V4-CH04-Complex Control Rev 1 - Upto PELLET FLOW CONTROL

PETRONAS RAPID Project Nov 2012
Johor, Malaysia
350 KTA LLDPE PLANT Vol. : 4
Project n° 61070F
Process Design Package
VOLUME 4
CHAPTER 4
COMPLEX CONTROL
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial
Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or
amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.
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Project Package Originator Discipline Doc. Type Unit n° Serial n°
Technologies RAPID L20 INE PRO DES 3200 0014

LICENSOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
350 kta LLDPE PLANT 61070F 3200 SP - 014 1 1 / 74
SPECIFICATION
COMPLEX CONTROL
Complex Control Loops and Calculations
1 12-DEC-12 PDP update FMA A. CONIL A.CONIL

0 05-NOV-12 ISSUE FOR PDP A. CONIL A. CONIL A.CONIL
XA 21-SEP-12 FOR COMMENT A.RUISENOR A. CONIL A.CONIL
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© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and
the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the
express permission of INEOS Commercial Services UK Limited.
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COMPLEX CONTROL
TABLE OF CONTENTS
1. INTRODUCTION ................................................................................................................................................................ 5
1.1 ABBREVIATIONS .............................................................................................................................................. 6
1.2 REFERENCE DOCUMENTS ................................................................................................................................ 6
2. REACTOR TEMPERATURE CONTROL ....................................................................................................................... 7
2.1 MAIN TEMPERATURE CONTROLLER (TIC-40046)............................................................................................... 7
2.2 STEAM MAKE-UP FLOW FIC-40072 .................................................................................................................. 8
2.3 COOLING WATER MARGIN ................................................................................................................................ 8
2.4 ALARMS AND TRIPS ......................................................................................................................................... 9
2.5 OPERATOR INTERFACE .................................................................................................................................... 9
3. REACTOR MISCELLANEOUS CONTROL ................................................................................................................ 10
3.1 REACTOR GRID TEMPERATURE AND GRID DIFFERENTIAL TEMPERATURE ........................................................... 10
3.2 REACTOR SKIN TEMPERATURE DEVIATION....................................................................................................... 11
3.3 REACTOR TEMPERATURE TO CYCLONES TEMPERATURE DEVIATION .................................................................. 11
3.4 REACTOR DIFFERENTIAL TEMPERATURE ......................................................................................................... 12
3.5 MAIN LOOP COMPRESSOR GUIDE VANES ......................................................................................................... 12
3.6 SPRAY NOZZLE TO MAIN LOOP CONDENSER CONTROL ..................................................................................... 12
4. HIGH PRODUCTIVITY .................................................................................................................................................... 13
4.1 NOZZLE CONTROL ......................................................................................................................................... 13
4.2 MAIN LOOP SEPARATOR LEVEL CONTROL ....................................................................................................... 13
4.3 HP LIQUID PUMPS MINIMUM FLOW CONTROL ................................................................................................... 13
4.4 CONDENSATION ............................................................................................................................................ 14
5. CATALYST ....................................................................................................................................................................... 15
5.1 CALCULATION OF CATALYST QUANTITY IN LP/HP STOCK PIPES........................................................................ 15
5.2 CATALYST INJECTION (ZIEGLER OR METALLOCENE) ........................................................................................ 20
5.3 CATALYST INJECTION SCHEMES ..................................................................................................................... 20
5.4 INTERLOCKS AND ALARMS .............................................................................................................................. 21
5.5 OPERATOR INTERFACE .................................................................................................................................. 21
6. REACTOR GAS PHASE ANALYSERS (AT-40050/AT-40051)............................................................................... 22
35200L-000-DOD-P332-0004
© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and
images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial
Services UK Limited.
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6.1 AT-40050/40051 GAS CHROMATOGRAPHS .................................................................................................... 22

7. VRU MULTISTREAM ANALYSERS ............................................................................................................................ 26
8. DEWPOINT IN REACTOR CALCULATION ............................................................................................................... 26
8.1 INPUTS ......................................................................................................................................................... 27
8.2 DEW POINT CALCULATION PRINCIPLES ........................................................................................................... 28
8.3 FUGACITY CALCULATION ................................................................................................................................ 28
8.4 SUM OF LIQUID FRACTION CALCULATION ......................................................................................................... 31
8.5 DEW POINT CALCULATION ALGORITHM ............................................................................................................ 32
8.7 ALARMS ........................................................................................................................................................ 34
8.8 ERROR HANDLING ......................................................................................................................................... 34
9. AVERAGE MOLECULAR MASS IN REACTOR AND IN GAS AND LIQUID PURGES ..................................... 34
10. ETHYLENE ................................................................................................................................................................... 36
10.1 ZIEGLER OPERATION ..................................................................................................................................... 36
10.2 METALLOCENE OPERATION ........................................................................................................................... 37
10.3 ALARMS AND TRIPS ....................................................................................................................................... 37
11. HYDROGEN ................................................................................................................................................................. 38
11.1 ZIEGLER AND METALLOCENE OPERATION ....................................................................................................... 39
12. COMONOMER ............................................................................................................................................................. 43
12.1 COMONOMER FLOW....................................................................................................................................... 43
12.2 CONTROL ..................................................................................................................................................... 44
13. PENTANE ..................................................................................................................................................................... 46
14. REACTOR PRESSURE CONTROL......................................................................................................................... 47
15. REACTOR BED LEVEL ............................................................................................................................................. 50
15.1 BED LEVEL FROM PRESSURE DROP ............................................................................................................... 50
15.2 BED LEVEL CONTROLLER OUTPUT LIMITS ........................................................................................................ 53
16. TEAL INJECTION CONTROL................................................................................................................................... 54
17. CHEMICAL ADDITIVES B1 AND S1 INJECTION CONTROL ............................................................................ 56
17.1 B1 INJECTION CONTROL................................................................................................................................. 56
17.2 S1 INJECTION CONTROL................................................................................................................................. 57
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18. STRIPPING GAS FLOW TO THE DEGASSER CORRECTION ......................................................................... 58

19. GRADE OPERATING WINDOW LIMITS (GROWL) ............................................................................................. 59
19.1 OPERATOR INTERFACE FOR DEGASSING FLOWS DURING TRANSITIONS ............................................................. 62
20. FLUIDISATION VELOCITY IN REACTOR ............................................................................................................. 63
20.1 FLUIDISING GAS DENSITY ............................................................................................................................... 63
20.2 FLUIDISATION GAS MASS FLOW RATE .............................................................................................................. 64
20.3 FLUIDISATION VELOCITY ................................................................................................................................ 65
21. PRODUCTION RATE ................................................................................................................................................. 66
22. REACTOR RESIDENCE TIME, BED MASS, FLUIDISED BULK DENSITY ..................................................... 66
23. EXTRUDER FEEDS CONTROL ............................................................................................................................... 68
23.1 INTRODUCTION.............................................................................................................................................. 68
23.2 POWDER FEED CONTROL ............................................................................................................................... 68
23.3 DETAILED CONTROL SCHEME OF PELLET FLOWRATE THROUGH EXTRUDER........................................................ 69
23.4 ADDITIVE FEEDS AND PELLET RERUN CONTROL ............................................................................................... 71
23.5 DETECTION OF POWDER BLOCKAGE IN THE POLYMER VIBRATING SCREEN ......................................................... 72
24. PELLETS FLOWRATE CONTROL .......................................................................................................................... 73
24.1 PELLETS FLOW RATE TO ELUTRIATION FROM PELLET BLENDERS ....................................................................... 73
25. INTERFACE BETWEEN DCS AND APC (OPTION) ............................................................................................. 74
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COMPLEX CONTROL
CONTENTS
1. INTRODUCTION
This document defines the specification for complex regulatory control, where this is not clear from the
PID.
The licensee and detailed engineering contractor are responsible, during the detailed engineering and
implementation, for ensuring that the final installed system is safe, reliable and operable. This
document (along with the Instrument and Process Control Philosophy document) provides guidance in
achieving these aims.
Controllers listed in this specification must have the ability to have their setpoint ramped up and down
by the operator. The operator must be able to enter the final setpoint and the ramp rate or time over
which the setpoint is ramped. This facility is particularly useful during transitions.
Throughout the control PDP the words may, should, and must have the following specific meaning:
May: is used where an alternative provision is acceptable to INEOS Technologies
Should: is used where INEOS Technologies prefers the provision
Must: is used where the provision is mandatory
To improve reading of the document, the instrument and equipment tags do not include the prefix3200
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1.1 Abbreviations
DCS Distributed Control System (Main plant control system)
SIS Safety Instrumented System (Protective system)
PID Process and Instrument Diagram
PV Process value
OP Controller or calculation block output
SP Controller setpoint
Oper Parameter set by operator
Calc Calculated Parameter
Meas Parameter given directly by a measure
IDS Instrument Data Sheet
D.E. Detailed Engineering Contractor
1.2 Reference documents

 Instrument & Process Control Philosophy
 PID‟s
 Sequence Description
 Process Interlock description
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2. REACTOR TEMPERATURE CONTROL
Heat is removed from the reactor gas loop by water circulating through the main loop condenser. The
cooled gas and condensed liquid returns via the main loop separator to the polymerisation reactor
where it cools the polymer bed. The cold water is added to the main loop condenser circulating water
loop, at the inlet of the loop condenser.
The reactor temperature is controlled by manipulating the setpoint for the circulating water
temperature controller. The reactor temperature control system has physical characteristics that make
the design of the control loop critical. Due to the exothermic nature of the reaction, at high production
rates the temperature is open loop unstable. This means that it cannot be manually controlled by the
operator. There are long process and measurement delays. This makes the loop susceptible to
oscillation if disturbances or non-linearity are present. The temperature interacts with other
parameters on the reactor particularly the separator level, the ethylene partial pressure and the
reactor bed level.
2.1 Main temperature controller (TIC-40046)
Reactor outlet pipe Reactor outlet pipe
TI TI
40047 40048
PV PV
HS-40001
Main loop condenser Main loop condenser

APC cooling water inlet cooling water inlet
(Option) PV
TI TI
TIC Reactor
SP 40072A 40072B
40046
PV PV
OP
OPER
HS-40072
PV
Main loop
TIC
SP condenser
40072 inlet
OP
SP Cooling
water to
FIC
PV Main loop
40070 condenser
OP inlet
Cooling water return

FV from Main loop
condenser
40070A/B (Split range)
The reactor temperature is measured in the reactor gas outlet pipe using TI-40047 or TI-40048. The
temperature probes are directly inserted in the process gas without Thermowell to improve the
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response time. The actual measurement used is selectable by the operator via HS-40001 or
automatically in the case of transmitter fault.
The output of TIC-40046 resets the slave temperature controller TIC-40072 for the circulating water at
the inlet of the main loop condenser. The slave temperature controller adjusts the cold cooling water
flow entering the circulating water at the inlet nozzle of the main loop condenser.
The circulating water temperature is measured by two temperature measurements using TI-40072A or
TI-40072B. The temperature probes are directly inserted in the cooling water without Thermowell to
improve the response time. The actual measurement used is selectable by the operator via HS-40072
or automatically in the case of transmitter fault.
The operator has the option of using a setpoint ramp function on master controller to limit the
disturbance caused by sudden setpoint changes. This ramp function ramps from the current setpoint
to a new setpoint at a rate of 1.5°C/h. The ramp must stop if the operator makes a manual change to
the setpoint or the controller is put into manual mode.
Interlock I-4021-S (Maxi Kill) acts if the reactor temperature exceeds TIC-40046.SP by more than 5°C.
Protection must be provided to prevent the operator from setting the setpoint more than 5°C below the
current process variable. This is to prevent the operator accidentally initiating the interlock that acts on
the difference between setpoint and process variable.
The mechanical distance between the cooling water mixing point (cooling water & circulating water)
and the main loop condenser inlet nozzle must be minimised to reduce the transport delays as far as
possible.
2.2 Steam make-up flow FIC-40072
Steam is used to heat up part of the main cooling water loop flow in main loop condenser in order to
heat the reactor during start-up. The set point is provided by the operator.
2.3 Cooling water margin
The heat removal capacity of the main loop condenser is a limit on the design production capacity of
the plant. As this limit is reached the temperature control will become unstable. The cooling water
margin is an indication that the reactor is approaching this limit.
MARGIN = TIC-40072.PV – TI-40201
Where
TIC-40072.PV Meas Recirculating water inlet to main loop °C
condenser
TI-40201 Meas Fresh cooling water to main loop condenser °C
water circulating system
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2.4 Alarms and trips
The following interlock act on the temperature control

If TIC-40046.PV – TIC-40046.SP > 5 °C then the maxi-kill sequence, I-4021-S is initiated.
Alarms are defined as follows:

TIC-40046.PV – TIC-40046.SP > +/-1 °C Low priority
TIC-40046.PV – TIC-40046.SP > +/-3 °C High priority
MARGIN < 3 °C High priority
Deviation alarm between TI-40047 and TI- Low priority

40048 when difference > +/-1 °C
2.5 Operator interface
All the components of the temperature control should be shown on a single display. The main loop
separator level control and flow to the high productivity nozzles should be shown on the same display.
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3. REACTOR MISCELLANEOUS CONTROL
3.1 Reactor grid temperature and grid differential temperature
3.1.1 Reactor grid differential temperature
The reactor grid differential temperatures are used to give an indication of agglomerate formation.
TDI-40001 = TI-40001 – TIC-40046.PV (Note these values will normally be negative)
TDIF-40001 = TDI-40001 filtered T0.
Where
T0 =5 Filter time, adjustable on line min
These calculations are repeated for TI-40002/40003/40004/40007/40008 and TDI-

40002/40003/40004/40007/40008.
A common alarm is raised for each of the three following conditions:

TDI-40001 or TDI-40002 or TDI-40003 or TDI-40004 or TDI-40007 or TDI- Low priority
40008 > +1 °C
TDI-40001 or TDI-40002 or TDI-40003 or TDI-40004 or TDI-40007 or TDI- Low priority

40008 < -10 °C
TDIF-40001 or TDIF-40002 or TDIF-40003 or TDIF-40004 or TDIF-40007 or Low priority

TDIF-40008 < -7 °C
3.1.2 Reactor grid temperature
Reactor grid temperature also gives an indication of agglomerate formation.
TIF-40001 = Absolute value | TI-40001 – (TI-40001 filtered T1) |
This calculation is repeated for TI-40002/40003/40004/40007/40008.
A common low priority alarm is raised for the following condition:
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TIF-40001 or TIF-40002 or TIF-40003 or TIF-40004 or TIF-40007 or Low priority

TIF-40008 > +1 °C
Where
T1 =5 Filter time, adjustable on line min
3.2 Reactor skin temperature deviation
The reactor skin temperatures are also used to give an indication of agglomerate formation.
A common low priority alarm is raised if any skin temperature satisfies the following condition:
Absolute value :
| (TI-40010 – AVERSKIN) – [(TI-40010 – AVERSKIN) filtered T2] | > +1°C
Where
AVERSKIN Calc Average of all reactor skin temperatures, °C
TI-40010 to TI-40038.
T2 =6 Filter time, adjustable on line h
This calculation is repeated for all reactor skin temperatures, TI-40010 to TI-40038.
3.3 Reactor temperature to cyclones temperature deviation
Reactor temperature to cyclones temperature deviation gives an indication of cyclone blockage by the
powder. High priority alarms are generated as follow:
Absolute value:
| (TI-40050 – TICF-40046.PV) – [ (TI-40050 – TICF-40046.PV) filtered T4 ] | > +1 °C
Absolute value:
| (TI-40051 – TICF-40046.PV) – [ (TI-40051 – TICF-40046.PV) filtered T4 ] | > +1 °C
Where
TICF-40046.PV = TIC-40046.PV filtered T3

T3 = 10 Filter time to compensate for time lag sec
between reactor and cyclone temperature
measurements.
T4 =6 Filter time, adjustable on line h
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3.4 Reactor differential temperature
The reactor differential temperature gives an indication of the start-up of the reaction.
Reactor differential temperature:
TDI-40904 = TIC-40046.PV – Mo3 TZI-40064A/B/C.
Where
TDI-40904 Calc Reactor differential temperature °C
TIC-40046.PV Meas Reactor temperature °C
TZI-40064A/B/C Meas Reactor gas inlet temperature °C
3.5 Main loop compressor guide vanes
It should not be possible for the operator to move the main loop compressor guide vanes HV-40061
by more than 2° in a single step.
3.6 Spray nozzle to main loop condenser control
Liquid is sprayed at the inlet of the main loop condenser. In case of loss of liquid flow to the spray
nozzle, there is a risk of nozzle blockage by fines from process. To avoid the nozzle blockage, the
nozzle is automatically flushed with process gas.
If PDI-40056 < 0.3 bar then open gas valve XV-40056
If PDI-40056 > 0.5 bar then close gas valve XV-40056
The operator should be able to switch this control scheme into manual if required
Where:
PDI-40056 Meas Difference between liquid to nozzle and bar
inlet gas to main loop condenser
XV-40056 Loop gas to nozzle isolation valve
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4. HIGH PRODUCTIVITY
4.1 Nozzle control
The high productivity nozzles are flushed with process gas during start-up of the reactor. As the
production rate rises and condensed hydrocarbons collect in main loop separator, this liquid is injected
through the nozzles. As the liquid pressure rises, the control scheme cuts off the flow of gas to the
nozzles. If the liquid pressure falls then process gas flow is reinstated.
If PDI-40952 < 0.5 bar then close gas valve XV-40953
If PDI-40952 > 0.8 bar then open gas valve XV-40953
The operator should be able to switch this control scheme into manual if required
Where:
PDI-40952 Meas Difference between gas and liquid supply bar
pressures
XV-40953 Loop gas to nozzles isolation valve
4.2 Main loop separator Level control
The level is measured in main loop separator using LZI-40901 or LZI-40902. The actual measurement
used is selectable by the operator (selector LHS-40900) or automatically in the case of transmitter
fault.
The level control (LIC-40900) of main loop separator needs to be quick acting due to the short
residence time.
4.3 HP liquid pumps minimum flow control
The HP liquid injection pump(s) have a minimum flow controller FIC-40903. The total flow through the
pump is calculated from the sum of the flow to the nozzles (FI-40902) and the recycle flow (FI-40901).
Low limit is required on the valve output for FIC-40903 to prevent the fines settling in the recycle line.
This limit should be set to keep the flow above the low alarm level for the recycle flow (FI-40901)
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4.4 Condensation
The condensation rate is the proportion of the gas circulating around the loop that is condensed prior
to injection into the reactor. This is calculated from the fluidising gas flow and the flow to the nozzles.
COND = FI-40902 / G *100
Where
COND Calc Condensation rate % Weight
G Calc Calculated fluidising gas flow (see kg/h

fluidisation velocity)
FI-40902 Meas Liquid flow to nozzles kg/h
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5. CATALYST
5.1 Calculation of Catalyst quantity in LP/HP stock pipes
The calculated total quantity of catalyst in LP and HP stock pipes is useful information to the operator
for grade transition and catalyst tote bin management (refer to sequences 34 and 35 for automated
catalyst transfer). The operator can then estimate the time of operation with the remaining catalyst in
the stock pipes.
The volume in the two stock pipes is calculated from the geometry of vessels and various parameters
that will need to be reviewed by the detailed engineering to meet the actual vessels lay-out.
The following scheme shows the different parameters required for the calculations for the Ziegler SDX
LP/HP stock pipes. The vessel lay-out is similar for the Ziegler NCT LP/HP stock pipes and
Metallocene LP/HP stock pipes.
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LT
30075
100 %
LP STOCK
PIPE
LI-30075
ALP%
0%
H1LP
H2LP
XV
30075
LT
XV 30076
30078
100 %
HP STOCK
PIPE
LI- 30076
AHP %
0%
H1HP
H2HP
Rotary Rotary
valve valve
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5.1.1 Ziegler SDX LP/HP stock pipes
The calculation of the volume of catalyst powder in the LP/HP stock pipes system is based on the
following assumptions:
- The radar level LI-30075 is calibrated between 0% and 100% where 0% is located at a height
H1LP (H1HP) from the cone bottom and 100% at the top TL of the vessel. The height will be
determined by the detailed engineering after level calibration
- When the level is below or equal to 0%, the vessel is assumed empty
- When the level is above or equal to 100%, the vessel is assumed completely full, including the
hemispheric top part
- ALP (AHP) is the level expressed in % at the bottom TL of the vessel.
- The total volume is the sum of the calculated volume in LP and HP stock pipes systems
- The total weight is the total volume times the catalyst poured bulk density
LP stock pipe Volume calculation: LPVOL {the following calculation should run continuously}
CONEHLP = DLP/2 * Tangent (CONEβLP/2)
VOLLP1 = π/3 * [Tangent (CONEβLP/2)]2 * CONEHLP3
ALP = (CONEHLP - H1LP) / (CONEHLP + CYLHLP - H1LP) * 100
VOLLP2 = π * (DPIPELP/1000)2/4* H2LP
If LI-30075 <= 0% Then LPVOL = 0
If 0% < LI-30075 < ALP Then LPVOL = π/3 * [Tangent (CONEβLP/2)]2 * [LI-30075/100 * (CYLHLP+CONEHLP-H1LP) +
H1LP]3+VOLLP2
If ALP < LI-30075 < 100% Then LPVOL = VOLLP1 + VOLLP2 + π * DLP2 / 4* CYLHLP *(LI-30075 - ALP) / (100-ALP)
If LI-30075 >= 100% Then LPVOL = VOLLP1 + VOLLP2+ π * (DLP)2 / 4* CYLHLP+ π * DLP3 / 22.8
Where:
CONEβLP Oper,30 Cone angle of LP stock pipe °
DLP Oper, LP stock pipe internal diameter m

0.9906
DPIPELP Oper, 73.66 Internal diameter of pipe between LP and HP mm

stock pipes
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CONEHLP Calc Height of cone m
LPVOL Calc LP stock pipe volume m3
H1LP Oper Distance between the cone bottom and the m

calibrated 0% of LI-30075
VOLLP2 Calc Volume of the pipe between the cone bottom m3
and XVs – Pipe diameter = DPIPELP, pipe
length = H2LP
H2LP Oper Length of the pipe between the cone bottom m
and XVs
LI-30075 Meas Level in LP stock pipe %
ALP Calc level expressed in % at the bottom TL of the %

vessel
VOLLP1 Calc Volume of the cone m3
CYLHLP Oper, 1.003 Cylinder part height m
HP stock pipe Volume calculation: HPVOL {the following calculation should run continuously}
CONEHHP = DHP/2 * Tangent (CONEβHP/2)
VOLHP1 = π/3 * [Tangent (CONEβHP/2)]2 * CONEHHP3
AHP = (CONEHHP - H1HP) / (CONEHHP + CYLHHP - H1HP) * 100
VOLHP2 = π * (DPIPEHP/1000)2/4* H2HP
If LI-30076 <= 0% Then HPVOL = 0
If 0% < LI-30076 < AHP Then HPVOL = π/3 * [Tangent (CONEβHP/2)]2 * [LI-30076/100 * (CYLHHP+CONEHHP-H1HP) +
H1HP]3+VOLHP2
If AHP < LI-30076 < 100% Then HPVOL = VOLHP1 + VOLHP2 + π * DHP2 / 4* CYLHHP *(LI-30076 - AHP) / (100-AHP)
If LI-30076 >= 100% Then HPVOL = VOLHP1 + VOLHP2+ π * (DHP)2 / 4* CYLHHP+ π * DHP3 / 22.8
Where:
CONEβHP Oper,30 Cone angle of HP stock pipe °
DHP Oper, HP stock pipe internal diameter m

0.700
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DPIPEHP Oper, 73.66 Internal diameter of pipe between HP stock mm

pipe and catalyst rotary valves
CONEHLP Calc Height of cone m
HPVOL Calc HP stock pipe volume m3
H1HP Oper Distance between the cone bottom and the m

calibrated 0% of LI-30076
VOLHP2 Calc Volume of the pipe between the cone bottom m3
and rotary valves – Pipe diameter = DPIPEHP,
pipe length = H2HP
H2HP Oper Length of the pipe between the cone bottom m
and rotary valves
LI-30076 Meas Level in HP stock pipe %
AHP Calc level expressed in % at the bottom TL of the %

vessel
VOLHP1 Calc Volume of the cone m3
CYLHHP Oper, 0.838 Cylinder part height m
The total weight in the LP/HP stock pipe:
TOTALWHPLP = (LPVOL + HPVOL) * Dcat
Where:
TOTALWHPLP Calc Total weight in LP/HP stock pipe kg
Dcat Oper Catalyst poured bulk density kg/m3

= 330 Ziegler SDX
5.1.2 Ziegler NCT LP/HP stock pipes
The calculation of the volume of catalyst powder in the LP/HP stock pipes system is the same as
Ziegler SDX stock pipes with the following table of tags/data correspondence:
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= 420 Ziegler
NCT
5.1.3 Metallocene LP/HP stock pipes
The calculation of the volume of catalyst powder in the LP/HP stock pipes system is the same as
Ziegler SDX stock pipes with the following table of tags/data correspondence:

= 380
(Metallocene)
5.2 Catalyst injection (Ziegler or Metallocene)
The catalyst is fed into the reactor in a continuous manner via lines equipped with variable speed
rotary valves. The Ziegler SDX and NCT catalyst is delivered by rotary valves X-380A/B. The
Metallocene catalyst is delivered by rotary valves X-386A/B/C .
The operator enters individual speed set points for each rotary valve. The actual individual and total
catalyst flow rate is calculated in the APC (Option).
5.3 Catalyst injection schemes
Zg injection Zg injection Mt injection Mt injection Mt injection

SP SP SP SP SP
SIC SIC SIC SIC SIC
PV PV PV PV PV
30010 30110 30210 30310 30410
OP OP OP OP OP
Zg Rotary A Zg Rotary B Mt Rotary A Mt Rotary B Mt Rotary C
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5.4 Interlocks and alarms
Interlocks stop the rotary valves (refer to interlock descriptions).
The catalyst injection system should have a dedicated display including the catalyst transfer
sequence.
Overrides for the maxi-kill interlock (I-4021-S) and the mini-kill sequence should be shown on this
display to prevent the operator injecting catalyst with overrides set.
The catalyst rotary valve speeds should also be shown on the display for control of the reactor
composition.
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6. REACTOR GAS PHASE ANALYSERS (AT-40050/AT-40051)
The reactor gas phase analysers AT-40050/AT-40051 are used to calculate the partial pressure of
each component of the gas phase. These values are used in the control and monitoring of the gas
phase composition.
6.1 AT-40050/40051 gas chromatographs
6.1.1 Hardware
Analyser redundancy is required due to the criticality of the measurements. Each analyser has a cycle
of approximately 6 minutes. The two analysers should be synchronised with overlapping sample times
so that a new result is available every 3 minutes.
The number of GC‟s regarding the heavy components from C8‟s has to be confirmed by DE.
The results of each component are reported in units of volume %. The values reported are not
normalised values.
Each analyser typically has high and low ranges for hydrogen, hexene-1 and butene-1 and octene-1.
The ranges are selected for each analyser by separate signals from the DCS. High and low range
measurements are transmitted to the DCS as separate signals.
A data ready signal (READ40050/40051) is provided by each analyser once new data is available to
the DCS.
6.1.2 Analyser Data Handling
The measurement of each component should be continuously read from each analyser.
The required components are:

N2 Nitrogen AI-40050A/AI-40051A
H2 Hydrogen AI-40050B/AI-40051B
Ma Methane AI-40050C/AI-40051C
Ea Ethane AI-40050D/AI-40051D
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C2 Ethylene AI-40050E/AI-40051E
C4 Butene-1 AI-40050F/AI-40051F
Total inert C4 Total inert C4 AI-40050G/AI-40051G
iPt Isopentane AI-40050H/AI-40051H
nPt n-pentane AI-40050I/AI-40051I
Total inert C6 Total inert C6 AI-40050J/AI-40051J
C6 Hexene-1 AI-40050K/AI-40051K
Total inert C8 Total inert C8 AI-40050M/AI-40051M
C8 Octene-1 AI-40050N/AI-40051N
Total C10+ Total C10 and heavier AI-40050P/AI-40051P
Separate range selectors on the DCS for each analyser should switch between high and low ranges
for butene-1, hexene-1, octene-1 and hydrogen (C4HLR40050/40051, C6HLR40050/40051,
C8HLR050/051, H2HLR40050/40051).
The measurements on each analyser must be totalised to give an overall total (TOT40050,
TOT40051) volume%.
A selector (AI-40050SEL) is used to determine which analyser – AT-40050, AT-40051 or both - is to

be used for control and calculations.
When the DCS receives a data ready signal (READ40050/40051) it copies the current values from the
relevant analyser to holding data set for validation.
A selector (VALIDATE_xx) is used by the operator to switch on the validation algorithm for the
relevant analyser.
 If VALIDATE_xx is set ON by the operator then if any component in the analysis has changed by
more than x% of reading and y% of range from the previous validated value and the reactor
pressure is above 17 barg (to avoid holding reads when the reactor gas phase is being composed),
the data for the entire sample is held and the previously validated data is not overwritten. The
component which failed the validation should be highlighted on the screen. An alarm should be
raised if two successive analyser results fail to validate. The reactor pressure is measured by PIC-
40039A.PV.
 If VALIDATE_xx is set OFF by the operator then the most recent analyser data replaces the
previous validated data. If VALIDATE_xx is set to OFF and back to ON this is equivalent to a
manual validation of the most recent data from the analysers.
 If MAINT_xx is set ON by the operator then no new data from the analyser is validated and the
previous validated values are kept.
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 The VALID_xx flag is set OFF if the validation has failed or MAINT_xx is set. The flag set ON when
the validation is healthy (VALIDATE_xx = ON and MAINT_xx = OFF and Validation not failed). This
flag will be used by the APC (if implemented) to prevent the APC models calibrating if the analyser
signals are not valid.
The values of x% and y% should have default values of 0.5%. These values should be displayed on
the screen and be independently adjustable for each component.
The validated values are used by the reactor controls.
A timeout alarm is raised if the data ready signal is not received from an analyser within the expected
cycle time plus 2 minutes.
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Reactor analyser (AT-40050 / AT-40051) data validation typical scheme:
TYPICAL ARRANGEMENT MAINT VALIDATE

AI-40050 AI-40050
AT-40050
C2
C2
AI-40050E C2
H2
HOLD AI-40050SEL : H2
AT-40050 or AT-40051 or both C4
GC DATA VALIDATED
AE-40050 DATA C4
N2
Idem for all
components N2
DATA READY
SIGNAL
READ 050
AT-40051
C2
MAINT VALIDATE
AI-40051 AI-40051
AI-40051E
HOLD
GC DATA
AE-40051
Idem for all
components
DATA READY
SIGNAL
READ 40051
A total pentane composition is calculated for use in pentane controls: C5 = iPt + nPt.
Validated composition values are used to calculate the partial pressure of each component. For each
component:
Px = x / 100 * (PIC-40039A.PV + ATM)
Where:
Px Calc Partial pressure of component x in bara
reactor
x Meas/ Validated quantity of component x in vol%
Calc reactor. Example: x = C2, Validated
data, AI-40050E or AI-40051E
PIC-40039A.PV Reactor pressure barg
ATM = Refer to Atmospheric pressure (constant) bara

project basis
These values are used by the reactor gas phase control.
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6.1.3 Alarms
TOT40050 < 98% Low priority
TOT40050 >102% Low priority
TIMEOUT40050 Low priority

Raised if the READ40050 signal is not raised within
the expected cycle time plus 2 minutes.
The above alarms are repeated for analyser AI-40051
HOLDAI Low priority
Raised if any component is not validated. The
component is highlighted in the held data
DEVAI Low priority
Raised if any individual component differs by more
than 2% between analysers. The component is
highlighted for both analysers
6.1.4 Operator Interface
The operator interface for the analysers must clearly show the data flow from the raw analyser inputs
to the validated data sets. Where deviation and hold alarms are raised the component leading to the
alarm must be clearly identified on the display in a similar way to standard alarms.
The raw and validated data from all the GCs should be shown on a single display.
Trends should be configured allowing the readings from each analyser to be easily compared.
7. VRU MULTISTREAM ANALYSERS
There are 2 multistream analysers in the VRU. The streams are located on the main gas and liquid
purges. A new reading update should be available every 30 minutes, with two consecutive analysis
reports before switching back to the other analyser streams.The data should be handled and validated
in a similar manner to the other GCs.
8. DEWPOINT IN REACTOR CALCULATION
Operation at too high dew point temperature in the reactor can cause several problems:
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• Condensation in instrument sample lines, such as chromatograph.
• Poor reactor temperature control
• Liquid in lateral withdrawals
8.1 Inputs
Following values are given by chromatographs. Values are the validated ones. See the previous
chapter specific to gas chromatograph data handling.
limits
P = PIC- Absolute Reactor bara 0 to 25

40039A.PV + pressure for
ATMbar calculation purpose
filtered 10s
ATMbar = ATM Atmospheric pressure bara

See project
basis
Treact (*) = TIC- Reactor temperature °C 15 to 120

40046.PV
N2 Meas nitrogen concentration Vol% 0-100
H2 Meas hydrogen Vol% 0-100

concentration
Ma Meas methane concentration Vol% 0-100
Ea Meas ethane concentration Vol% 0-100
C2 Meas ethylene concentration Vol% 0-100
C4 Meas butene-1 concentration Vol% 0-100
Total inert C4 Meas Total inert C4 Vol% 0-100

concentration
iPt Meas iso-pentane Vol% 0-100
concentration
nPt Meas n-pentane Vol% 0-100
concentration
concentration
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C6 Meas hexene-1 Vol% 0-100

concentration
concentration
C8 Meas Octene-1 Vol% 0-100
concentration
Total C10+ Meas Total C10 and heavier Vol% 0-100
concentration
(*) not needed in the calculation. Only used to be compared with the dew point Tdew and check if the
alarm has to be raised or not – see below chapter Alarms
8.2 Dew point Calculation principles
The calculations are based upon vapour/liquid equilibrium theory, using the concept of “fugacity”.
The principle behind the dew point temperature calculation is that given the vapour mole fractions of
the components given by analysers the liquid mole fractions can be calculated. The dew point
temperature is the temperature where the sum of the liquid mole fractions equates to 1.
The dew point temperature is calculated by an iterative method.
Where these calculations are performed within the DCS, it is recommended that the number of
iterations for each calculation is optimised in order to limit the load of the DCS.
The final figures from a previous run of the calculation should be used as the starting figures on the
next run, whether or not these calculations have converged.
As the component concentrations given by analyser are refreshed on a minute basis, the dewpoint
calculation can be placed in a low priority processor thread of the DCS.
Also pressure used for calculation must be filtered to avoid spurious alarm if reactor pressure
measurement is noisy
8.3 Fugacity calculation
A specific subroutine calculates the two partial equilibrium ratio constants (so call fugacities) for a
given gas phase component at a given temperature.
This subroutine is used by Xsum function described in next chapter.
For each component, corresponding equations are given below.
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Subroutine Fugacity_calculation (component_i, Temp, fu0_i, fu20_i)
With
component_i Input measured by gas
chromatographs
Temp Input Temperature °C
fu0_i Output Partial equilibrium ratio (-)

constant at 0 atmosphere of
component_i
fu20_i Output Partial equilibrium ratio (-)
constant at 20 atmosphere of
component_i
It is mandatory to insure that all the fugacity values are positive. Thus, if fux_i < 0 then fux_i = 10-5
Methane (Ma)
2 3 4
fu0_i = 158.07 - 1.6799E-01 xTemp + 3.4454E-02 xTemp - 3.9703E-04 xTemp + 1.7238E-06 xTemp -
5
2.6386E-09 *Temp
fu20_i = fu0_i
Ethylene (C2)
2 3 4
fu0_i = 24.8798 + 7.2412E-01xTemp - 1.8314E-03xTemp + 1.2805E-05xTemp - 4.0862E-08xTemp
2 3 4
fu20_i = 33.2743 + 5.3857E-01xTemp + 1.8691E-03xTemp - 1.6762E-05x Temp + 3.2448E-08xTemp
Ethane (Ea)
2 3 4
fu0_i = 17.7528 + 3.3163E-01xTemp + 3.2595E-03xTemp - 1.8718E-05x Temp + 3.4839E-08xTemp
2 3 4
fu20_i = 19.6454 + 5.3911E-01xTemp+ 1.5470E-04xTemp - 2.6552E-06x Temp + 5.2916E-09xTemp
Butene-1 (C4)
2 3 4
fu0_i = 1.5477 + 2.5696E-02xTemp + 7.0124E-04xTemp + 3.9124E-06xTemp – 2.0088E-08xTemp
2 3 4
fu20_i = 2.5666 + 4.0012E-02xTemp + 1.5571E-03x Temp + 3.8454E-06xTemp – 4.7318E-11xTemp
Hydrogen (H2)
fu0_i = -5.95x Temp + 1463.1
fu20_i = -6.27xTemp + 1541.6
Total inert C4 (total inert C4)
2 3 4
fu0_i = 1.3074 + 1.8273E-02xTemp + 6.8108E-04x Temp + 3.6642E-06xTemp - 1.8223E-08xTemp
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2 3 4
fu20_i = 2.1893 + 3.6499E-02xTemp + 1.3468E-03xTemp - 2.1498E-06x Temp - 3.1196E-09xTemp
n-Pentane (nPt)
2 3 4
fu0_i = 5.3222E-03 + 2.9795E-02xTemp - 3.0179E-04x Temp + 6.4498E-06xTemp - 1.4969E-08xTemp
2 3
fu20_i = 6.5952E-01 + 1.3872E-02x Temp + 4.8373E-04xTemp + 2.6451E-06xTemp - 1.0241E-
4
08xTemp
i-Pentane (iPt)
2 3 4
fu0_i = 2.0444E-01 + 2.4793E-02xTemp - 6.7204E-05xTemp + 4.9923E-06xTemp - 1.2015E-08xTemp
2 3
fu20_i = 6.29168E-01 + 3.4083E-02x Temp + 3.7551E-04xTemp + 2.8961E-06xTemp - 1.0270E-
4
08xTemp
Hexene (C6)
fu0_i = 10 ^ [4.71128 - 1597.816 / (Temp + 273) - (0.27 / 20 * {10 ^ [4.71128 - 1597.816 / (Temp + 273)]})]
0.27
fu20_i = fu0_i * 10
Total inert C6 (total inert C6)
2 3 4
fu0_i = -3.6242E-02 + 1.1304E-02xTemp - 1.3948E-04x Temp + 2.9431E-06 Temp - 4.6228E-09x Temp
2 3
fu20_i = -3.4664E-01 + 4.5829E-02xTemp - 6.8872E-04x Temp + 9.0073E-06x Temp - 2.1899E-08x
4
Temp
Octene-1 (C8)
fu0_i = Exp(A_coef + B_coef / (Temp + 273) + C_coef * Ln(Temp + 273) +
D_coef * (Temp + 273))
fu20_i= fu0_i * (A_lin + B_lin * Temp)
Where:
A_lin = 2.17241
B_lin = -0.00224138
A_coef = -58.46344105
B_coef = -3204.016983
C_coef = 12.79531216
D_coef = -0.025229352
Ln: Neperian Logarithm fonction
Total inert C8 (Total inert C8)
2 3
fu0_i = -2.4030E-02 + 2.9400E-03x Temp - 5.9999E-05x(Temp ) + 7.3896E-07x(Temp ) + 3.0502E-10x
4
(Temp )
2 3
fu20_i = -2.0157E-01 + 1.8082E-02x Temp - 3.9204E-04x(Temp ) + 4.1651E-06x(Temp ) - 7.5792E-09x
4
(Temp )
Total C10+ (Total C10+)
fu0_i = 10 ^ (3.296399 - 1031.56 / (136.8 + Temp))
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fu20_i = 10 ^ (3.949235 - 1405.34 / (203.5 + Temp))

Nitrogen (N2)
fu0_i = 10000
fu20_i = 10000
8.4 Sum of liquid fraction calculation
A specific function gives the sum of liquid fraction at given temperature, pressure and corrected
pressure.
This function is used in the Tdew main program calculation described in next chapter.
Function Xsum( Temp, Press, Presscor)
With:
Xsum Output Sum of liquid fraction
Temp Input Temperature °C
Press Input Pressure bara
Presscor Input Corrected pressure bara
For each component i:
Calculate Equilibrium ratio constant for each component i
Ki = ( fu0_i + (fu20_i – fu0_i) * Presscor / ( 20 * ATM bar)) * ATM bar / Press
Calculate Liquid Phase molar fraction for each component i
Xi = Yi / Ki , limited so as Xi = 0 if Ki < 10e-6
Calculate liquid molar fraction sum Xsum = Σ Xi
Where:
Ki Calc Equilibrium ratio constant of (-)
component i
Yi Meas Molar concentration of component i frac mol 0-1
in vapor phase
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Xi Calc Liquid phase molar fraction of frac mol 0-1

component i
8.5 Dew point calculation algorithm
This calculation uses previous defined function and subroutine
Algorithm:
Obtain analyser gas concentrations in %vol zi for all components in use
Normalise gas concentrations Zi = zi / ∑zi and assume Yi = Zi
Having P= absolute reactor pressure (in bara), calculate the corrected pressure
0,5
Pcor = P x (∑Zi) (summation does not include Hydrogen or Nitrogen)
Choose upper and lower temperatures to start the first dew point iteration:
Thigh = 60°C, Tlow = 30°C
Loop:
Perform the calculation below at temperatures Thigh and Tlow to obtain Xsum(Thigh P, Pcor) and
Xsum(Tlow P, Pcor) respectively, then interpolate new estimate of Tdew, given by:
Tdew = Thigh - (Thigh - Tlow) x (Xsum(Thigh P, Pcor) - 1) / (Xsum(Thigh P, Pcor) - Xsum(Tlow P,

Pcor))
Calculate Xsum(Tdew, P, Pcor)
If Xsum(Tdew, P, Pcor) = 1 ± Converg then iterations complete, otherwise
If Tdew > Thigh then Tlow = Thigh, Thigh = Tdew
Else If Tdew < Tlow then Thigh = Tlow, Tlow = Tdew
Else If Tlow < Tdew < Thigh then Thigh = Tdew, Tlow unchanged
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Move the limits in by ⅓ towards the dew point to prevent the algorithm becoming „stuck‟ at one of the
limits:
Thigh = Thigh – ((Thigh – Tlow) / 3)
Tlow = Tlow + ((Thigh – Tlow) / 3)
Loop to recalculate partial equilibrium ratio constants, Xsum(Thigh , P, Pcor), Xsum(Tlow , P, Pcor),
and hence Xsum(Tdew , P, Pcor)
A limitation is placed on the number of iterations executed: Maxiter
If the calculation does not converge after Maxiter, then the result is marked as non-convergent:
Error_dew = 1
Where:
zi Meas Gas concentration for component_i Vol%
Zi Calc Normalised gas concentration for mol frac 0-1

component_i
Yi Calc Molar fraction for vapour component_i mol frac 0-1
Xi Calc Molar fraction for liquid component_i mol frac 0-1
fu0_i Calc Partial equilibrium ratio constant at 0 (-)

atmosphere of component_i
fu20_i Calc Partial equilibrium ratio constant at 20 (-)
atmosphere of component_i
Ki Calc Equilibrium ratio constant
Pcor Calc Corrected pressure bara
Converg = e-5 (to be Convergence criteria

tuned)
Maxiter = 30 (to be tuned) Maximum number of iteration per

calculation
Tlow Calc Calculation parameter °C
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Thigh Calc Calculation parameter °C
Tdew Calc Dew point calculated temperature °C 15 to

120
Dew point error:
Error_dew Calc bool
0 = OK
1 = Calculation Error
The accuracy of Tdew is +/- 2 °C
The operator interface on the DCS consists solely of the calculated reactor Temperature dew point
Tdew along with the status of the result Error_dew, for instance normal for good and red when bad.
Alarms are also attached to that point.
8.7 Alarms
Reactor temperature close to dew point TDI-40046 = Treact – Tdew <7.5 °C

High Priority
Error in dew point calculation Error_dew Low

Priority
8.8 Error handling
If any input has a Bad status or the maximum number of iterations is exceeded or successive results
fail to converge or an unexpected error occurs then the dew point temperature calculation fails and the
error indication (Error_dew) is set to 1
It is reset to 0 following a successful calculation.
9. AVERAGE MOLECULAR MASS IN REACTOR AND IN GAS AND LIQUID PURGES
The average molecular mass is required for the main reactor to calculate the fluidisation velocity
The fluidising gas mean molecular mass in the reactor is given by:
MM = [16xMa + 28xC2 + 56xC4 + 58xTotal inert C4 + 2xH2 + 28xN2 + 30xEa + 72xC5 +

86xTotal inert C6 + 84xC6 + 114xTotal inert C8 + 112xC8 + 142xTotal C10+] / [Ma + C2 + C4 +
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Total inert C4 + H2 + N2 + Ea + C5 + Total inert C6 + C6 + Total inert C8 + C8 + Total C10+] -

g/mol
Where:
Ma Meas methane concentration Vol%
C2 Meas ethylene concentration Vol%
C4 Meas butene-1 concentration Vol%
Total inert C4 Meas Total inert C4 concentration Vol%
H2 Meas hydrogen concentration Vol%
N2 Meas nitrogen concentration Vol%
Ea Meas ethane concentration Vol%
C5 Calc Total pentane concentration Vol%
C6 Meas Hexene-1 concentration Vol%
C8 Meas Octene-1 concentration Vol%
Total C10+ Meas Total C10 and heavier concentration Vol%
Note that in the event of a bad value occurring in the analysers then the calculation of MM will
maintain its last good value. This is important as MM is used to calculate the fluidisation gas velocity in
the reactor.
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10. ETHYLENE
APC
(Option) PV
Ethylene partial
SP PC2 pressure
in Reactor
OP
OPER
SETPOINT HIGH
SP LIMIT from
FQIC Ethylene feed PIC-40039C.SP
PV
40063 to Reactor
OP
FV
40063
10.1 Ziegler Operation
The partial pressure of ethylene is controlled by adjusting the flow of fresh ethylene into the loop. The
output of the partial pressure controller should be in units of flow.
FQIC-40063.SP = PC2.OP
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Where:
FQIC-40063.SP Oper Setpoint of the ethylene feed flow controller t/h
PC2.OP Calc Output of the ethylene partial pressure t/h

controller PC2
If the reactor pressure rises the high setpoint limit for the ethylene feed to the reactor is reduced by
PIC-40039C to prevent the reactor safety valve lifting. Refer to the reactor pressure control
description.
10.2 Metallocene Operation
In metallocene operation the ethylene partial pressure is not directly controlled but float between
values defined in GROWL. It is manually controlled using the catalyst flow rate instead of the ethylene
feed flow. The ethylene feed rate is fixed by the operator.
10.3 Alarms and trips
Alarm is defined below:

Absolute value: Low priority
|(PC2.SP - PC2.PV)| > 0.4 bar
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11. HYDROGEN
APC
H2/C2 ratio Ethylene partial
(Option) SP pressure
RH2C2 PC2
OPER SP PV
BIAS_T BIAS_P
- SP +
PV PH2 Hydrogen partial
SP Hydrogen pressure SP
transition partial OP controller Hydrogen purge
PV PH2TRANS pressure PV PH2PURGE partial pressure
controller controller
OP OP
VRU purge H2 PURGE FLOW

SP SP
FIC FIC
PV PV
60601 60604
OP OP
SP SP
Hydrogen feed
PV FQIC Hydrogen feed to FQIC
PV to Reactor
40065
OP
Reactor (high flow) 40062
OP
(low flow) >
IN
SPLIT
RANGE
OP OP
FV FV FV FV
40065 40062 60601A 60601B
VRU purge flow
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11.1 Ziegler and Metallocene operation
The ratio of ethylene and hydrogen partial pressures is used to control the melt index of the polymer.
The setpoint for the partial pressure controller is calculated from the operator entered setpoint ratio
RH2C2 and the partial pressure of ethylene. The process variable is directly calculated from the partial
pressure of hydrogen and ethylene.
PH2.SP = RH2C2.SP * PC2.PV
RH2C2.PV = PH2.PV / PC2.PV (for monitoring only)
The partial pressure of hydrogen is controlled by adjusting the flow of fresh hydrogen into the loop. To
assist during transitions, the fresh hydrogen flow is injected into the loop with high flow hydrogen
controllers or removed more quickly by acting on the purge flow control valves.
When the hydrogen partial pressure drops below the normal operating value (at a value of the
hydrogen normal partial pressure minus PBIAS_T), the hydrogen transition partial pressure controller
acts on the high flow hydrogen controller to quickly add more hydrogen into the loop.
When the hydrogen partial pressure is above the normal operating value (at a value of the hydrogen
normal partial pressure plus PBIAS_P), the hydrogen purge partial pressure controller acts on the
purge flow hydrogen controller to remove part of the hydrogen in the loop. See pressure control loop.
PH2TRANS.SP = PH2.SP – PBIAS_T
PH2PURGE.SP = PH2.SP + PBIAS_P
FQIC-40062.SP = PH2.OP
FQIC-40065.SP = PH2TRANS.OP
FIC-60604.SP = PH2PURGE.OP if selected. There is a high selector signal between

FIC-60601.OP and FIC-60604.OP
FIC-60604.PV = FIC-60601.PV
Where:
RH2C2.SP Oper Setpoint for H2/C2 partial pressure ratio bara/Bara
RH2C2.PV Calc Actual H2/C2 partial pressure ratio bara/bara
FQIC-40062.SP Calc Setpoint of the hydrogen feed low flow kg/h

controller
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FQIC-40065.SP Calc Setpoint of the hydrogen feed high flow kg/h

controller
PH2TRANS.SP Calc Hydrogen transition partial pressure bara
controller SP
PBIAS_T Oper, Bias subtracted from normal Hydrogen bar
= 0.5 partial pressure controller SP for the
calculation of Hydrogen transition partial
pressure controller SP
PH2PURGE.SP Calc Hydrogen purge partial pressure controller bara
SP
PBIAS_P Oper, = Bias added to normal Hydrogen partial bar
0.5 pressure controller SP for the calculation of
Hydrogen purge partial pressure controller
SP
PH2.OP Calc Output of the hydrogen partial pressure kg/h
controller PH2 to hydrogen low flow
controller (normal operating case)
PH2TRANS.OP Calc Output of the hydrogen partial pressure kg/h
controller PH2TRANS to high hydrogen
flow controller (transition and start-up
operating cases)
PH2PURGE.OP Calc Output of the hydrogen partial pressure kg/h
controller PH2PURGE to purge flow control
valve (transition operating case)
FIC-60604 H2 Purge flow controller from the VRU
dedicated to remove quickly H2 during
transitions
The limits for PH2, PH2TRANS and PH2PURGE outputs should be back calculated from the setpoint
limits of FQIC-40062, FQIC-40065 and FIC-60604.
11.1.1 Hydrogen Flow control to catalyst nozzle jackets (Metallocene only)
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SPECIFICATION
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RH2C2
PV
X MWH2/MWC2
Converting
factor
X Kmt
Ethylene feed Ethylene feed Ethylene feed

to nozzle to nozzle to nozzle
jacket jacket jacket
FIC-30212 PV X X PV FIC-30312 X PV FIC-30412
SP SP SP
Hydrogen feed FIC Hydrogen feed Hydrogen feed
FIC PV to nozzle
FIC
PV to nozzle 30315 PV to nozzle
30215 jacket 30415 jacket
jacket
OP OP OP
FV FV FV
30215 30315 30415
The catalyst injection nozzle is made of an internal tube, inserted into a concentric jacket that is
flushed with a mixture of ethylene and hydrogen.
The hydrogen is injected in flow ratio to the ethylene gas to the nozzle jacket. The hydrogen to
ethylene gas flow ratio is determined to meet the same molar concentration ratio of hydrogen to
ethylene as in the reactor.
When there is process gas or Nitrogen injected instead of ethylene, the operator should stop the
hydrogen flow to the nozzle jackets by closing the hydrogen control valves.
FIC-30215.SP = RH2C2.PV x (MWH2/MWC2) * FIC-30212.PV x Kmt
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SPECIFICATION
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RH2C2.PV Calc Actual H2/C2 partial pressure ratio bara/ bara

FIC-30215.SP Calc Setpoint of the hydrogen feed flow kg/h
controller to catalyst nozzle J-386A
FIC-30212.PV Calc Flush gas flow to catalyst nozzle J- kg/h
386A
controller to catalyst nozzle J-386B
386B
controller to catalyst nozzle J-386C
386C
MWC2 =28 Molecular weight of Ethylene kg/kmol
MWH2 =2 Molecular weight of hydrogen kg/kmol
Kmt =by Factor to link H2/C2 mass
GROWL concentration ratio in reactor gas
phase to H2/C2 injection mass flow
ratio. Change with grade by
GROWL
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
12. COMONOMER
12.1 Comonomer flow
APC Comono/C2 Ethylene partial

(Option) ratio SP pressure
RCmC2 PC2
SP HS-20502
PV
OPER Comonomer
selector
X
SP Comonomer
partial
PV PCm pressure in
Reactor
OP
Comonomer
Ethylene feed /ethylene
to reactor X flow ratio
SP SP
FQIC IN PV
PV FCmC2
40063
OP
SP
FQIC Comonomer
PV
40905 feed to Reactor
OP
IN
SPLIT
RANGE
OP OP
FV FV
40905B 40905A
Low flow High flow
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
12.2 Control
The comonomers injected into the reactor gas phase are butene-1 and hexene-1 and octene-1.
In normal operation the feed flow ratio of ethylene and comonomer is used to control the polymer
density. A facility also exists to control the comonomer to ethylene partial pressure ratio for startup in
Zg operation .
The comonomer flows through common pumping system and header (and thus common flow control
valves – refer below) from dedicated storage drums. Mixing of comonomers in the feed system is
prevented by interlocks.
High and low flow ranges are required for comonomer injection. The high and low flows are passing
through dedicated routing with relevant flow meter and control valve. The control valves are
configured in split range from FQIC-40905 which receives as process value the sum of the low and
high flow.
During start-up, when no condensate is available, the comonomer may be injected to main loop
compressor discharge. The routing to main loop compressor discharge or main loop separator (normal
routing) via either XZV-40905 or XZV-40902 is handled manually by the operator.
Switching between comonomers during grade changes is done by the operator by routing on/off
valves at the commoner pumps discharge as required.
A common control scheme is used, parameters or measurements relevant to the selected comonomer
are downloaded depending on HS-20502 setting.
The setpoint for the partial pressure controller is calculated from the operator entered setpoint ratio
RCmC2 and the partial pressure of ethylene. The process variable is directly calculated from the
partial pressure of comonomer and ethylene.
PCm.SP = RCmC2.SP * PC2.PV
RCmC2.PV = PCm.PV / PC2.PV for monitoring only
The output of the partial pressure controller provides the setpoint for a flow ratio block calculation
(FCmC2) which controls the ratio of fresh comonomer feed to ethylene feed into the loop.
FCmC2.SP = PCm.OP
FQIC-40905.SP = FCmC2.SP * FQIC-40063.PV
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
FCmC2.PV = (FQIC-40905.PV) / FQIC-40063.PV- For monitoring only
Where:
RCmC2.SP Oper Setpoint for Como/C2 partial pressure ratio bara/Bara
RCmC2.PV Calc Actual Como/C2 partial pressure ratio bara/bara
PC2.PV Calc Ethylene partial pressure in gas loop bara
PCm.OP Calc Output of the comonomer partial pressure t/t

controller
FCmC2.SP Calc Setpoint for Como/C2 flow ratio t/t
FCmC2.PV Calc Actual Como/C2 flow ratio t/t

For monitoring only
FQIC-40905.SP Calc Setpoint of the comonomer feed flow t/h
controller
FQIC-40063.PV Meas Fresh Ethylene feed flow t/h
The output and setpoint limits for FCmC2 should be back calculated from the setpoint limits of FQIC-
40905.Output limits for PCm should be set to the same as the setpoint limits for FCmC2.
12.2.1 Parameters and Alarms
The scheme control process measurement, parameters and alarms depends on the selected
comonomer:
Parameters and HS-20502 = Butene-1 HS-20502 = Hexene-1 HS-20502 = Octene-1

process measurement
PCm.PV PC4.PV PC6.PV PC8.PV
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
13. PENTANE
APC
OPER
(Option)
SP
PC5 Pentane partial pressure
PV
in Reactor
OP
SP
FQIC Pentane feed to
PV Reactor
40906
OP
IN
SPLIT
RANGE
OP OP
Pentane injection Pentane injection

pump speed pump stroke
The partial pressure of total pentane (n-pentane + isopentane) is controlled by adjusting the flow of
fresh pentane into the loop via FQIC-40906 and by adjusting the speed and stroke of the pentane
feeding pump P-242A.
FQIC-40906.SP = PC5.OP
Where:
FQIC-40906.SP Calc Setpoint for the pentane feed flow controller kg/h
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
PC5.OP Calc Output of the total pentane partial pressure kg/h

controller
14. REACTOR PRESSURE CONTROL
SP
PIC MAIN
PV Reactor
40039A
pressure
OP Controller
+ PBIASC2 PBIASPURGE + - PBIASN2
Reactor pressure
PT-40039
Reactor high STARTUP

pressure Reactor Reactor low
pressure pressure
SP SP Controller SP
PIC PIC PIC
PV PV PV
40039C 40039D 40039B
OP OP OP
SP
FIC VRU purge
PV flow
To FQIC-40063 60601
C2 feed high SP OP
limit SP
From FIC-60604.OP FIC Reactor nitrogen
H2 reactor purge PV make-up
40061
OP
>
IN
SPLIT
RANGE
OP OP
FV FV PV FV
60601A 60601B 40039D 40061
VRU purge flow Reactor Nitrogen
purge flow flow
The operator enters the required reactor pressure (as set point of PIC-40039A). This is used, with
different biases, as the setpoint for the pressure controllers, PIC-40039A/B/C/D.
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
The main pressure controller PIC-40039A is used in normal operation when reactor powder
withdrawal system is running and VRU is commissioned.
A high selector determines whether FV-60601A/B receive their position setpoint from:
o FIC-60601, normally
o Hydrogen partial pressure controller PH2PURGE to increase the purge flow (see
hydrogen control).
A second override pressure controller PIC-40039B adds nitrogen by manipulating the setpoint of
the nitrogen feed (FIC-60061) if the reactor pressure falls too far below the setpoint.
PIC-40039B.SP = PIC-40039A.SP – PBIASN2
FIC-40061.SP = PIC-40039B.OP
Where:
PIC-40039A.SP Oper Reactor operating pressure barg
PBIASN2 = 0.3 allowable pressure below target bar

Oper
FIC-40061 Reactor make-up Nitrogen flow controller
If the reactor pressure increases above the normal operating pressure, a third override pressure
controller PIC-40039C reduces the ethylene feed flow to the reactor by manipulating the high setpoint
limit for the ethylene feed controller FQIC-40063.
PIC-40039C.SP = PIC-40039A.SP + PBIASC2
FIC-40063.SP high limit = PIC-40039C.OP
Where:
PBIASC2 = 0.6 allowable pressure above target (initiate bar
Oper ethylene feed reduction)
FQIC-40063 Reactor ethylene flow controller
A fourth pressure controller PIC-40039D is used during reactor start-up when withdrawal is not started
or VRU is not commissioned
We assume that VRU purge flow controller FIC-60601 is in MANUAL during start-up and the reactor
pressure is rising and is taken into control by PIC-40039D
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
PIC-40039D.SP = PIC-40039A.SP + PBIASPURGE
FIC-60601.SP = PIC-40039D.OP
Where:
PBIASPURGE = 0.2 allowable pressure above target (initiate bar
Oper purge at start-up)
FIC-60601 VRU purge flow controller
The reactor can be depressurised automatically or initiated by the DCS operator. Depressurisation
can be started by the operator opening the control valve and on/off valve from standard DCS
commands/interface or automatically by interlock I-4021-S (CO maxi kill).
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
15. REACTOR BED LEVEL
LBEDA LBEDB
Operator selector or
automatic selection
PV PV
DIC Reactor bed Reactor
SP 40001 SP LBED
density bed level
OP OP
>
SP
Sequence 64
The bed level is controlled by manipulating the powder withdrawal rate from the reactor (see the
withdrawal sequence SEQ-64). The level is measured using two methods:
 Differential pressure measurements
 Radioactive density measurement close to the surface of the bed.
The level calculated from the differential pressure measurement is used during commissioning and
start-up. The operator switches on the radioactive density measurement control once the level is
steady and within the nucleonic range. There is a controller (LBED and DIC-40001) based on each of
these measurements. The high output selector is an override to prevent fines carry-over.
15.1 BED Level from pressure drop
The LBED controller uses 2 different PVs selectable by the operator:
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
2 PVs are calculated from the pressure drops across the bed: LBEDA and LBEDB are calculated by
dividing the pressure drops across the whole bed by the pressure drop across a fixed height within the
bed
15.1.1 Pressure drop coefficient (COFPD)
PDI-40002 and PDI-40009 are used to give two values for the pressure drop across a section within
the bed. PDI-40002 is measured between 2.0 m and 5.0 m above the grid and is used when initially
filling the reactor. PDI-40009 is measured between 6.5m and 9.5 m and is generally used for normal
operation.
PDI - 40009
DP-40009 = Filtered 600s mbar/m
PDI - 40009 height difference 
PDI - 40002
DP-40002 = Filtered 600s mbar/m
PDI - 40002 height difference 
The operator can manually select either of the DP measurements to be used for COFPD or allow
automatic selection. The automatic selection uses DP-40009 if the bed level (LBED) is more than
0.5m above its top pressure tapping, otherwise it uses DP-40002.
COFPD should normally indicate between 20 mbar/m and 45 mbar/m maximum.
15.1.2 Bed level calculation from pressure drop
PDI-40001 and (PDI-40012 – PDI-40003) are used to give two values for the pressure drop across the
bed.
PDI-40001 is normally measured between 0.5m above the grid and the top of the reactor.
PDI-40012 is measured from the below the grid to the top of the reactor and PDI-40003 is measured
across the grid.
The bed level is calculated from each of the differential pressure measurements.
The two pressure drops across the reactor bed are filtered to remove noise
PDIF-40001 = PDI-40001 filtered 60s mbar
PDIF-40012 = (PDI-40012 – PDI-40003) filtered 60s mbar
Two values for the bed level are calculated.
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
LBEDA =
PDIF - 40001   PDI - 40001 lower tapping height  0.5m  m
COFPD
LBEDB =
PDIF - 40012   PDI - 40003 upper tapping height  0.5 m  m
COFPD
15.1.3 Alarms and trips
COFPD high = 45 mbar (Note 1) Low priority
COFPD low = 20 mbar (Note 1) Low priority
DEVCOFPD Low priority

Raised if ABS |(DP-40009 – DP-40002)| > 1 mbar/m
LBEDDEV Low priority.
Raised if ABS |(LBEDA-LBEDB)| > 0.5 m
LBED high = 21 m Low priority
LBED low = 19 m Low priority

LBEDCOMP Low priority raised if:
{( LBEDA or LBEDB<18.5 m AND nucleonic bed
density > X kg/m3) OR (LBEDA or LBEDB> 21.5 m
AND nucleonic bed density < Y kg/m3)
Where:
- nucleonic bed density is measured by DIC-
40001.PV
- X kg/m3 is confirmed during commissioning to be
equivalent to 18.5 m and
- Y kg/m3 is confirmed during commissioning to be
equivalent to 21.5 m.
DIC-40001.PV Low priority.

high Set at U kg/m3 where U kg/m3 is confirmed during
commissioning to be equivalent to 21 m
DIC-40001.PV Low priority

low Set at V kg/m3 where V kg/m3 is confirmed during
commissioning to be equivalent to 19 m
Note 1: In GROWL are defined more restricted values per grade
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
15.2 Bed level controller output Limits
The output of the bed level controllers are expressed in nominal t/h and used by the withdrawal
sequence to calculate the speed of the withdrawals. Output limits are calculated in the withdrawal
sequence to prevent the bed level controller driving the withdrawals beyond their design capacity. See
the withdrawal sequence SEQ-64 for calculation of the limits.
There should be a single display of the reactor loop showing all the reactor differential pressures, loop
differential pressures and the density at the surface of the bed
The same display should show the loop gas flow and density, the fluidisation velocity and the main
loop compressor guide vane position.
This display should have links to the withdrawals displays and the reactor controls display.
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
16. TEAL INJECTION CONTROL
Typical control scheme applicable to TEAL

APC (Option-
OPER TEAL Only)
Additive to Ethylene flow

ratio SP
IN IN
Block PV FQIC-40063
IN Ethylene feed
calculation
OP OP
SP
PV Additive Flow
controller
OP
IN
Final Elements
TEAL is the co-catalyst for Ziegler catalysts. It is also used during start-up for scavenging poisons
from the reactor.
In normal operation, only one pump is running.
The TEAL flow rate is controlled in ratio to the ethylene flow rate. The ratio is calculated from the
desired concentration of aluminium required in the powder, which is entered by the operator.
The TEAL flow meters are located at each TEAL pump suction.
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
The total TEAL flow is calculated by summing the two pump Teal flows.
During maintenance, flush with pentane must not affect the TEAL flow sum. A facility must be
implemented to allow the DCS operator to set to 0 any of the flow entering the flow sum.
The arrangement of TEAL pumps allows emptying of a TEAL cylinder at low speed and manual mode
while the other TEAL pump speed and stroke is automatically adjusted to meet the target ratio to
ethylene.
The flow controller FQIC-40501 is set to achieve the required TEAL flow by adjusting the metering
pump stroke and motor speed. The flow must change linearly with the controller output.
The TEAL flow setpoint and the resulting aluminium concentration are calculated as follows:
FQIC - 40063.PV * 103 * ALC2.SP * 10-6

FQIC - 40501.SP  ( ) * ( MTEA/ MAl)
TEACON
3 6
ALC2.PV = FQIC-40501.PV * TEACON * (MAL / MTEA) / (FQIC-40063.PV * 10 ) * 10 (for
monitoring only)
FQIC-40501.PV = FI-40501A + FI-40501B
Where:
FQIC-40501.SP Calc TEAL flow controller set point kg/h
ALC2.SP Oper Desired Al/C2 ratio entered by the operator ppm w
ALC2.PV Calc Actual Al/C2 ratio achieved. For monitoring ppm w

only
FQIC-40063.PV Meas Ethylene flow t/h
MTEA =114 Molecular weight of TEAL g/mol
MAL =27 Molecular weight of Aluminium g/mol
TEACON =1 Weight fraction of TEAL in solvent kg/kg

Oper
FI-40501A Meas TEAL injection Pump A flow kg/h
FI-40501B Meas TEAL injection Pump B flow kg/h
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
17. CHEMICAL ADDITIVES B1 AND S1 INJECTION CONTROL
17.1 B1 injection control
B1AL. SP
IN
Block PV
IN FQIC-40501 TEAL feed
calculation
OP
SP
PV B1 Flow
controller
OP
IN
Final Elements
The B1 is injected in Ziegler operation
The control system is set up to adjust the flow rate of B1 injected in direct ratio to the TEAL flow rate
to the loop.
B1 is injected directly into the reactor.
The flow controller FIC-40204 is set to achieve the required B1 flow.
When the control system is switched to cascade, the B1 injection rate required is calculated in ratio to
the TEAL flow.
FIC-40204.SP= (FQIC-40501.PV * TEACON* B1AL.SP) * (MB1 / MTEA) / B1CON
B1AL.PV = FIC-40204.PV * B1CON * (MTEA / MB1)/ (FQIC-40501.PV * TEACON) (for monitoring

only)
Where:
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
FIC-40204.PV Meas B1 flow kg/h
B1AL.SP Oper Desired B1/AL molar ratio entered mol/mol

typically 0.05 to 0.15 by the operator (there is one mole
of AL per mole of TEAL)
B1AL.PV Calc Actual B1/AL ratio achieved mol/mol
FQIC-40501.PV Calc TEAL flow kg/h
B1CON =1 Weight fraction of B1 in solvent kg/kg

Oper
TEACON =1 Weight fraction of TEAL in solvent kg/kg

Oper
MTEA = 114 TEAL molecular weight g/mol
MWB1 = 92.58 B1 molecular weight g/mol
The ratio block should display both the ratio setpoint and the actual calculated ratio
Other interlocks (refer to interlock descriptions) close the feed isolation valve.
17.2 S1 injection control
The S1 can be used with Metallocene but is not normally injected in Metallocene operation. A control
scheme is provided to allow injection under exceptional circumstances.
The control system is set up to adjust the flowrate of S1 injected in direct ratio to the ethylene flow-rate
to the loop.
S1 is injected directly into the metallocene catalyst injection lines.
The flow controller FIC-40202 is set to achieve the required S1 flow by adjusting the metering pump
stroke and motor speed in split range (split range to be defined by Contractor detailed engineering
Instrument specialist with pump vendor). The flow must change linearly with the controller output.
When the control system is switched to cascade, the S1 injection rate required is calculated in ratio to
the ethylene flow.
3 -6
FIC-40202 .SP= (FQIC-40063.PV * 10 * S1C2.SP * 10 ) / S1CON
3 -6
S1C2.PV = FIC-40202 .PV * S1CON / (FQIC-40063.PV*10 *10 ) (for monitoring only)
Where:
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
FIC-40202.PV Meas S1 flow kg/h

S1C2.SP Oper Desired S1/powder ratio ppmw
Typically 10 ppm
by weight, max
20 ppm
S1C2.PV Calc Actual S1/C2 ratio achieved ppmw
FQIC-40063.PV Meas Ethylene flow t/h
Filtered by 120s in the
calculation.
S1CON =1 Dilution of S1 in solvent kg/kg
Oper
The ratio block should display both the ratio setpoint and the actual calculated ratio
Other interlocks (refer to interlock descriptions) close the feed isolation valve.
18. STRIPPING GAS FLOW TO THE DEGASSER CORRECTION
The stripping gas flow controllers to the degasser must be calculated as actual flow into the degasser
to be in line with the stripping gas flow trip setpoints (refer to interlocks description).
The vortex stripping gas flow meters give actual flow in the pipe and must be corrected with the
pressure in the degasser and the pressure at the measure points.
FIC-60602.PV = FT-60602 * maximum [(PI-60602 + ATM) / (PI-60529 +ATM); 1.5]
Where:
FIC-60602.PV Calc Stripping gas flow into degasser m3/hr
FT-60602 Meas Stripping gas flow into pipe m3/hr
PI-60602 Meas Pressure next FT-60602 barg
PI-60529 Meas Pressure in degasser bottom. barg
ATM Refer to project Atmospheric pressure bara

basis
Similar calculation to be done for FIC-60603 with PI-60601 and PI-60529.
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
19. GRADE OPERATING WINDOW LIMITS (GROWL)
For each grade there is a set of operating parameters that define the normal operating conditions for
the grade. Deviation from any of these conditions beyond defined limits should raise an alarm XA-
WIN.
A separate display should show the current operating conditions and the optimal conditions and the
limits. Any limit that is exceeded should be highlighted on the display.
The operator should use a grade selector „GRADE‟ to define which grade is currently being produced
in the reactor. This selector will load the current set of limits for that grade from a predefined table.
Trends of all the GROWL parameters and the limits should be available to the operator. Ideally there
should be a single display showing trends for all the variables.
The operator should be able to adjust any of the current limits except the grade dependant parameters
to reflect the current operating conditions of the plant as required. The predefined table for each grade
should not be operator adjustable. These will be given initial values and then tuned in line with plant
operating experience
All the control parameters defined in GROWL must have a setpoint ramping facility that can be setup
by the operator.
The following table shows a sample of the variables required. This table should be expandable to
allow additional grades and parameters to be added as required. The final variables and alarm values
will be issued in the Operating Manual.
GRADE Examples: Zg Mt
LL6209 PF6212
Min Normal Max Min Normal Max
Ethylene partial PC2 (bara) tba tba tba tba NC tba
pressure
Hydrogen partial PH2 (bara) NA NA NA NA NA NA
pressure
Hydrogen/ethylene RH2C2 (Bara / bara) tba tba tba tba tba tba
partial pressure ratio
Comonomer partial PCm (bara) tba tba tba tba tba tba
pressure
Comonomer/ethylene RCm/C2 (bara / bara) tba NC tba tba NC tba
partial pressure ratio
Comonomer/ethylene FCm/C2 (kg/t) tba tba tba tba tba tba
flow ratio
Pentane partial PC5 (bara) tba tba tba 0.5 tba tba
pressure (cste)
VRU liquid purge FIC-60502 (kg/h) tba tba tba tba tba tba
flow
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
GRADE Examples: Zg Mt
LL6209 PF6212
Min Normal Max Min Normal Max
C8-VRU liquid purge FIC-60872 (kg/h) tba tba tba tba tba tba
flow
Reactor temperature TIC-40046 (°C) tba tba tba tba tba tba
TEAL feed ALC2 (ppmw) tba tba tba NA NA NA
S1 feed S1C2(ppmwPE) NA NA NA tba tba tba
B1 feed B1AL (mol/mol) tba tba tba NA NA NA
Fluidisation velocity Vf (cm/s) tba tba tba tba tba tba
Pressure drop COFPD tba tba tba tba tba tba
coefficient
Production rate PR (t/h) tba tba tba tba tba tba
MI spec M_spec tba tba tba tba tba tba
MI blending limit M_blend tba tba tba tba tba tba
Density spec D_spec (kg/m3) tba tba tba tba tba tba
Density blending limit D_blend (kg/m3) tba tba tba tba tba tba
Extruder specific tba tba tba tba tba tba
energy
Degasser degassing FIC-60603 (m3/h) tba tba tba tba tba tba
flow
VRU purge gas flow FIC-60602 (kg/h) tba tba tba tba tba tba
C8 Degasser FIC-60865 (kg/h) tba tba tba tba tba tba
degassing flow
Purge column FIC-60013 (kg/h) tba tba tba tba tba tba
degassing flow
GRADE DEPENDANT PARAMETERS

Group number Note 1 tba tba
Catalyst CAT tba tba
Comonomer Cm tba tba
Compressibility factor Z tba tba
Powder bulk density D_BULK (kg/m3) tba tba
H2 to C2 to injection Kmt tba tba
nozzles corrective
factor
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
Note 1: The SIS sends the group number to the DCS. This information is compared with group
number defined in GROWL for each grade. An alarm in DCS will be issued in case of discrepancy.
This alarm may happen at the start-up of the transition when operator will change of grade setting via
the GROWL but has not yet fulfilled the conditions to determine the group number. In steady state the
group in SIS and DCS are normally identical.
NC: Not Controlled in steady state
tba: to be advised – ref to Operating Manual
NA: Not Applicable
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
19.1 Operator interface for degassing flows during transitions
An operating interface gathering the degassing flow setpoint alarms and trips will help the operator to
monitor the grade transition around the degassers and purge column. A trend example is given below.
Reactor Temp
Start transition –
change grade in
GROWL
End transition
Degasser flow
FAHH (SIS)
Residence time
FAH (GROWL)
Degasser flow SP 30 min
(GROWL)
Degasser flow SP for

transition (operating
FAL (GROWL) guideline)
FALL (SIS)
Degasser flow SP
(GROWL)
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
20. FLUIDISATION VELOCITY IN REACTOR
The fluidisation velocity is a key variable in the operation of the reactor. It is calculated from the
measured fluidisation gas flow rate around the loop. It is calculated at the top of the reactor bed.
20.1 Fluidising gas density
The fluidising gas density is calculated as follows:
100 ATM  PIC - 40039A  MM

FGD  
R 273  TIC - 40046  Z
Where:
FGD Calc Fluidising gas density kg/m3
PIC-40039A.PV Meas Reactor pressure barg
ATM Refer to project basis Atmospheric pressure bara
TIC-40046.PV Meas Reactor temperature °C
Z = 0.92 Compressibility factor at

reactor outlet, change with
grade by GROWL
MM Calc Mean molecular mass g/mol
R = 8.314 Gas constant
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
20.2 Fluidisation gas mass flow rate
The fluidisation gas flow rate is measured by a venturi flow meter. This is corrected for pressure,
temperature and composition.
G = FI-40050 * (PI-40053 +ATM) / (Pc +ATM) * (Tc + 273) / (TI-40053+273) *

0.5
(MM/Mc)]
Where:
G Calc Corrected mass flow rate in loop kg/h
FI-40050 Meas Uncorrected mass loop flow kg/h

measurement
Mc = Calc or refer Molecular mass used for the flow g/mol
IDS meter calculation at operating
conditions
This can be calculated from the
density used for calculation if required:
R (Tc  273).Dc.Z
Mc  x
100 Pc  ATM
Tc Refer IDS Temperature used for the flow meter °C
calculation at operating conditions
Dc Refer IDS Density used for the flow meter kg/m3
Pc Refer IDS Pressure used for the flow meter barg
ATM Refer to atmospheric pressure bara
project basis
Z = 0.92 compressibility factor, change with

grade by GROWL
PI-40053 Meas Pressure at the venturi meter barg
TI-40053 Meas Temperature at the venturi meter °C
R Refer Gas constant

elsewhere in
this document
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
20.3 Fluidisation velocity
The fluidisation velocity is developed for the flow expressed in kg/h.
The fluidisation velocity is finally calculated as follows:
G (kg/h)
VF  *100
3600 * FGD * A
G Calc Corrected mass flow rate in loop kg/h

2
A = 20.42 Reactor cross sectional area m
VF Calc Fluidisation velocity cm/s
FGD Calc Fluidising gas density kg/m3
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
21. PRODUCTION RATE
Calculate Production Rate in t/h, as:
PR (t/h) = (FQIC-40063.PV + FQIC-40905.PV / 1000) / KCmEff
PR should be filtered using a 120s first order filter
Where:
FQIC-40063.PV Meas Ethylene feed rate t/h
FQIC-40905.PV Meas Comonomer feed rate kg/h
KCmEff Oper, 1.011 Comonomer and Monomer t/t
efficiency
KCmEff varies slightly from grade to grade or with the plant operating conditions. An average value is
used. If necessary it should be tuned to account for losses and actual impurities in the comonomer
and monomer feeds.
22. REACTOR RESIDENCE TIME, BED MASS, FLUIDISED BULK DENSITY
Calculate Residence Time (hours):
BMASS kg
Tau =
PR t/h  1000
Calculate mass of fluidised bed in kg, as:
BMASS (kg) = D_FLBULK * A * LBED.PV

2
D_FLBULK = COFPD * 10 / g
Where:
COFPD Calc Pressure drop per unit height mbar/m
D_FLBULK Calc Fluidised bulk density kg/m3
LBED.PV Calc Bed level m
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
2
A = Refer to Reactor cross sectional area m
fluidisation velocity
calculation
2
g = 9.81 Gravitational constant m/s
Tau Calc Residence time h
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
23. EXTRUDER FEEDS CONTROL
23.1 Introduction
This chapter defines the philosophy for the extruder feeds control including interfacing with the
extruder during normal, start-up and grade changes.
All control schemes and sequences must be developed by detailed engineering in conjunction with the
main equipment Vendors. This section has to be read in conjunction with the extruder PDS.
23.2 Powder feed control
OP FHS-80002
Start-up
FY SP
80001B FQIC
IN PV
Purge column 80001
OP
PV
SIC SP
60012
OP
+ FY
- PV 80515B
- IN
Additives Rerun
Feeders Rerun Pellet Silo
IN IN PV
FFIC SP FFIC SP SIC
xxx 80515 SP
80515
OP OP OP
OP
IN FY
80515A
Extruder feed screw(s)

PV
FI
80001A
Extruder
The operator will adjust the set point of the powder feed controller in order to maintain a suitable level
in the purge column.
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
23.3 Detailed control scheme of pellet flowrate through extruder
In normal operation pellet mass flow meter FE-80001 provides the process variable for the powder
feed controller FQIC-80001 which controls the powder flow by manipulating the speed SIC-60012.SP
of purge column outlet rotary valve. During start-up (or in the event of a failure of the flow meter) this is
not possible and a calculated flow, based on the speed of the rotary valve and powder bulk density,
must be used as the process variable. This calculated flow should be used during the start-up of the
extruder. Switching between the two modes of control is manual (operator) and must be bumpless
with the controller setpoint being aligned with the actual powder flow to prevent discrepancies
between the calculation and the actual flow causing a sudden change in controlled output.
The calculated powder flow rate is as follows:
FQIC-80001.PV = FI-80001A or FY-80001B depending on FHS-80002 position
FY-80001B.OP = SIC-60012.PV * (K1*K2)
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
Where
FQIC-80001 Master pellet flow controller
FI-80001A Meas Pellet flow kg/h
FY-80001B.OP Calc Estimated powder feed rate from purge kg/h

column outlet rotary speed
FHS-80002 Powder or Pellet flow selector for
Master pellet flow controller
SIC-60012.PV Meas Actual rotary valve speed revs/h
K1 Oper volume of powder fed by rotary valve m3 powder/rev

Set by operator after calibration
K2 Oper Powder density kg/m3
FQIC-80001.OP to be rate of change limited to smooth the transition between powder or pellet flow
measurement.
On line Calibration of Pellet Mass flow meter
In order to maintain accuracy of the pellet mass flow meter on line frequent (> once/month) calibration
is required. The Mass flow meter Vendor (Refer to Process Data Sheet) must develop a scheme in
their own controller to carry this out using the blender weigh cells. This will be initiated at the Vendor
Panel.
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
23.4 Additive feeds and pellet rerun control
The additive flow control using loss in weight feeders will be carried out by the vendor‟s own PLC. The
required flow setpoints (SP) of the feeders will be calculated by the DCS by multiplying the measured
pellet flow minus the rerun pellet flow times the additive ratio setpoints. The rerun pellet flow is
calculated from the rerun rotary valve speeds. An alarm must be raised on the DCS if there is a
deviation between the flow set point to the additive feeder and the actual flow achieved. The additive
and pellet rerun ratios will be input by the operator as part of the extruder start up sequence and can
be modified thereafter as a correction for quality control or due to a grade change.
Rerun pellet is subtracted from the overall pellet flow because it is assumed that this already contains
the required additives.
Additive flow control:

-6
FFIC-80512.OP = FFIC-80512.SP*10 * [FQIC-80001.PV – FY-80515B.OP]
Where
FFIC-80512.OP Calc Additive feeder A additive flow set point kg/h
FFIC-80512.SP Oper Additive feeder A additive to powder flow ppmwt

ratio set point
FQIC-80001.PV Meas/Calc Pellet or powder flow kg/h
FY-80515B.OP Calc Rerun pellet flow kg/h
The rerun pellet flow is calculated from the rerun rotary speed as follows:
FY-80515B.OP = SIC-80515.PV * (K3*K4)
Where:
SIC-80515.PV Meas Actual rotary valve speed revs/h
FY-80515B.OP Calc Rerun pellet flow kg/h
K3 Oper volume of rerun pellet fed by rotary valve m3

Set by operator after calibration powder/rev
K4 Oper Pellet density kg/m3
Similar calculation for other additive feeders.
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
Rerun pellet flow control:
For the rerun pellet flow injection control, the operator sets the flow ratio of rerun pellets to powder
flow
The rerun pellet flow setpoint is then converted to rerun pellet rotary valve speed setpoint.
FFIC-80515.OP = FFIC-80515.SP/100 * [FQIC-80001.PV –FY-80515B.OP]
FY-80515A.OP = FFIC-80515.OP / (K3*K4)
SIC-80515.SP = FY-80515A.OP
Where:
SIC-80515.SP Calc Rotary valve speed set point revs/h
FFIC-80515.OP Calc Rerun pellet flow setpoint kg/h
FFIC-80515.SP Oper Rerun pellet to powder ratio flow setpoint % wt
K3 Oper volume of rerun pellet fed by rotary valve m3 powder/rev

Set by operator after calibration
K4 Oper Pellet density kg/m3
23.5 Detection of powder blockage in the polymer vibrating screen
A blockage in the polymer vibrating screen is detected by monitoring a high difference between the
powder flow at purge column outlet and the pellet flow.
In case of blockage, the pellet flowrate will decrease and the powder feed controller FQIC-80001 will
increase the speed of the purge column outlet rotary valve. An alarm will warn the operator when the
powder flow calculated from the rotary valve speed is higher than the measured pellet flow rate.
High priority alarm is generated as follow:
(FY-80001B.OP – FI-80001A) filtered T5 > 1000 kg/h
Where
FI-80001A Meas Pellet flow kg/h
FY-80001B.OP Calc Estimated powder feed rate from purge kg/h

column outlet rotary speed
T5 5 Filter time, adjustable on line min
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
24. PELLETS FLOWRATE CONTROL
24.1 Pellets flow rate to elutriation from pellet blenders
This control is out of scope of the PDP. Nevertheless it is described for guidance during detailed
engineering phase.
The pellets are conveyed from the homogenisation silos to elutriation. One of the homogenisation
silos A or B is selected as the master by the operator and delivers the main pellet flow to the
elutriation. The other slave silo complements the flow.
The weight of the “master” homogenisation silo is controlled by adjusting the speed of the relevant
outlet rotary valves A/B. The speed of the other homogenisation silo outlet rotary valve is then
controlled in ratio.
A homogenisation silo is “master” when the relevant weight controller is in cascade mode. Logic will
only allow one silo weight controller to be “master”.
In the description below, Pellet blender A/outlet blender rotary valve A is assumed to be the master
system and Pellet blender B/outlet blender rotary valve B the slave.
SIC-xxxxxA.SP = WIC-80031.OP (cascade control)
SIC-xxxxxB.SP = SIC-xxxxxA.PV * SpeedHomoRatio
Where:
WIC-80031 Blender A weight controller (master)
WIC-80031.OP Blender A weight controller output Revs/h
SIC-xxxxxA Blender outlet rotary valve A speed

controller (master)
SIC-xxxxxB Blender outlet rotary valve B speed
controller (slave)
SpeedHomoRatio Oper Slave speed to master speed ratio Rev/Rev
The ratio block should display both the ratio setpoint and the actual calculated ratio.
Speed controller output limits:
In order to avoid overloading the conveying line the speed controller outputs must be limited:
SIC-xxxxxA.OPHIGH = TOTALSPEEDHIGH / (1+ SpeedHomoRatio)
OWNER REFERENCE

SPECIFICATION
COMPLEX CONTROL
SIC-xxxxxB.OPHIGH = TOTALSPEEDHIGH * SpeedHomoRatio / (1+ SpeedHomoRatio)
Where:
SIC-xxxxxA.OPHIGH Calc Blender outlet rotary valve A max speed Revs/h
(master)
SIC-xxxxxB.OPHIGH Calc Blender outlet rotary valve B max speed Revs/h
(slave)
TOTALSPEEDHIGH Oper Maximum allowable total rotary speed Revs/h
SIC-xxxxxA.OPHIGH and SIC-xxxxxB.OPHIGH are calculated only when WIC-80031 is in cascade

mode.
In addition to the calculated speed limits, conveying pressure controllers PIC-xxxxx protect against
overpressure: If conveying pressure is high the speed controllers will be cut back. The pressure
controller overrides the speed controllers‟ outputs.
The same calculations should be made when Pellet blender B/outlet blender rotary valve B or Pellet
blender C/outlet blender rotary valve C is the master system with any other slave combinations.
25. INTERFACE BETWEEN DCS AND APC (OPTION)
Provision for APC hardware should be provided in any case:
Hardware requirements:
- APC computer (PC running Windows XP or 7) in the engineers room close to the
panel operator
- One serial link w/ cables
The interface with the APC system (separate PC communicating with the DCS) should be developed
within the DCS according to the communication data exchange tables.
The DCS should be programmed to handle remote setpoints from the APC system and communicate
data to the APC system. Some data will require further development of piece of logics and
calculations within the DCS.
Estimated number of I/O‟s through the serial link: about 100.

V4-CH04-Complex Control Rev 1 - Upto PELLET FLOW CONTROL

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V4-CH04-Complex Control Rev 1 - Upto PELLET FLOW CONTROL

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PETRONAS RAPID Project Nov 2012

Technologies RAPID L20 INE PRO DES 3200 0014

Complex Control Loops and Calculations

1 12-DEC-12 PDP update FMA A. CONIL A.CONIL

Technologies RAPID L20 INE PRO DES 3200 0014

Technologies RAPID L20 INE PRO DES 3200 0014

6.1 AT-40050/40051 GAS CHROMATOGRAPHS .................................................................................................... 22

Technologies RAPID L20 INE PRO DES 3200 0014

18. STRIPPING GAS FLOW TO THE DEGASSER CORRECTION ......................................................................... 58

Technologies RAPID L20 INE PRO DES 3200 0014

May: is used where an alternative provision is acceptable to INEOS Technologies

Should: is used where INEOS Technologies prefers the provision

Must: is used where the provision is mandatory

Technologies RAPID L20 INE PRO DES 3200 0014

DCS Distributed Control System (Main plant control system)

SIS Safety Instrumented System (Protective system)

PID Process and Instrument Diagram

OP Controller or calculation block output

Oper Parameter set by operator

Calc Calculated Parameter

Meas Parameter given directly by a measure

IDS Instrument Data Sheet

D.E. Detailed Engineering Contractor

1.2 Reference documents

Technologies RAPID L20 INE PRO DES 3200 0014

2. REACTOR TEMPERATURE CONTROL

2.1 Main temperature controller (TIC-40046)

Reactor outlet pipe Reactor outlet pipe

Main loop condenser Main loop condenser

Cooling water return

Technologies RAPID L20 INE PRO DES 3200 0014

2.2 Steam make-up flow FIC-40072

2.3 Cooling water margin

Technologies RAPID L20 INE PRO DES 3200 0014

2.4 Alarms and trips

The following interlock act on the temperature control

Alarms are defined as follows:

TIC-40046.PV – TIC-40046.SP > +/-3 °C High priority

MARGIN < 3 °C High priority

Deviation alarm between TI-40047 and TI- Low priority

2.5 Operator interface

Technologies RAPID L20 INE PRO DES 3200 0014

3. REACTOR MISCELLANEOUS CONTROL

3.1 Reactor grid temperature and grid differential temperature

3.1.1 Reactor grid differential temperature

TDI-40001 = TI-40001 – TIC-40046.PV (Note these values will normally be negative)

TDIF-40001 = TDI-40001 filtered T0.

These calculations are repeated for TI-40002/40003/40004/40007/40008 and TDI-

A common alarm is raised for each of the three following conditions:

TDI-40001 or TDI-40002 or TDI-40003 or TDI-40004 or TDI-40007 or TDI- Low priority

TDIF-40001 or TDIF-40002 or TDIF-40003 or TDIF-40004 or TDIF-40007 or Low priority

3.1.2 Reactor grid temperature

Reactor grid temperature also gives an indication of agglomerate formation.

TIF-40001 = Absolute value | TI-40001 – (TI-40001 filtered T1) |

This calculation is repeated for TI-40002/40003/40004/40007/40008.

A common low priority alarm is raised for the following condition:

Technologies RAPID L20 INE PRO DES 3200 0014

TIF-40001 or TIF-40002 or TIF-40003 or TIF-40004 or TIF-40007 or Low priority

3.2 Reactor skin temperature deviation

3.3 Reactor temperature to cyclones temperature deviation

TICF-40046.PV = TIC-40046.PV filtered T3

Technologies RAPID L20 INE PRO DES 3200 0014

3.4 Reactor differential temperature

Reactor differential temperature:

TDI-40904 = TIC-40046.PV – Mo3 TZI-40064A/B/C.

TDI-40904 Calc Reactor differential temperature °C