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Medium Voltage Motor Auto

Re-Start Logic Review Report

Process Technology Department


T-PRTER # 0001
4/3/2019

Process Team - Process Technology Department - T-PRTER # 0001 1


Executive Summary
The Process Team has completed the evaluation assessment for the Medium Voltage (MV) motors
Auto Re-start logic developed by the contractor for ERC Refinery. This study was initiated after
DHT makeup gas compressor (K-1401B) auto re-start occurred during compressor MRT, caused
by continuous electrical hold up signal.

The Process team has revised the logical sequence for the MV motors list with all connected
loops (water cooler pump, post lube oil pump, and running status of standby unit), evaluated
the coincidence of corresponding initiation time on each equipment, and revised the process
sequence of each unit separately.

The team concluded that the applied logic is considered accepted from process prospective
with minor modification as detailed in the following recommendations.

1. Thermal reactors combustion air blowers KM-8001 B/C/D of the sulphur unit auto restart
time delay is specified as 60 S, while as per the blower’s vendor logic a 20 minutes delay
is required to be able to reset the ESD on these blowers. Accordingly, it is recommended
to remove these blowers from the auto-restart logic list. (Appendix-1)
2. Change the auto restart signal from latch signal to pulse electrical signal to avoid motor
restart after the original set delay time.
3. NHT recycle gas compressors K-1101 A/B have a specified auto-restart delay time of 0.1
sec. this time delay is considered very low and will not allow the DCS operator to reset
the ESD, this time delay need to be revised with a reasonable more practical value.
4. Operation team should be completely aware with Auto Re-start philosophy and the list
of included equipment.
5. Power dip alarm icon to be added to DCS to alert the panel operator in case of a power
dip event.
6. The a/m icon to be linked to a newly developed Auto Re-start equipment list DCS
interface to allow panel operators to easily reset the ESD in the right sequence and in a
timely manner.

Process Team - Process Technology Department - T-PRTER # 0001 2


Table of Contents

Executive Summary.................................................. 2
Introduction ........................................................... 4
Technical Assessment ............................................... 5
Area-1 ...................................................................................................................... 5
AREA-2/A ................................................................................................................ 5
AREA-2/B ................................................................................................................ 6
AREA-3 ..................................................................................................................... 6
AREA-4 ..................................................................................................................... 7
Conclusion & Recommendations .................................. 7

Process Team - Process Technology Department - T-PRTER # 0001 3


Introduction
As per electrical specification required by ERC, in case of voltage dip for a period 0.2 to 2
seconds, auto restart logic is applied to a selected group of motors after a specified time delay
as per motor group restart priority list.
As a result of DHT makeup gas compressor (K-1401B) auto re-start occurred during compressor
MRT, caused by continuous electrical hold up signal. A Field Change Notice (FCN No. 7T04) is
performed by GS to change the auto restart signal from latch signal to pulse electrical signal.
So, the equipment included in Auto Re-start list and is connected to ESD system has a certain
defined delay time to reset it, after that time with 2 sec the equipment will not start
automatically even so its status is ready (illustrated in the following tables).
The existing logic auto restart logic can be summarized as follows
1. After the voltage restoration within 2 seconds, the motor auto restart was, initiated
after the intentional time delay.
2. The auto restart signal is a continuous hold-on signal.
3. In case of previous ESD trip signal to the motor CB motor did not auto re-start due to CB
close blocking.
4. After a long duration when the ESD trip, signal to the motor CB was reset- by the
operator. The motor circuit breaker CB close block was removed and the motor) started
automatically later after several minutes as the auto restart command was continuously
holding on.
The Contractor proposed logic modification can be summarized as follows
1. After the voltage restoration within 2 seconds, the motor auto restart will be initiated
after the intentional time delay.
2. The auto-restart signal will be changed from continuous signal to a 2 second pulse.
3. The operator will be required to reset any previous ESD trip signal within the intentional
time delay for auto restart to initiate.
4. The motor will not start automatically unintentionally later period as the auto restart
command pulse will only hold on for 2 second after auto restart command initiation.

Process Team - Process Technology Department - T-PRTER # 0001 4


Technical Assessment
Process team revised the logical sequence of connected loops (water cooler pump, post lube oil
pump and running status of standby unit) on each equipment and revise the coincidence of
initiation time corresponding to each of them. Also, process sequence of each unit is revised
separately. Process team suggest and recommend some modifications on motor Auto-Start list.
These recommendations are listed and attached with ESD Auto-Restart motor list according to
each area as following:
1. For thermal reactors combustion air blowers KM-8001B/C/D the auto restart sequence is
meaningless because we couldn’t reset the blowers before 20 min as per vendor logic
diagram (U-80).
2. NHT recycle gas compressor (K-1101/A, B) have very low restart time (0.1 sec.) which
can’t be allowed for operator to reset ESD and visually check the compressor (U-11).
3. The cooling water motor pump P-3201D should be listed to the auto restart list to keep
the header pressure and not to affect the process unit operations in case of pump is
running due to one of turbine pumps is in maintenance (U-32).

The motors connected to the ESD system and must be reset to activate auto start sequence
along with the specified delay time to reset each equipment can be summarized as follows.

Area-1
Switchgear Unit Tag no. Equipment Service Rating Restart Remarks Permissive
No. [kW] delay
time
SG-S2-03-01B U-80 KM-8001B COMBUSTION AIR BLOWER 620 60 s ESD In site
SG-S2-03-01A U-80 KM-8001C COMBUSTION AIR BLOWER 620 60 s ESD In site
SG-S2-03-01B U-80 KM-8001D COMBUSTION AIR BLOWER 620 60 s ESD In site

AREA-2/A
Switchgear Unit Equipment Service Restart Remarks Permissive
no. Time Delay
SG-S4-03-01B U-11 NHT RECYCLE GAS COMPRESSOR 0.1 S ESD DCS
SG-S4-03-01A U-11 NHT RECYCLE GAS COMPRESSOR 0.1 S ESD DCS
SG-S4-03-01B U-14 DHT-RECYCLE COMPRESSOR 10 S ESD DCS
SG-S4-03-01A U-14 DHT-RECYCLE COMPRESSOR 10 S ESD DCS
SG-S4-03-01A U-14 DHT-FEED PUMP 100 S ESD DCS
SG-S4-03-01B U-14 DHT-FEED PUMP 100 S ESD DCS
SG-S4-03-01A U-14 DHT-MAKE-UP COMPRESSOR 150 S ESD DCS
SG-S4-03-01B U-14 DHT-MAKE-UP COMPRESSOR 150 S ESD DCS
SG-S4-03-01A U-13 REGENERATION LOOP COMPRESSOR 150 S ESD DCS
SG-S4-03-01B U-13 REGENERATION LOOP COMPRESSOR 150 S ESD DCS
SG-S4-01-01A U-12 33/11.5kV TR FOR KM-1202A H2 RICH GAS 160 S ESD DCS
COMPRESSOR
SG-S4-01-01B U-12 33/11.5kV TR FOR KM-1202B H2 RICH GAS 160 S ESD DCS
COMPRESSOR
SG-S4-03-01B U-12 RECONTACTING CHILLER COMPRESSOR 170 S ESD DCS
SG-S4-03-01A U-14 DHT-LEAN AMINE PUMP 170 S ESD DCS

Process Team - Process Technology Department - T-PRTER # 0001 5


SG-S4-03-01B U-14 DHT-LEAN AMINE PUMP 170 S ESD DCS
SG-S4-03-01B U-11 NHT FEED PUMP 70 S ESD DCS
SG-S4-03-01A U-11 NHT FEED PUMP 70 S ESD DCS

AREA-2/B
Switchgear Unit Equipment Service Rating Restart Remarks Permissive
No. [kW] Time
Delay
SG-S5-03-01B U-22 FURNACE CHARGE PUMP 350 140 S ESD DCS
SG-S5-03-01A U-22 FURNACE CHARGE PUMP 350 140 S ESD DCS
SG-S5-03-01A U-22 LCGO PUMPAROUND PUMP 350 140 S ESD DCS
SG-S5-03-01B U-22 LCGO PUMPAROUND PUMP 350 140 S ESD DCS
SG-S5-03-01A U-22 HCGO PA PUMP 230 170 S ESD DCS
SG-S5-03-01B U-22 HCGO PA PUMP 230 170 S ESD DCS
SG-S5-03-01A U-22 33/11.5kV TR FOR KM-2201 WET GAS 170 140 S ESD DCS
COMPRESSOR

AREA-3
Switchgear Unit No. Equipment Service Rating Restart Remarks Permissive
[kW] Time
Delay
SG-S2-03-01A U-21 HVGO PUMPAROUND PUMP 900 100 S ESD DCS
SG-S2-03-01B U-21 HVGO PUMPAROUND PUMP 900 100 S ESD DCS
SG-S2-03-01A U-21 MVGO PUMPAROUND PUMP 690 100 S ESD DCS
SG-S2-03-01B U-21 MVGO PUMPAROUND PUMP 690 100 S ESD DCS
ESG-S2-03-01 U-21 VACUUM RESIDUE PUMP 550 100 S ESD DCS
ESG-S2-03-01 U-21 VACUUM RESIDUE PUMP 550 100 S ESD DCS
SG-S2-03-01A U-21 LVGO PUMPAROUND PUMP 390 120 S ESD DCS
SG-S2-03-01B U-21 LVGO PUMPAROUND PUMP 390 120 S ESD DCS
SG-S2-03-01A U-21 VDU FEED PUMP 760 130 S ESD DCS
SG-S2-03-01B U-21 VDU FEED PUMP 760 130 S ESD DCS
SG-S2-03-01A U-21 LIQUID RING COMPRESSOR 450 140 S ESD DCS
SG-S2-03-01B U-21 LIQUID RING COMPRESSOR 450 140 S ESD DCS
SG-S2-03-01B U-21 INDUCED DRAFT FAN 320 150 S ESD DCS
SG-S2-03-01A U-21 FORCED DRAFT FAN FOR H- 200 150 S ESD DCS
2101
SG-S2-03-01B U-16 FLUE GAS FAN 860 30 S ESD DCS
SG-S2-03-01A U-16 COMBUSTION AIR FAN 470 30 S ESD DCS
SG-S2-03-01A U-16 BFW PUMP 490 150 S ESD DCS
SG-S2-03-01B U-16 BFW PUMP 490 150 S ESD DCS
HCU MAKE-UP GAS DCS
SG-S1-01-01A U-15 5500 40 S ESD
COMPRESSOR
HCU MAKE-UP GAS DCS
SG-S1-01-01B U-15 5500 50 S ESD
COMPRESSOR
HCU MAKE-UP GAS DCS
SG-S1-01-01A U-15 5500 50 S ESD
COMPRESSOR
SG-S1-03-01B U-15 HCU FEED PUMP 2600 70 S ESD DCS
SG-S1-03-01A U-15 HCU FEED PUMP 2600 70 S ESD DCS
SG-S1-03-01B U-15 RECYCLE PUMP 2100 70 S ESD DCS
SG-S1-03-01A U-15 DIESEL PUMPAROUND PUMP 300 140 S ESD DCS
SG-S1-03-01B U-15 DIESEL PUMPAROUND PUMP 300 140 S ESD DCS

Process Team - Process Technology Department - T-PRTER # 0001 6


SG-S1-03-01A U-15 HP WASH WATER PUMP 475 170 S ESD DCS
SG-S1-03-01B U-15 HP WASH WATER PUMP 475 170 S ESD DCS
SG-S1-03-01A U-15 HCU LEAN AMINE PUMP 1850 220 S ESD DCS
SG-S1-03-01B U-15 HCU LEAN AMINE PUMP 1850 220 S ESD DCS

AREA-4
Switchgear Unit No. Equipment Service Rating Restart Remarks Permissive
[kW] Time
Delay
SG-S5-03-01B U-33 HP BFW PUMP 950 140 S ESD DCS
SG-S5-03-01A U-33 FD FAN FOR H-3301A 350 140 S ESD DCS
SG-S5-03-01A U-33 FD FAN FOR H-3301C 350 140 S ESD DCS
SG-S5-03-01B U-33 FD FAN FOR H-3301B 350 140 S ESD DCS
SG-S5-03-01A U-31 INTERMEDIATE 230 170 S ESD DCS
WATER PUMP
SG-S5-03-01B U-31 INTERMEDIATE 230 170 S ESD DCS
WATER PUMP
SG-S5-03-01A U-31 TREATED WATER 170 140 S ESD DCS
PUMP
SG-S5-03-01B U-31 TREATED WATER 170 140 S ESD DCS
PUMP
SG-DB-04-02A U-31 FILTERED WATER 150 190 S DCS
PUMP

Conclusion & Recommendations


1. ESDs that require reset from DCS should have reasonable Auto-restart delay time to
assure the panel operator will have the enough time to reset it.
2. ESDs that require reset from site should have reasonable Auto-restart delay time to
assure the outside operator will have the enough time to reset it.
3. The specified Auto-restart delay time for the thermal reactors combustion air blowers
KM-8001 B/C/D in Unit-80 should be revised and corrected because it will not restart
before 20 min as per the vendor logic.
4. NHT recycle gas compressors K-1101 A/B have a specified auto-restart delay time of 0.1
sec. this time delay is considered very low and will not allow the DCS operator to reset
the ESD, this time delay need to be revised with a reasonable more practical value.
5. Power dip alarm icon to be added to DCS to alert the panel operator in case of a power
dip event, in addition to a hyperlink to a newly developed Auto Re-start equipment list
DCS interface to allow panel operator to easily reset the ESD in the right sequence and
in a timely manner.
6. Operation team should be completely aware with Auto Re-start philosophy and the list
of included equipment.

Process Team - Process Technology Department - T-PRTER # 0001 7