AHG

L150 Plant

New Backup System Control Philosophy

P&ID Sheet-1(Rev16), Sheet-2(Rev05), Sheet-3(Rev14)

L150 plant upgrade project Prepared by Ahmed Ashraf

Oxygen backup system Reviewed by Sampath Felix
Rev:04 01/08/2019 Project manager Ahmed Desoky
System description:

1- Backup Pumps (P-701A/B):

All manual valves for inlet pipeline, discharge pipeline and recycle
pipeline should in open position in normal condition.
Inlet shut-off valves KV-7101A/B should be in closed position.
Discharge valves PV-7126A/B should be in closed position.
Recycle valves PV-7117A/B should be fully closed.
Both vent valves KV-7115A/B, should be opened.

2- HP Tank (T702):
The Tank pressure PIC-7220 will be maintained at 20 bar, by PV-7220
(PBU Inlet valve).
PV-7224 (HP tank vent valve) set point will be 22 bar (Max set point
is 22 bar). If tank pressure PIC-7224 increased, valve will open to
maintain the Set point value.
Finally, PV-7203 (liquid withdrawal valve) will be in Auto mode, to
control the pipe line pressure PIC-6801, the set point will be 16 bar.
(All manual valve in liquid withdrawal pipeline should be open)

3- Vaporizers (V703A/B)
We have two systems each system capable to vaporize 5000 nm3/hr.
One system should be online for 8 hours, while the other system will
be defrosting, every 8 hours vaporizer should shift automatically.
For online system inlet shut off valve should be opened KV-7303A/B
Both systems should be in Auto to allow change over between the two
systems.
(All inlet and outlet manual valves for both systems should be opened
in normal condition)
System Control philosophy:
1- Backup Pumps (P-701A/B):

A- Backup Pumps Permissive: (Ready to start)

 Inlet shut off valves should be opened KV-7101A/B.

 Cool down Temperature TE-7112A/B should be less than -160o c,
then 3 minutes on delay timer will be activated.
 Seal leak detection TE-7135A/B should be normal.
 Pump should be electrically ready.
 Cavitation protection DPS-7109A/B should be normal.
 Seal leak detection failure TE-7135A/B
 Motor bearing heaters healthy, E-701A/E701B
 Recycle valves PV-7117A/B should be fully open (100%) before
starting the pump.
 Discharge valves PV-7126A/B should be fully close before starting
the pump.
 Liquid oxygen storage tank level LI-4901 more than 15%, with
option to override.
B- Backup pumps auto cool down system:
 A Soft switch button will be available, once you click this button,
the system should make the following sequence:
1- Pumps inlet valve KV-7101A/B should fully open
2- Pumps discharge valves PV-7126A/B should close 0%.
3- Open Pumps Purge valve KV-7115A/B and close after 30 sec.
4- Recycle valves PV-7117A/B open to 100 % open.
5- Wait for TE-7112A/B to reach -160 o c. then wait for 3 min.
6- Activate a notification that cool down finished and pump
ready to start.
C- Backup Pumps Operation:

 Pump will start manually from the system by the operator, once
started, the recycle valves PV-7117A/B of the running pump should
turn to Auto mode, to control the pump discharge pressure PIC-
7124A/B, Auto and manual mode will be available at the valve face
plate.
 The recycle valve PV-7117A/B will open in case of the pump
discharge pressure PIC-7124A/B increases and close if decreases.
 Both discharge valves PV-7126A/B will be controlled by the pipe
line pressure control loop PIC-6801.
 The discharge valves PV-7126A/B will open in case of the pipe line
pressure PIC-6801 decreased and close if increased.

XV-7126A/B interlocks

- Both KV-7303A/B in closed position.

- GOX pipe line flow FI-6801 more than 6000 and pipe line
pressure PIC-6801 less than 8 bar.
- Pump discharge pressure PIC-7124A/B less than 20 bar.
 Once discharge pressure PIC-7124A/B reached to 21 bar the
discharge valve PV-7126A/B will turn to auto mode with 23 bar set
point.
 Timer counter to count working time for each pump.
 If any pump stopped or tripped, the discharge valve PV-7126A/B of
the pump should close and turn to manual mode. Also recycle
valves PV-7117A/B should fully open and turn to manual mode.
 Vent/purge valve KV-7115A/B, no change.
D- Backup pumps Shutdown:

 The shift operator should decide if the pump will be down for short
or long period.

 In case of short period:

- Press pump standby soft switch button from the DCS screen.
The following sequence will be generated from the system:
- Stop the pump
- Turn Recycle valves PV-7117A/B to manual mode with 100%
open.
- Trip, pumps discharge solenoid valve XV-7126A/B.

 In case of long period:

- Press pump isolation soft switch button from the DCS screen.
The following sequence will be generated from the system:
- Stop the Pump.
- Trip, pumps inlet valves KV-7101A/B.
- Trip, pumps discharge solenoid valve XV-7126A/B.
- Turn Recycle valves PV-7117A/B to manual mode with 100%
open for 30 sec then close 0 %.
- Open, pumps purge valves KV-7115A/B, if the DP between PIC-
6801 AND PIC-7124A/B less than 8 bar. Otherwise activate the
alarm.
E- Backup Pumps will Trip/Interlocks:

 Inlet shut off valve close KV-7101A/B

 Seal leak detection failure TE-7135A/B
 Motor Over load or any electrical failure, such as heater trips,
winding temperature, etc.
 Dry running protection switch activated, DPS-7109A/B
 GOX pipe line flowFI-6801 more than 6000 nm3/hr, with pipe line
pressure less than 8 bar PIC-6801.
 Liquid oxygen storage tank level LI-4901 less than 15%, with option
to override.

Note:

 If both vaporizers systems inlet valves KV-7303A/B closed/tripped,

system should stop the pump and follow pumps standby mode
sequence.
2- HP Tank T-702:
 If the pipe line pressure PIC- 6801 reading reached to 16 bar, the
withdrawal valve PV-7203 will start opening and supply the liquid
to the system, to maintain the pipe line pressure PIC-6801 at16 bar.

Note:

Regarding the above case, the backup pumps will not start
automatically, so once the HP tank withdrawal valve open more
than 5 %, or pipe line pressure PIC-6801 reaches to 16 bar, system
should give an alarm/indication to the operator.

XV-7203 interlocks, (HP tank Withdrawal valve)

- Both vaporizer inlet valve KV-7303A/B in closed position.

- GOX pipe line flow FI-6801 more than 6000 and pipe line
pressure PIC-6801 less than 8 bar.

Note:

- IF HP tank T-702 Level LIC-7235 reached 25%. System should

activate low level alarm.

 If tank pressure PIC-7224 increased to 22 bar the vent valve PV-

7224 will open to maintain the tank pressure set point (Max set
point 22 bar).
 Withdrawal valve control loop PIC-7220 will maintain the tank
pressure at 20 bar by opening or closing the withdrawal valve PV-
7220
Note:
- Max set point for PIC-7224 is 22 bar.
 If tank level LIC-7235 reached 90 % High alarm should be activated.
And 95% will activate the HH alarm.
  If tank pressure PIC-7224/PIC-7220 reached 19 bar, low pressure
alarm will be activated. If pressure dropped to 17 bar a LL alarm
will be activated.

3- Vaporizers:

 The temperature Probes TE-7308/09/10, will read the vaporizers

outlet temperature, if two of three probes readings are equal or
less than 5 o c, System will automatically switch over from the
online vaporizer to the standby one, by operating the vaporizers
inlet valves KV-7303A/B.
 BUT first, the standby system inlet valve will open, System will
wait till valve reach to open position and activate open position
limit switch. On delay timer with 5 sec to be activated, then the
inlet valve of the online vaporizer will close.
 If the valve of the standby system doesn’t open, the system will
activate an alarm.
 If the temperature readings of two temperature probes reached
– 10 o c, then the following valves should be tripped:
1- Vaporizers Inlet valves KV-7303A/B of both online and standby
system should trip.
2- Pump discharge valves solenoid XV-7126A/B should trip.
3- Liquid withdrawal valve XV-7203 solenoid, should trip.
 8 hours timer to be added to switch between the vaporizers inlet
valves KV-7303A/B every 8 hours, the same switching system should
be followed i.e. (standby valve should open first, wait for 5 sec for
the closed position limit switch to be activated, then close the
online valve. Otherwise give an alarm and keep the online one in
open position.
 IF DCS disturbed, the timer will stop, once resumed both valves
should keep open. Once operator select the vaporizer, reset switch
will start the timer.
 If any one of the temperature probes malfunction an alarm will be
activated.
 If two temperature probes malfunctions, system should monitor
only the 3rd probe reading, in case of this reading reached - 15 o c,
trip the system immediately by closing the vaporizers inlet valves
KV-7303A/B.
 If three temperature probes malfunctions, system should trip
immediately by closing the vaporizers inlet valves KV-7303A/B.
 The vaporizer inlet valve will shut off. If the oxygen flow >6000
nm3/hr. FI-6801 with pipe line pressure PIC-6801 less than 8 bar.