Page 72 of 92 LGN SREP 04-3001-02.8 Interfaces N/A. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. 3.ABB Lummus Global B.DOT ./Sect.3. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.

011 Dept.V. 04217 Project E-15100-TN-5306-0001 Document Number 2. We know that the steam turbine will be tripped anyway. 151XI-xxx 151XI-xxx 151XI-xxx 151XI-xxx 151XI-xxx 151XI-xxx 151XI-xxx 151XI-xxx Signal 151US-xxx Signal 151US-xxx Signal 151US-xxx Signal 151US-xxx 151TIZA-239 panel Switch on local panel Switch on local panel Indication in DCS Indication on local panel Indication in DCS Indication on local panel Indication in DCS Indication on local panel Signal Signal Indication in DCS Indication on local panel Signal To start auxiliary lube oil pump To stop auxiliary lube oil pump Indication that KM-15161 is ready to start Indication that KM-15161 is ready to start Indication that KT-15161 is running Indication that KT-15161 is running Indication that KM-15161 is running Indication that KM-15161 is running Signal to MCC to start KM-15161 Signal from MCC to confirm that KM-15161 is running Indication any failure Indication any failure Trip FD Fan (stop electric motor KM-15161) upon High High temperature HOLD (to be discussed with NEM.151UC-XXX 151TIZA-240 Signal 151TIZA-240 Signal 151PZA-223 Signal 151UZ 151US 151US-xxx Signal Switch on local panel Signal 151UZ-xxx Signal LGN SREP 04-3001-02. refer to TZA19 and TZA20 on NEM P&ID.DOT PCFS NEM_R2. but we don’t know if the Fan on motor is also the be tripped/stopped ) Trip FD Fan (stop electric motor KM-15161) upon Low Low and High High pressure HOLD (to be discussed with NEM.008 (Rev 0. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. refer to PZA06 on NEM P&ID. refer to TZA19 and TZA20 on NEM P&ID. but we don’t know if the Fan on motor is also the be tripped/stopped ) Signal from BMS 151UZ-500 to stop the Fan Emergency stop of the Fan Permissive signal to KT-15161 Woodward Governer 151UC-XXX that the steam turbine is allowed (or not) to be started Running confirmation of steam turbine from KT-15161 Woodward Governer . We know that the steam turbine will be tripped anyway.doc Page 73 of 92 . but we don’t know if the Fan on motor is also the be tripped/stopped ) Trip FD Fan (stop electric motor KM-15161) upon High High temperature HOLD (to be discussed with NEM. We know that the steam turbine will be tripped anyway. We know that the steam turbine will be tripped anyway. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. refer to TZA19 and TZA20 on NEM P&ID./Sect.00 Rev.ABB Lummus Global B. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. but we don’t know if the Fan on motor is also the be tripped/stopped ) Trip FD Fan (stop electric motor KM-15161) upon High High temperature HOLD (to be discussed with NEM.

3. KT-15161 Bentley Nevada – 151UZ-xxx 6. LGN SREP 04-3001-02. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. Cooling water for the lube oil system will be supplied from the emergency cooling water system.doc Page 74 of 92 . Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. 04217 Project E-15100-TN-5306-0001 Document Number 2. start up and shutdown the air flow through the FD Fan will be limited by means of a mechanical minimum stop.00 Rev.10 Special Considerations During purge./Sect.V.3.151UC-XXX 5. KT-15161 Woodward Governer .13.DOT PCFS NEM_R2. The steam turbine KT-15161 will be started/stopped from the “KT-15161 Woodward Governer .011 Dept.008 (Rev 0. The electric motor will be started/stopped from this block.4 History Date 20-07-2007 Author HuR/WiH Description Original Document On this P&ID we have shown/made three (3) control/safeguarding blocks: 4. The number of consecutive starts with the E-motor is limited to: • 3 cold starts • 2 warm starts When a start is not succeeded after 3 cold or 2 warm starts a waiting time of 300 minutes is required to cool-down the motor sufficiently.13. FD Fan KT-15161 Operation – 151US-xxx In this block the Operator has to select the type of driver for FD Fan K-15161. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.ABB Lummus Global B.151UC-XXX”. FD Fan KT-15161 Operation – 151US-xxx We will send you our “Shellified” P&ID for your consideration. 3.

3 Start up 3.14 COOLING AIR FANS K-15162A/B AUTO TAKE-OVER P&ID 36005-105-12 PISA . Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.14.15162B or KM .15162A = START KM .15162A.1 Objective The fans supply cooling air to the boiler view ports and burner igniters.V. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.15162A.V. J.15162A = STOP 3.Cooling Air Viewports See typical control loop PUMP AUTO TAKE-OVER in General Functional Specification.DIS_ALARM OR KM .3. doc.14.1 Operational and Implementation Aspects Operational Modes This control scheme is required to be operational during start up.LO = SET OR KM .3 3. shutdown.15162B.4 Crippled Mode Operation Instrument Controller Action - Tag Name PISA-205 NOTE: Output BAD Output Freeze LGN SREP 04-3001-02. US-540 UEFS E-15100-TN-2395-0038 Steam Boiler Package A-15101 .2 Normal Steady State 3.15162A on detection of a low discharge pressure PISA-205 or a discrepancy alarm on the duty fan. US-540: Cooling Air Fans Auto Take-over Input Logic Description PISA-205 OR KM .00 Rev. KM .DOT PCFS NEM_R2. The air will also be used as seal air for the sootblower wall box and to prevent ingress of flue gas into the sootblower lance when the sootblower is not blowing steam.DIS_ALARM = SET OR KM .011 Dept.14.15162B = START KM . PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. 3.008 (Rev 0./Sect. E-00000-TN-5306-0001.3.15162B.doc Page 75 of 92 .15162B. 3.3.2 Functional Description To start the standby fan KM .14.14. and take-over. normal operation.DIS_ALARM PISA-205.205. KM .14.3. 04217 Project E-15100-TN-5306-0001 Document Number 2.ABB Lummus Global B.14.DIS_ALARM = SET Action KM . I don’t know if this is still applicable to a FAN. 3.15162A. to advise. 3.15162B = STOP OR KM .

7 Initialisations Alarms Level Indication Indication TAG PISA-205 PISA-205 NOTE: Description AA-- Value HOLD HOLD Units Barg(g) Barg(g) Low discharge pressure switch PISA-205 will be automatically reset when the pressure rises above the low switch setting. 3.ABB Lummus Global B.14.14.DOT PCFS NEM_R2.8 Interfaces 3.00 Rev. 3.9 Operator Interfaces Operator can access tags on the DCS./Sect.14.10 Special Considerations 3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.3.011 Dept.3.V.3.doc Page 76 of 92 .4 History Date 20-07-2007 Author HuR/WiH Description Original Document LGN SREP 04-3001-02. 04217 Project E-15100-TN-5306-0001 Document Number 2.3. 3.3.5 Shutdown 3.3.14. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.14.008 (Rev 0.14.6 Calculations 3.14.

/Sect.00 Rev. 3. Especially during firing of fuel oil the sootblowers will blow MP steam to the heating surfaces within a certain time interval.doc Page 77 of 92 .1 Objective The sootblowers will be used to keep the heating surfaces of superheaters and economizers in the boiler free from soot and dust as much as possible. TISA-220. The sootblower sequence will be started by the operator from the DCS.15 SOOTBLOWER SYSTEM P&ID 36005-105-10 36005-105-11 PISA-208.2 Functional Description The sootblowers operate normally a few minutes each day so the normal position for the steam valve is to be closed and the drain valves to be opened. HCB10 AA010 (KBS-212)and HCB10 AA030 (KBS-213) are automatically opened. When the sootblower is inserted the steam valve is open.008 (Rev 0. Always one sootblower at a time is in operation. In retracted position the steam valve is closed. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.ABB Lummus Global B. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. If the steam temperature is satisfied the warming up valves HCB10 AA010 (KBS212) and HCB10 AA030 (KBS-213) are closed and steam blowing can be started.DOT PCFS NEM_R2.15.011 Dept. Sootblowers will operate one by one usually from the hot to the cold parts. When starting the sequence warming up will commence (typically 10 to 15 minutes) and valves HCB10 AA001 (KBS-211). The operator can select for either a fixed programmed sequence to be followed or a manual random sequence.V.15. During sootblow operation the steam lines will be kept at the required temperature via the orifices RO-203 and RO-205 in steam lines HCB10 BR013 and BR033. DCS . Steam Boiler Package A-15101 – Sootblower System Sootblower Logic Diagram 3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. 04217 Project E-15100-TN-5306-0001 Document Number 2.Discrete Control Tag name PISA-208 Service Steam supply pressure Limit LOW (S) Action Retract sootblowers and stop sequence Close valve Close valve Valve/Controller KBS-211 TISA-220 TISA-221 NOTE: Steam temperature at drain valve Steam temperature at drain valve HIGH (S) HIGH (S) KBS-212 KBS-213 LGN SREP 04-3001-02. Seal air is supplied the sootblower wall box to prevent flue gases escaping from the boiler and to prevent ingress of flue gas into the sootblower lance when the sootblower is not blowing steam. TISA-221 UEFS E-15100-TN-2395-0037 Reference document 36005-553-04-118 3.

• • • • • • • • • • • • • • • • • • • • • • • • • • Power on Check all sootblowers in retracted position If not retracted press retract/fault reset button All sootblowers in retracted position Drain valves HCB10 AA010 (KBS-212) and HCB10 AA030 (KBS-213) are opened Steam supply valve HCB10 AA001 (KBS-211) is opened Preheating steam line If steam temperature TISA 220 > HIGH (S+).00 Rev.doc Page 78 of 92 LGN SREP 04-3001-02. 3. After the first of the selected sootblowers is finished subsequently the other selected sootblowers will be started automatically.3. drain valve HCB10 AA010 closes If steam temperature TISA 221 > HIGH (S+). Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.DOT .3 Normal Steady State Start up Automatically blowing sequence: This sequence will start with the boiler sootblowers in lane 1./Sect. check steam pressure PISA 208 > HIGH (S+) Select ‘ALL’ button (AUTO sequence selected) Press start button Sequence started for lane 1 up to 9 (individual sootblower operation) Sootblower motor energized Sootblower inserted Sootblowing in advance When limit switch position ‘close’ is reached motor is switched to reverse action Sootblower is retracted When limit switch position ‘open’ is reached sootblower motor is switched off Sequence starts next sootblower Sequence continues up to last sootblower Wait for timer is finished Check for all sootblowers retracted Steam supply valve HCB10 AA001 (KBS-211) is closed Drain valves HCB10 AA010 (KBS-212) and HCB10 AA030 (KBS-213) are opened Power off Manual blowing sequence: The sequence can be started random. drain valve HCB10 AA030 closes If drain valves closed.011 Dept.1 Operational and Implementation Aspects Operational Modes The boiler can be claeaned by an automatically fixed sootblowing sequence or by manual/individual sootblowing. Subsequently the sootblowers in lane 2 up to 7 will be started. 3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.3 3. The sequence ends with the sootblowers of the external economizer of lane 8 and 9.15.2 3.008 (Rev 0.3.ABB Lummus Global B.15. • • • • • • • Power on Check all sootblowers in retracted position If not retracted press retract/fault reset button All sootblowers in retracted position Drain valves HCB10 AA010 (KBS-212) and HCB10 AA030 (KBS-213) are opened Steam supply valve HCB10 AA001 (KBS-211) is opened Preheating steam line PCFS NEM_R2.V.15.15. 04217 Project E-15100-TN-5306-0001 Document Number 2.3.

15.15.008 (Rev 0. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.3.15. 04217 Project E-15100-TN-5306-0001 Document Number 2. drain valve HCB10 AA030 closes If drain valves closed.ABB Lummus Global B.3.doc Page 79 of 92 .3.6 Calculations 3. drain valve HCB10 AA010 closes If steam temperature TISA 221 > HIGH (S+).3. check steam pressure PISA 208 > HIGH (S+) INDIVIDUAL sootblowers selected Press start button Sequence started (individual sootblower operation) Sootblower motor energized Sootblower inserted Sootblowing in advance When limit switch position ‘close’ is reached motor is switched to reverse action Sootblower is retracted When limit switch position ‘open’ is reached sootblower motor is switched off Sequence starts next sootblower Sequence continues up to last sootblower Wait for timer is finished Check for all sootblowers retracted Steam supply valve HCB10 AA001 (KBS-211) is closed Drain valves HCB10 AA010 (KBS-212) and HCB10 AA030 (KBS-213) are opened Power off Crippled Mode Operation Instrument Controller - Tag Name PISA-208 TISA-220 TISA-221 NOTE: Output BAD BAD BAD Action Open valve KBS-211 Close valve KBS-212 Close valve KBS-213 Output Freeze Freeze Freeze 3.15.DOT PCFS NEM_R2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.5 Shutdown See start up above.7 Initialisations TAG PISA-208 TISA-220 TISA-221 HOLD (MAX blowing time elapsed) NOTE: Description AA+ A+ A+ Alarms Level Indication Indication Indication Indication Value 17 350 350 15 Units Barg(g) ° C ° C minutes TAG PISA-208 Settings Description Retract sootblowers & stop sequence if pressure < LOW (S-) Value 18 Units Bar(g) LGN SREP 04-3001-02.011 Dept.4 If steam temperature TISA 220 > HIGH (S+). Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.00 Rev./Sect.V. 3. • • • • • • • • • • • • • • • • • • • 3.

doc Page 80 of 92 .3. Following functions/signals are present: 151HS-xxx 151HS-xxx 151HS-xxx 151HS-xxx 151HS-xxx Switch in DCS Switch in DCS Switch in DCS Switch in DCS Switch in DCS Power on/off Emergency retract/fault reset push button Selection sequence ‘ALL’ or ‘INDIVIDUAL’ button Start button (Emergency) stop button 3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. TISA-220 TISA-221 TISA-220 TISA-221 HOLD (Blowing time) NOTE: 3.V.10 Special Considerations 3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. 04217 Project E-15100-TN-5306-0001 Document Number 2.011 Dept.15.3.4 History Date 20-07-2007 Author HuR/WiH Description Original Document LGN SREP 04-3001-02.3.15.008 (Rev 0.15.15.DOT PCFS NEM_R2.8 Interfaces Close drain valve KBS-212 if steam temperature > HIGH (S+) Close drain valve KBS-213 if steam temperature > HIGH (S+) Sootblowing suspended if steam temperature < LOW (S-) Sootblowing suspended if steam temperature < LOW (S-) Sootblower operating will retract and suspended if MAX blowing time (insert + retract time) is elapsed 280 280 260 260 10 ° C ° C ° C ° C minutes 3.9 Operator Interfaces Operator can access tags on the DCS.00 Rev./Sect.ABB Lummus Global B.

3.A.011 Dept. Too low or high pressures and temperatures will be alarmed.doc Page 81 of 92 .V. To mix the two flows with nearly equal pressures a pressure controller PC-115 controls the MPD steam to a fixed pressure downstream of the control valve.Discrete Control Tag name N. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. NOTE: Service Limit Action Valve/Controller 3. NOTE: Service Limit Action Valve/Controller Valve Name PICA-115 TICA-081 Tag name PC-115 TC-081 IPS .16. DCS .Analogue Control Service Action PV-Tracking PID Direct Yes PID Direct Yes DCS .1 Objective To supply MP steam to the fuel skid with a constant superheated temperature used for atomizing of the fuel oil in the burners.A.2 Functional Description To supply MP steam of the required conditions to the fuel skid MP steam and MP desuperheated steam will be mixed.3.Discrete Control Tag name N. If atomizing steam is selected both controllers will be switched to AUTO mode. LGN SREP 04-3001-02.16.DOT PCFS NEM_R2. 04217 Project E-15100-TN-5306-0001 Document Number 2. Temperature control of the mixed flows is achieved by temperature controller TC-081. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.16.16.16 ATOMIZING STEAM CONTROL LBG30AA011 (PICA-115) LBG30AA016 (TICA-081) P&ID PCD UEFS E-15100-TN-2395-0004 36005-105-14 114 Steam Boiler Package A-15101 – Atomising Steam System 3. 3. If atomizing gas or no atomizing medium is selected (NG selected) the controllers will be in MAN mode 0% output. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.008 (Rev 0./Sect.3 3.ABB Lummus Global B.00 Rev.1 Operational and Implementation Aspects Operational Modes This control scheme is required to be operational during start up and normal operation.

/Sect. 3.16.00 Rev.3.16.16.16. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.100 Units % % TAG PICA-115 PICA-115 TICA-081 TICA-081 NOTE: Description A+ AA+ A- Alarms Level Indication Indication Indication Indication Value 20 16 320 215 Units Bar(g) Bar(g) ° C ° C TAG N.DOT PCFS NEM_R2.3. 04217 Project E-15100-TN-5306-0001 Document Number 2.5 Shutdown Action Mode to MAN Mode to MAN Output Freeze Freeze 3.7 Initialisations x1 x2 x3 TAG PC-115 TC-081 NOTE: Ranges Description Pressure controller Temperature controller Range 0 . NOTE: 3.3.doc Page 82 of 92 .V.6 Calculations Output (y) Calculation Input (x1.008 (Rev 0.3.A.x3) TAG N.A.3.x2.16.ABB Lummus Global B.4 Crippled Mode Operation Instrument Output Controller BAD PC-115 BAD TC-081 Tag Name PICA-115 TICA-081 NOTE: 3.2 3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. NOTE: Description Trips Level Value Units Settings TAG HC-115 HC-081 NOTE: Description SP pressure controller SP temperature controller Value 18 237 Units Bar(g) ° C LGN SREP 04-3001-02.3.16.100 0 .3 Start up Normal Steady State During normal operation the controllers PC-115 and TC-081 shall be in AUTO.011 Dept. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. 3.

DOT PCFS NEM_R2.4 History Date 20-07-2007 Author HuR/WiH Description Original Document LGN SREP 04-3001-02.3.ABB Lummus Global B.16.16.10 Special Considerations The maximum allowable mixed temperature (324° is lower than the design temperature of the C) MP steam (400° If the mixed temperature exceeds the allowable temperature the opening of C). 3. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. the MP steam control valve will be limited. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120./Sect.8 Interfaces N/A.3.008 (Rev 0.3.9 Operator Interfaces Operator can access tags on the DCS.00 Rev.doc Page 83 of 92 . 3.16. 3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.V. 3.16.011 Dept. 04217 Project E-15100-TN-5306-0001 Document Number 2.

ABB Lummus Global B.V.

Client Subject

SHELL EASTERN PETROLEUM (PTE) LTD. PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011 Dept./Sect.

04217 Project

E-15100-TN-5306-0001 Document Number

2.00 Rev.

3.17

BOILER START UP AND SHUTDOWN HLA10AA001, FIC-502, XC504 P&ID 36005-105-?? PCD (HOLD)

(HOLD) (HOLD)

Question to JV: Will there be a check on conditions as a release signal for start up? Fuel supply OK Feedwater conditions OK MP and LP steam conditions for steam turbine OK Industrial water conditions OK Cooling water conditions OK Instrument air conditions OK Atomizing steam conditions OK Sootblower steam conditions OK

3.17.1

Objective To start up and shutdown the boiler according specific procedures. An automatic sequence is incorporated for start up with NG. Manually start up with other fuels is possible. Boiler shutdown will be done manually.

3.17.2

Functional Description When starting the fuel control valves are positioned by the start sequence program or operator. During start phase the fuel and air control will be switched to AUTO when all burners are in operation. The boiler is disconnected from the grid by main steam valve LBA10 AA003 (MOV-201) which is closed. The steam pressure will controlled by controller PC-207. Start up is ended when the boiler is at 40% MCR. From that point the boiler can be connected to the steam grid. When the boiler is connected to the steam grid the load controller will be switched to AUTO (pressure or flow) and receive their set points from the overall load control Several controllers are in MAN or AUTO mode as described in the specific start up sections above.

Please briefly describe all calculation blocks, switches, High or Low Selectors, etc. For DCS control see other sections above.

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.DOT

PCFS NEM_R2.doc

Page 84 of 92

ABB Lummus Global B.V.

Client Subject

SHELL EASTERN PETROLEUM (PTE) LTD. PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011 Dept./Sect.

04217 Project

E-15100-TN-5306-0001 Document Number

2.00 Rev.

3.17.3 3.17.3.1 3.17.3.2

Operational and Implementation Aspects Operational Modes Start up CHECK UPS PRIOR TO START PROGRAM • Auxiliary systems standby at the required conditions for normal operation, i.e. feedwater, cooling water, industrial water, auxiliary steam systems, oil system FD fan, fuel system, chemical dosing systems, plant/instrument air. • Boiler equipment standby. • All valves in correct position. • Boiler is vented and drum level is brought to start level. • Burner system and fuel lines standby. • The water level in the intermittent blowdown drum is brought to minimum level by supplying industrial water. START UP MODES As far as applicable three different start up modes are distinguished: • Cold start up: defined as t drum < 100° C • Warm start up: defined as t drum ≥ 100 and < 300° C • Hot start up: defined as t drum ≥ 300 ° C START PROGRAM Purging The boiler shall be purged prior to the burner start according NFPA 85. Start of the FD fan at minimum required combustion airflow would purge the boiler. Minimum purging conditions are described in the table below. Furthermore, all burner air dampers (6 in total) need to be open during purging. More details can be found in the Burner System Description. Purging due to Minimum purge flow (m3/s)/kg/h Maximum purge air Minimum temperature (° C) time (min) Boiler + duct purge volume (once) (m3) Excl. Stack Boiler 18.7/90000 35 6 1300

Table 1. Purge conditions After purging, the 6 burner air dampers remain open with at least the minimum purge flow. Fuel selection The fuel selection is set in the DCS system. There are two options: 1. Natural Gas selection (for automatic start up procedure) 2. Oil selection (for manual start up procedure) Mixed fuel operation during start up is not recommended. NG will always be used as ignition fuel.

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.DOT

PCFS NEM_R2.doc

Page 85 of 92

ABB Lummus Global B.V.

Client Subject

SHELL EASTERN PETROLEUM (PTE) LTD. PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011 Dept./Sect.

04217 Project

E-15100-TN-5306-0001 Document Number

2.00 Rev.

Boiler start-up At starting of the boiler the set point of the pressure controller PC-207 is, via an automatic switch, put in memory to the remaining pressure in the boiler with a minimum of 2 bar(g) The boiler start-up is initiated by setting the desired boiler load from the DCS with a maximum of 40% MCR. This will initiate a starting sequence of the burners (for NG). During the start program is running other actions will be initiated such as open and closing of drains, level increase of the drum level from SL to NWL, activate of control functions. Details can be found in the Functional Control Diagrams (HOLD). Burner start The burner start is described in the Burner System Description. Each burner start is performed from the DCS or burner local panel. Burner starting sequence The burner starting sequence as described in this paragraph needs to be followed to start-up the boiler in the correct manner. Once more it is noted that the boiler has six (6) burners located at the front side of the furnace divided into 2 rows with each 3 burners. The bottom row burners will be started first, and later on the top row burners, in order to heat up the boiler as gradually as possible. Furthermore, two holding points are included to startup the boiler correctly. The burner starting sequence is described in the table 2 below. Burner front is shown in figure 1 below. Step Burner number 1 2 3 4 8 10 12 13 Action Nr of burners on 1 2 3 3 4 5 6 6 Hold Load per boiler burner (%) load (%) point 25 25 25 79.9 59.9 47.9 40 100 4.2 8.3 12.5 40 40 40 40 100

Burner 5 1 burner start nd Burner 4 2 burner start rd Burner 6 3 burner start Increase load 3 burners th Burner 2 4 burner start th Burner 1 5 burner start th Burner 3 6 burner start Increase load 6 burners

st

1

2

Table 2. Burning starting sequence

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.DOT

PCFS NEM_R2.doc

Page 86 of 92

04217 Project E-15100-TN-5306-0001 Document Number 2. the condensate in the superheater tubes needs to be removed. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. A too high medium temperature in the drum will be limited by further opening of the start up valve.V./Sect. At that point a hold point (1) is applied to heat up the boiler gradually. (HOLD) Load to 40% As soon as the above conditions for hold point (1) are met. • Drum temperature gradient within allowed range. The boiler load and or steam pressure will be limited when the allowable gradients are exceeded.doc Page 87 of 92 . PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. (HOLD) LGN SREP 04-3001-02. The first three (3) burners are started in the sequence as given in table 2. steam temperature and pressure will increase. (HOLD) A too high steam temperature gradient will limit the load increase.00 Rev. The hold point (1) needs to be maintained until the following conditions are met: • Drum level HAD10 CL004/5/6 (LT-202A/B/C) is constant for at least 120 seconds. The boiler load and or steam pressure will be limited when the allowable gradients are exceeded.011 Dept. • Maximum start up valve opening = 30% During this stage. • Drum pressure HAD10 CP001 (PIA-206) is > 2 bar(g) and stable for at least 120 seconds. During this stage. The boiler load increase is controlled by: • Allowable HP steam drum temperature gradient • Allowable HP main steam temperature gradient.5% MCR. the load of the HP auxiliary boiler is gradually increased to 40%. steam temperature and pressure will increase. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. (HOLD) A too high steam temperature gradient will limit the load increase. Load increase can recommence as soon as the gradients are acceptable.DOT PCFS NEM_R2.008 (Rev 0. Burner 1 (A) Burner 2 (B) Burner 3 (C) Burner 4 (D) Burner 5 (E) Burner 6 (F) Figure 1. • Main steam temperature gradient within allowed range. Load increase can recommence as soon as the gradients are acceptable. A too high medium temperature in the drum will be limited by further opening of the start up valve. Load increase can recommence as soon as the gradients are acceptable. This means that the load is reduced as soon as the allowable gradients has been passed. Furthermore. When the load is at 40% the last three (3) burners are started in the sequence as given in table 2.ABB Lummus Global B.5% boiler load (final value to be defined during commissioning) The load of the boiler is set to 12. This means that the load is reduced as soon as the allowable gradients has been passed. Load increase can recommence as soon as the gradients are acceptable. Burner front (seen from burner platform) Load to 12. During this stage. steam temperature and pressure will increase further.

DOT PCFS NEM_R2. The steam pressure will reach the set point of the start up blow off valve LBA10 AA051 (PICA-207) and the valve will control the steam pressure at 120 bar(g).00 Rev.ABB Lummus Global B. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.2. Feedwater control valves during start up To close and open control valve LAB10 AA032 (TIC-207B) see section 3. When the steam pressure has reached normal set point pressure controller PC-207 is switched to MAN mode and at the same time the 30% opening limit of PICA-207 is removed.008 (Rev 0.9. During start up of the boiler control valve LAB10 AA032 will be forced to close.011 Dept. Open main steam valve LBA10 AA003 (MOV-201) As soon as the following conditions are met the main steam valve can be opened (and the start-up blow off valve LBA10 AA051 (PICA-207) is closed): • Steam line pressure LBA10 CP001 (PICA-207) is ≥ 120 bar(g) • Main steam temperature LBA10 CT001 (TICA-217) ≤ 525 ° C • Differential pressure over boiler HP steam valve LBA10 AA003 (MOV-201) < 2 bar Note: The temperature of steam lines downstream main steam valve LBA10 AA003 should have an acceptable level. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. LGN SREP 04-3001-02./Sect. The start up drain valves will be closed during the start up procedure. pressure and temperature will rise. the steam flow. Note: Draining of the steam system downstream boiler main steam valve is required. Pressure controller PC-207 is put in AUTO mode after a certain time (to stabilize) and then controls the pressure at normal the operating value of 120 bar(g).3. then: • Output temperature controller LAB10 CT003: 0% • Output of control valve LAB10 AA032: 0% When boiler load > 15%. 04217 Project E-15100-TN-5306-0001 Document Number 2. Warming up common steam system during start-up (0-40%) The common steam system is the system downstream boiler valve LBA10 AA003 (MOV201) and can be warmed up by opening bypass valve LBA10 AA005 of main steam valve LBA10 AA003 (MOV-201). PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. When the boiler load < 15%. then: • Temperature controller and control valve LAB10 AA032: AUTO-mode Warming up steam lines As soon as the steam production starts the superheater and main steam line will be warmed up by the steam/condensate discharged via the start up drain valves HAH10 AA402/424 and LBA10 AA404. ECO circulation valve during start-up The ECO circulation valves HAD15 AA001 (US-532) and HAD15 AA002 (US-531) can be closed as soon as the following conditions are met: • FW flow LAB10 CF101 is > 15 t/h for at least 60 seconds. (HOLD) Start-up steam blow off CV LBA10 AA051(PICA-207) during start-up (0-40% load) The control valve opens at 2 bar(g) minimum or actual pressure and controls the actual pressure until a maximum open position of 30% is reached.doc Page 88 of 92 .V. With increasing boiler load.

3. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. 40 to 100%. The boiler is in operation at pressure or flow control. The boiler produces steam with a constant steam temperature over the boiler load range of approx. 3. 0% output when: • Valve PICA-207 is closed and • Valve MOV-201 is open If valve LBA10 AA051 is closed the set point of the valve will be increased with a upset of 2 bar to 122 bar(g)./Sect. Boiler steam flow control. 1.17. • Start up valve LBA10 AA051 (PICA-207) closed. Controller PC-207 will be switched to MAN. Master pressure control or flow control can be activated if: • Valve PICA-207 is closed and • Valve MOV-201 is open Transfer from 40% load to 100% load The boiler load can be transferred from 40% to normal operation as soon as the following conditions are met: • Boiler load is 40% MCR.4 Crippled Mode Operation For crippled mode operation see sections above. Pressure control by master pressure control system.DOT PCFS NEM_R2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.17. Close start up valve LBA10 AA051 (PICA-207) The valve will automatically close as soon as there is a steam demand from the common steam system respectively steam turbines. 3.3.doc Page 89 of 92 . The HP auxiliary boiler is at a load between 40 to 100 % MCR and produces steam with a constant pressure of 120 bar(g) (maximum 125 bar(g)).008 (Rev 0.3 Normal Steady State N. LGN SREP 04-3001-02.V.00 Rev. (HOLD) Boiler control Control can be performed in two different manners. • Main steam valve LBA10 AA003 (MOV-201) is opened. 04217 Project E-15100-TN-5306-0001 Document Number 2.A. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. • Boiler steam temperature and pressure control on AUTO • Steam drum temperature gradient < allowable • Steam temperature gradient < allowable • Main steam line pressure LBA10 CP001 (PICA-207) is ≥120 bar(g) • Main steam temperature LBA10 CT001 (TICA-217) ≤ 525 ° C IN OPERATION STATUS The boiler is in operation status during normal operation.011 Dept. 2.ABB Lummus Global B.

Client Subject SHELL EASTERN PETROLEUM (PTE) LTD.9 Operator Interfaces Operator can access tags on the DCS.5 Shutdown In order to shut down the boiler.10. An alarm is given in case the allowable steam drum pressure gradient during cool down is exceeded.ABB Lummus Global B.011 Dept. Allowable temperature gradients: See section 3.3.4 History Date 20-07-2007 Author HuR/WiH Description Original Document LGN SREP 04-3001-02. 0% output • The start up valve set point will follow the actual steam pressure (with a margin of 2 bar) during boiler cool down Forced cooling of the boiler by running the FD Fan should be kept to a minimum.V.3.17. the following actions need to be taken: • Open manual steam blow off valve LBA10 AA050 • Adjust set point for pressure controller PC-207 to an appropriate value just above of the actual pressure in main steam line (to avoid steam blow off) • Put pressure controller/start up valve PICA-207 on AUTO • Reduce boiler load slowly to approximately 20% MCR (with constant steam header pressure) • The HP steam line MOV LBA10 AA003 (MOV-201) can be closed (manually from CCR) as soon as the boiler load is < 40%.3.10 Special Considerations During purge. • As soon as the boiler load is < 20% MCR the top burners and finally the bottom burners are stopped consecutively • As soon as all burners are out of operation FD Fan HLB10 AN001 (K-15161) will automatically stopped by activating the stop program of the steam turbine or electric motor • The economizer circulation valves HAD15 AA001/002 are opened automatically as soon the FW flow LAB10 CF101) < 12 t/h for at least 60 seconds • The drum level will be brought from normal level to start level • Close continuous blowdown valve HAD10 AA460 (QISA-202) • Put pressure controller/start up valve PICA-207 on MAN.17.DOT PCFS NEM_R2.3. Potential stored heat can be released by the start up valve LBA10 AA051 operating as pre-safety valve.17.3. 3.doc Page 90 of 92 .6/7 above. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120. 04217 Project E-15100-TN-5306-0001 Document Number 2.00 Rev.17.6 Calculations For calculations see sections above. 3. 3. 3.3.17.8 Interfaces 3. 3.6/ 7 and 3./Sect.11.17.3. 3.17. start up and shutdown the air flow through the FD Fan will be limited by means of a mechanical minimum stop.3. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.7 Initialisations For initialisations see sections above.008 (Rev 0.

19 DOCUMENTS Operating data 36005-103-01 36005-103-38 36005-646-01 Reference documents 36005-824-04-148 36005-560-04-148 36005-560-04-148-001 36005-553-04-118 36005-646-01 Legend and symbols for P&ID's Legend and symbols for P&ID's PFD and material balance P&ID Flue gas system P&ID Economiser system P&ID Evaporator system P&ID Superheater system P&ID Main steam line P&ID Drain system P&ID Blow down system P&ID Sample unit P&ID Sootblower system boiler P&ID Sootblower system economizer P&ID Cooling air view ports P&ID Steam lines turbine P&ID Atomizing steam desuperheater station P&ID Cooling water P&ID Instrument air P&ID Burner piping system P&ID Dual drive Fan P&ID Lubrication system (dual drive fan) P&ID Common skid P&ID Local burner fuel system Performance data Material balance Process control diagrams Burner system description (including control and safeguarding) Operating procedure Dual Driven FD Fan Control Narratives Dual Driven FD Fan Sootblower Logic Diagram Functional Control Diagrams (LATER) LGN SREP 04-3001-02. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.008 (Rev 0.18 DRAWINGS PID’s 36005-104-01 36005-104-02 36005-105-01 36005-105-02 36005-105-03 36005-105-04 36005-105-05 36005-105-06 36005-105-07 36005-105-08 36005-105-09 36005-105-10 36005-105-11 36005-105-12 36005-105-13 36005-105-14 36005-105-15 36005-105-16 36005-105-17 36005-560-04-151 36005-560-04-151-002 36005-824-04-151-002/003/004 36005-824-04-151-005/006/007 3. Client Subject SHELL EASTERN PETROLEUM (PTE) LTD./Sect.V. REFERENCES 3.doc Page 91 of 92 .ABB Lummus Global B.00 Rev. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.011 Dept.DOT PCFS NEM_R2. 04217 Project E-15100-TN-5306-0001 Document Number 2.

00 Rev./Sect.V.doc Page 92 of 92 . Client Subject SHELL EASTERN PETROLEUM (PTE) LTD. LGN SREP 04-3001-02.DOT PCFS NEM_R2. May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE. 04217 Project E-15100-TN-5306-0001 Document Number 2. PROCESS CONTROL FUNCTIONAL SPECIFICATION 120.011 Dept.008 (Rev 0.ABB Lummus Global B.

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