Steam Manual

SURMONT
Training Manual
Steam Operator
Document No.
Rev Originator Reviewed By Approved Date Description

No. By
0 Wesley Demas Dave Pandachuck,
Greg Bangarth
2 Adam Lockyer Graeme Harris, Rob Alistair 12/6/2011
Hemingson, Colin Cartwright
Herbert
1
Introduction
The Steam Operator Training Manual in conjunction with the Surmont Web-based Training and the
Steam Operator Competency Manual are materials provided for the Surmont Operations Training.
Successful completion of the Steam Operator Competency Manual meets the requirement of the
Competency Assurance Coordinator for progression.
The information in this supplement centers on a broad overview of the Unit 500 building equipment,
chemicals, and processes. In completing this manual, the learning will provide the candidate with
fundamental techniques and skills needed to conduct his or her job.
For information on operator development and training visit the Human Performance Website. Here you
will find quick links for Operations Excellence, Web-based Training System, Onboarding as well as OE
Express, the competency assurance database. You will also find manuals for Assessor Training, New
Employee Induction Manual, Pilot Plant Training Program, Student Training Manual and the entire suite
of Competency Manuals. Guides and Matrices for Competency Training, Training and Competency Guide,
and other pertinent material. Presentations on the Web Based Training can also be found here.
Also, terms commonly used in reference to Steam generation are used throughout this document. These
terms or phrases may be unfamiliar to new operators and therefore an explanation may be found in the
definitions portion of the manual.
2
Record of Amendments
Number Date Date Entered Page(s) Entered By

Affected
Glycol System 11/06/2011 11/06/2011 A.L
Instrument Air 11/06/2011 11/06/2011 A.L
Bath Heater 11/06/2011 11/06/2011 A.L
Bentley Nevada 11/06/2011 11/06/2011 A.L
BMS 11/06/2011 11/06/2011 A.L
FD Fan, Burner 11/06/2011 11/06/2011 A.L
CEMS 11/06/2011 11/06/2011 A.L
L.P & H.P. Pump 11/06/2011 11/06/2011 A.L
supplemental
Steam Sample 11/06/2011 11/06/2011 A.L
Collector
3
Table of Contents
Introduction
Record of Amendments
Table of Contents
Definitions
Chapter 1: Safety
1.0: General
1.1: Introduction to Safety
1.2: Safety Briefing
1.3: Introduction and Expectation
1.4: Operating Philosophy and Core Values
1.5: Safety and You
1.6: Our Safety Motto
1.7: HSE
1.7.0: Introduction
1.7.1: Refusal of Unsafe Work.
1.7.2: Emergency Procedures
1.7.3: Personal Protective Equipment
1.7.4: Hearing Protection
1.7.5: Gas Detection – Personal Monitors
1.7.6: Eye Wash Stations
1.7.7: Fire Extinguishers
1.7.8: First Aid
1.7.9: SCBA - Air Packs
1.7.10: Spill Prevention Kits

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1.7.11: Safety Cupboards
1.7.12: Muster Points
1.7.13: MSDS’s
Chapter 2: Once Through Steam Generators (OTSG)
2.0: Introduction
2.1: History
2.2: Our Design Specifications (TIW)
2.3: Purpose of Operation/Start-Up procedure
2.4: BMS (Burner Management System)
2.5: Start-Up Permissive
2.6: Steam Sample Collectors
Chapter 3: Auxiliary Equipment
3.0: Low Pressure Feedwater pumps
3.0.1 LP BFW specifications
3.0.2 LP BFW Theory of Operation
3.1: High Pressure Feedwater pumps
3.1.1: HP BFW specifications
3.1.2: HP BFW Theory of Operation
3.1.3: Lube oil skid
3.1.4: GE Bentley Nevada
3.2: Associated Heat Exchangers
3.2.1: E-541 (Description/Specs)
3.2.2: E-221/211 (Description/Specs)
5
3.3: Steam Separators (V-502)
3.4: Medium Pressure Steam Separator (V-501)
3.5: FD Fan, Motor, Wind Box and Burner
Chapter 4: Chemicals
4.0: Filming Amine
Chapter 5: Boiler Feedwater
5.0: Boiler Feedwater Tank Purpose
5.0.1: BFW Tank Specifications
Chapter 6: Air Make-Up Units
6.0: Air Make-Up Unit description/purpose
Chapter 7: CEMS (Continuous Emissions Monitoring System)
7.0: CEMS Purpose/History
Chapter 8: Utility Steam System
8.0: Process Diagram
8.1: Purpose/Description
Chapter 9: Blowdown system
9.3: Disposal System (wells & pumps)
Chapter 10: Glycol System and Heater
Chapter 11: Instrument Air
Chapter 12: Fuel Gas Sigma Thermal Bath Heater
6
Definitions:
• Adsorption - refers to a surface rather than a volume: adsorption is a process that occurs when
a gas or liquid solute accumulates on the surface of a solid or, more rarely, a liquid (adsorbent),
forming a molecular or atomic film (the adsorbate). It is different from absorption, in which a
substance diffuses into a liquid or solid to form a solution.
• Ambient temperature - The temperature at a point or area expressed as an average of the

surrounding areas or materials.
• Barrels of oil per day - A common unit of measurement for the daily volume of crude oil
produced by a well or from a field. The volume of a barrel is equivalent to 42 US gallons,
abbreviated BOPD.
• cgs - centimeter-gram-second system.
• cP - If a fluid with a viscosity of one Pa·s is placed between two plates, and one plate is pushed
sideways with a shear stress of one pascal, it moves a distance equal to the thickness of the layer
between the plates in one second.
• CPF - Central Processing Facility.
• DCS - Distributed Control System refers to the control system used at a plant, in which the
controller elements are not central in location (like the brain) but are distributed throughout the
system with each component sub-system controlled by one or more controllers. The entire system
of controllers is connected by networks for communication and monitoring.
• Degree API - A unit of measurement established by the American Petroleum Institute (API) that
indicates the density of a liquid. Fresh water has an API density of 10.
• Density - Mass per unit of volume. Density is typically reported in g/cm3.
• Dew Point - The dew point is the temperature at which a given parcel of humid air must be
cooled, at constant barometric pressure, for water vapor to condense into water.
• Diluent - A hydrocarbon fluid that is used to dilute heavy oil and reduce its viscosity for easier
transportation. Generally a distillation tower cut such as naphtha is used as for heavy oil dilution
and transportation. The added diluent may be recovered at the destination using distillation and
the diluent may be subsequently pumped back for blending.
• Expansion joint - A device or completion component designed to enable relative movement

between two fixed assemblies in the event of thermal expansion or contraction. The forces
generated by thermal expansion or contraction can be significant.
• H2S – Hydrogen Sulfide is an extremely poisonous gas. At low concentrations, H2S has the odor
of rotten eggs, but at higher, lethal concentrations, it is odorless. H2S is hazardous to workers and
a few seconds of exposure at relatively low concentrations can be lethal, but exposure to lower
concentrations can also be harmful.
7
• Hydrocarbon - In organic chemistry, a hydrocarbon is an organic compound consisting entirely
of hydrogen and carbon. The majority of hydrocarbons found naturally occur in crude oil, where
decomposed organic matter provides an abundance of carbon and hydrogen which, when
bonded, can catenate to form seemingly limitless chains.
• In situ - Is a Latin phrase meaning in the place.
• Kilopascal - A unit of measurement for pressure in the International System of Units (SI),
symbolized by kPa. The conversion factor from lb/in2 to kPa is 6.9 kPa per lb/in2 (psi). For
example, 5000 psi = 34,500 kPa.
• MOV – Motor Operated Valve
• MSDS - Material Safety Data Sheet - A specific document that shows important physical and
chemical characteristics of a chemical or product to alert a user, transporter or other interested
party to potential safety hazards that may be associated with the material. The MSDS also
contains treatments for exposure or ingestion as well as the type of equipment needed for safe
handling.
• Natural gas - A naturally occurring mixture of hydrocarbon gases that is highly compressible and
expansible. Methane [CH4] is the chief constituent of most natural gas (constituting as much as
85% of some natural gases), with lesser amounts of ethane [C2H6], propane [C3H8], butane
[C4H10] and pentane [C5H12]. Impurities can also be present in large proportions, including carbon
dioxide, helium, nitrogen and hydrogen sulfide.
• Oil Sand - In the context of heavy oil, an oil sand is a porous rock layer, often considered to be a
mixture of sand, clay, water, and bitumen. Oils from such sands may have a gravity of less than
10° API. Both in-situ recovery and mining methods are used to extract the resource, with surface
mining used for extracting deposits of extra heavy oil at shallow depths of less than 100 m [328
ft].
• Produced fluid - A generic term used in a number of contexts but most commonly to describe
any fluid produced from a wellbore that is not a treatment fluid.
• Produced water - A term used to describe water produced from a wellbore that is not a
treatment fluid.
• PPM – Parts Per Million, A unit of measurement in chemical testing which indicates the parts by
weight of a substance in relation to one million parts by weight of water may also be expressed in
milligrams/liter (mg/L). 1ppm = 1 mg/l.
• Relative Density - The ratio of the density of a substance to the density of a standard
substance under specified conditions. For liquids and solids the standard is usually water at 4°C.
• SAGD - A thermal production method for heavy oil that pairs a high-angle injection well with a
nearby production well drilled along a parallel trajectory. The pair of high-angle wells is drilled
with a vertical separation of about 5 m [16 ft]. Steam is injected into the reservoir through the
upper well. As the steam rises and expands, it heats up the heavy oil, reducing its viscosity.
Gravity forces the oil to drain into the lower well where it is produced
8
• Specific gravity - The dimensionless ratio of the weight of a material to that of the same volume
of water.
• Steam-Oil Ratio – SOR is a parameter used to monitor the efficiency of oil production processes
based on steam injection. It measures the volume of steam required to produce one unit volume
of oil.
• Sour gas – A general term for those gases that are acidic either alone or when associated with
water. Two sour gases associated with oil production are hydrogen sulfide, H2S, and carbon
dioxide, CO2.
• TCPL - TransCanada Pipeline is a system of natural gas pipelines that carries gas through Alberta,
Saskatchewan, Manitoba, Ontario and Quebec. It is maintained by TransCanada Pipelines, LP. It is
the longest pipeline in Canada.
• Viscosity - A property of fluids and slurries that indicates their resistance to flow, defined as the
ratio of shear stress to shear rate.
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Chapter 1 Safety
1.0 General
All well pad chemicals, produced fluids, steam, and oils must be handled with safety upper-most in mind.
The operators must familiarize themselves with the characteristics, hazards, precautions and emergency
procedures to be taken when using these chemicals or being around the steam and production fluids.
The following outlines the protective measures aimed at minimizing the risk when handling chemicals
and being around process fluids.
• Current Material Safety Data Sheets (MSDS) must be within close proximity for each chemical
and test reagent on site.
• Always refer to the MSDS, prior to use, for precautionary measures when working with
chemicals and reagents.
• Ensure chemicals and reagents are labeled as per Workplace Hazardous Materials Information
System (WHMIS) regulations.
• Personal protective equipment (PPE) must be worn when handling products as outlined on the
MSDS.
• Ensure appropriate emergency response equipment (eyewash, shower, etc) is available within
close proximity.
• In the event of accidental exposure, always follow the First Aid Measures indicated on the
MSDS.
• Store chemicals in a dry and well ventilated location as outlined on the MSDS.
• Storage and test cupboards should be kept clean and uncluttered.
• Ensure bottles and containers are capped or closed immediately after use.
• Reagents should not be transferred to different bottles.
• DO NOT mix different chemicals together.
• Clean up all chemical spills immediately as per the instructions on the MSDS.
• Site storage containers should be well labeled and kept clean.
• Expired or contaminated chemicals and reagents and their bottles, must be disposed of in
accordance with the procedures indicated in Section I – Environmental Guideline.
• Refrain from handling dry chemicals in areas of air turbulence.
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1.1 Introduction to Safety
One of the objectives of training is to help you to work more efficiently and safely. The
prevention of accidents is a prime objective of the ConocoPhillips HSE policy and Management
System. There is great importance therefore attached to the safety of all employees.
The Management acknowledges their duty to do everything possible to prevent personal
injuries and this duty is a major consideration in the design, construction, operation and
maintenance of all plant equipment and facilities.
Every endeavor will be made to provide appropriate safety training for all employees, together
with the provision for appropriate safety equipment and personal protective clothing. It is also
our policy to provide regular safety instruction and to stimulate joint consultation in the area of
health and safety.
Most importantly, every employee has a continuing duty to exercise responsibility in all his/her
activities and to do everything possible to prevent injury to themselves and others.
You will be expected, at all times, to wear the appropriate safety clothing provided and you
must report promptly to your Supervisor, any accidents, incidents, near-misses and/or
potential safety hazards.
ConocoPhillips is committed to the provision of superior standards of safety and health in the
work place.
Safety is the responsibility of us all. At ConocoPhillips, we believe that there is always room
for improvement and that achieving excellence must be our primary objective. Our goal is zero
incidents.
You will be involved in regular safety training and meetings. The objective of the safety
training is to ensure that safe working practices are adopted, understood and adhered to.
Regular safety meetings are held to help us to improve our safety awareness and
performance. All of ConocoPhillips personnel (including onsite contractors) are required to
attend group safety meetings and understand the safety policies of the Surmont operation.
Always consider what could go wrong in every Pre-Job Safety Meeting (PJSM) you attend and
ensure you follow the recommendations from those meetings.
Although there are legal obligations relating to safety, let us not forget that our real objective
is for you to continue making a valuable contribution to ConocoPhillips and enjoy a full life for
many years to come. Everyone gains if you remain fit and healthy. Please take these
comments on safety and operations excellence very seriously in everything you do.
1.2 Safety Briefing
The HSE Specialist or his/her delegate will ensure a full plant safety briefing is given. This
may include watching a safety video, and a tour of the facilities, instructing you on all the
important safety related aspects to ensure you have the basic knowledge to look after yourself
throughout your stay.
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1.3 Introduction and Expectation
Your Supervisor, the Shift Lead will welcome you to his team and introduce you to the
Operations Supervisor and Chief Steam. The Shift Lead will then explain the structure of the
Surmont Operations organization and will explain your responsibilities and role and what he
expects from you. You will be indoctrinated through the Management of Change for Personnel
to ensure you have the correct training.
1.4 Operating Philosophy and Core Values
We wish to ensure and foster a culture of safety as an integral part of all work done at
Surmont. Risks will be identified, assessed, and managed for people and the environment. It is
our operating philosophy at Surmont that we will be a legacy asset that delivers maximum
value and incorporates the COP SPIRIT core values. Key aspects of this philosophy include:
Safety Our passion every minute, everyday, taking care of everyone’s health,
safety & the environment.
People Success depends on our extraordinary people that care, respect and
support each other.
Integrity Consistently apply high standards & principles in all our actions.
Responsibility 100% accountable, zero excuses in all that we do.
Innovation Creatively seeking solutions for today & tomorrow so we continuously
improve.
Teamwork Our strength lies in being a true team aligned to deliver common goals.
You will be expected to adopt and demonstrate our core values.

1.5 Safety and You
Think about these questions for a few moments:
• Do you want to work safely?
• Do you want others in your workplace to work safely?
• Do you want to learn how to prevent accidents and injuries to yourself and others?
Hopefully you have answered “Yes” to these questions ……because it makes sense to want to
work safely and avoid accidents and injuries.
Now consider the following:
• How often do you think about safety as you do your job?
• How often do you look for things that cause injuries?
Never switch off to Safety,
Never be afraid or embarrassed to stop a colleague from committing an unsafe act;
Intervention could save an accident or incident, even prevent a fatality.
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1.6 Our Safety Motto
“At ConocoPhillips our work is never so urgent or important that we cannot take time to do it
safely in an environmentally prudent manner”
Before carrying out a task ask yourself “What could go wrong?” and “What are you
going to do about it?”
1.7 HSE
• We are committed to protecting the health and safety of everybody who plays a part in our
operations, lives in the communities in which we operate or uses our products.
• Triple Zero Goals:

• No Recordable Injuries
• No Recordable Vehicle Incidents
• No Regulatory Reportable Spills
• We want you and everyone working with you to make it home safely at the end of the day.
1.7.1 Refusal of Unsafe Work.
• Worker’s Obligation to Refuse Unsafe Work.
- Correct Unsafe Conditions.

- STOP Work until Unsafe Condition is Corrected.
- Immediately Notify Supervisor.
- Explain Circumstances Leading to Refusal.
- Work Refusals Must be Reported and Investigated.
1.7.2 Emergency Procedures
• IN THE EVENT OF AN EMERGENCY:
1. The horns will sound.
2. Go to the nearest most appropriate Muster Point
3. Wait there for a head count and further direction
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1.7.3 Personal Protective Equipment
• All workers shall meet the following minimum PPE requirements at CPC field work sites as
identified and communicated by the PJHA. All PPE must be CSA approved.
- Head Protection
- Safety-toed footwear
- Safety eyewear complete with side shields
- Gloves (Appropriate to task)
- Fire-Resistant Clothing (Nomex, Proban)
- Personal Gas Monitor Requirement
1.7.4 Hearing Protection
• Signage is posted in areas where hearing protection is required.
• Additional areas may be identified during the PJHA process.
• Certain work activities may require you to wear hearing protection.
• Ear Plug Dispensers are located at every entrance/exit in the steam generator building. Signs are
posted where hearing protection is mandatory.
1.7.5 Gas Detection – Personal Monitors
• All workers must have personal style gas detection monitor (properly calibrated) readily available.
• Employees must be trained in the use, care and maintenance of the personal style monitor they
are using. See the Quick Reference Guide included with your assigned personal monitor.
• The gas detection monitor must be able to detect LEL, O2, H2S, and CO as a minimum.
• All personal gas monitors must be bump tested daily.
• All monitors used for hot work and confined space entry must be active continuous monitors.
1.7.6 Eye Wash Stations
The eye wash stations are located in the NW area of the BLDG. It is an eyewash/shower
combination. Operations tests this weekly.
1.7.7 Fire Extinguishers
The fire extinguishers are located at every entrance/exit. They are also located on every pillar in
the building (middle of the building). There is also a fire extinguisher located on the burner platform
of each steam generator.
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1.7.8 First Aid Kits
The first aid kit is located in the safety cupboard which is located in the NW area of the BLDG.
The fire blanket and burn kits are located on the two pillars located near the south of the building.
1.7.9 SCBA - Air Packs
There are no SCBA’s in the 500bldg. The closest SCBA’s are located in the 400bldg or 200bldg
1.7.10Spill Prevention Kits
2x in total, Yellow barrels, placed throughout the building.
1.7.11Safety Cupboards
Located in the NW area of the bldg
• Inventory includes:
- 2 sets of Chemical Rubber Boots.
- 4 Chemical Suits.
- Burn Dressing.
- 2 sets of Chemical Rubber Gloves.
- 4 boxes of Disposable Rubber Gloves.
- Respirator Wipes.
- Respirator.
- Respirator Cartridges.
- Face Shields.
- Face Shield Replacement.
- Safety Glasses.
- Yellow Caution Tape.
- Red - Do Not Enter Tape.
1.7.12MSDS’s
• MSDS’s for the 500Bldg can be found on the ConocoPhillips Canada Homepage.
• Departments → HSE & SD
• 6 Programs and Procedures → MSDS
• Click On To log onto to the 3E Company Database to access your MSDS’s,
• Enter user name: Username: conoco Password: burstall
• Site/Location 9 Surmont Hit: Select Hit: Search
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Chapter 2: Once Through Steam Generators (OTSG)
2.0: Introduction
The primary function of a boiler is to transfer heat from hot gases generated by the combustion of fuel
into water until it becomes hot or turns to steam. The steam or hot water can then be used in building
or facility processes.
Once-through steam generators are heat exchangers that convert water to steam (or other liquids to
vapor) in a single pass.
The 'once-through' designation means that the heat exchanger is a single-pass where water/liquid
enters at one end, gets vaporized in the straight pipe through which it travels, and exits at the other as
steam/vapor. There's no second pass from doubling back into the heat-exchange zone, the steam exits
the heat exchanger right away. OTSG boilers do away with internal recirculation and have no steam
drum. This allows for lighter construction using a separator instead of a steam drum.
OTSG OTSG (Double Barrel design)
2.1: History
Although not a new technology, the once-through steam generation has not gained widespread
application. Unlike conventional heat recovery steam generators (HRSGs), OTSG’s do not have defined
evaporator or superheater sections. The point at which the steam-water interface exists is free to move
through the horizontal tube bank depending on the heat input and the mass flow rate and pressure of
the water. The single point of control for the OTSG is the feedwater control valve; valve actuation
depends on predefined operating conditions that are set through the distributed control system (DCS).
The DCS is connected to a feed forward and a feedback control loop, which monitor the transients in
outlet steam conditions.
Once through boilers have long been the visions of boiler design engineers. In the United States, patents
for once through boiler concepts date from as early as 1824. These early inventors were undoubtedly
motivated by the desire to improve the product safety because of the notoriety of pressure vessel
failures associated with the early fire tube and water tube boilers. Once Through technology has earned
a reputation as the simple way to help owners and operators generate more money with their plant.
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OTSG’s avoid the complications of boil out and chemical cleaning; they eliminate the operational
headaches related to the control of blow-down systems and steam drum levels. Further, OTSG’s provide
significant additional cost reduction since there is no heat loss and maintenance of the bypass stacks
with diverter valves, often required in traditional drum type steam generator systems.
The OTSG’s unique modular design lends itself to rapid and low cost installation, thereby creating an
installed cost that is regularly less expensive then conventional drum-type HRSG technology.
Erection and commissioning time is reduced drastically from 24 weeks to 6 weeks. The design and
manufacturing process is completed quicker than conventional boilers. In production terms the OTSG
modular design approach benefits in the following ways:
• reduces design/manufacturing time

• reduces site erection dramatically
• commissioning time reduced
• smaller and lighter
• allows for in-house hydrostatic testing
• improves quality, efficiency and performance
• improves ease of shipment
• HRSG is usually removed from plant's critical path
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Operating Steam Quality 75%
Operating Discharge Pressure 9,653 kPag
Operating Flow Rate at Generator Outlet 149,053 kg/h
Corresponding Boiler Feedwater rate 149,053 kg/h
Boiler Feed Water Temp. 175 °C
Design Total Heat Output of Generator (Above BFW Temp.) 68.153 MW
Net Thermal Efficiency of Steam Generator >90.8 % (LHV)
Tubing Layout for a Once Through Steam Generator
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Simple process Flow of Steam Generator
Principles of Operation - NOx Emissions

Combustion involves the burning of air and fuel. Air is comprised of approximately 79% nitrogen
molecules and 21% oxygen molecules. A molecule of nitrogen is made up of two atoms of nitrogen
bonded together by their electron structure. The same goes for a molecule of oxygen being two boned
atoms of oxygen. Both molecules are quite stable in the atmosphere. However, expose them to high
temperature and they can absorb the heat energy up to a point where the atoms will break apart. When
the two atoms break apart, they release all the heat energy that had been storing up. As atoms they
are unstable because their electron shell structure is not satisfied. The atoms have to react with other
atoms that have broken apart and produce a new molecule. The two atoms braking apart are referred
to as thermal dissociation. If an atom of nitrogen meets with an atom of oxygen, the new molecule is
nitric oxide (NO). Should an atom of nitrogen meet a molecule of oxygen that has not yet dissociated, a
reaction can take place to form nitrogen dioxide (NO2). NO and NO2 make up what is referred to as
NOx. Since the heat of the flame created the dissociation of the nitrogen molecules, which in turn could
react with excess burner oxygen molecules or atoms, we refer to this as "THERMAL NOX". Thermal NOX
is associated with all combustion.
There is another means of making NOX with residual oil, certain refinery gases that contain ammonia
and coal fuels. It is referred to as "FUEL NOX". The fuels mentioned all have nitrogen atoms bonded
directly to the hydrocarbon molecules that make up what we call the fuel. As the hydrogen and carbon
is oxidized during combustion (to CO2 and H2O), the nitrogen atoms will at some point be ejected out of
the hydrocarbon molecule. That is the hydrogen and carbon has a strong desire (i.e. affinity) to bond
electrons with oxygen, rather then the nitrogen, during combustion. As an atom, the ejected nitrogen is
19
unstable. Just as it was with thermal dissociation in Thermal NOx but the important point is that with
Fuel NOx, it is not high temperature that created nitrogen atoms, rather, the nitrogen atoms bonded to
the fuel hydrocarbon molecules are liberated as the carbon and hydrogen burn. With Thermal NOx, it is
a crapshoot as to which nitrogen molecules will dissociate. With Fuel NOx, all fuel nitrogen will at some
point be liberated as unstable nitrogen atoms. Being unstable, they have to react with something. If
oxygen is available, the nitrogen atoms will go after it making Fuel NOx. Thus, fuels containing
chemically bound nitrogen can have a significant and usually predominant effect on NOx.
NOx emissions contribute to atmospheric pollution. These emissions are generated by both natural and
man made sources. Although the quantity of nitrogen oxides emissions reproduced by human activity
throughout the world is on the order of 10% of the nitrogen oxides produced from natural sources, man
has the bad habit of concentration these emissions in populated areas.
The majority of the NOx emitted from a combustion source are emitted as NO (95 to 98%) and the
remained as NO2 (Nitrogen Dioxide) is a brownish colored gas with a detectable odor in concentrations
as low as 0.15 PPM. The emission of nitrogen oxides in conjunction with hydrocarbon emissions from
refiners and automobiles result in the production of atmospheric "Photochemical Smog" and "Ozone"
when these pollutants are subjected to solar radiation. The severity of Photochemical Smog will vary
from day to day, hour to hour depending on the level of solar radiation and the atmospheric
concentration of hydrocarbons and nitrogen oxides.
Thermal NOx
As discussed, Thermal NOx is formed at high temperature under excess air conditions. The principal
reactions governing the formation of NO from molecular nitrogen during the combustion of fuel air
mixtures are given by the "Zeldovich" equations. Experimental Studies of NO formation in heated
mixtures of NO, O2, and Argon at atmospheric pressure have been correlated with a "Kinetic" equation of
the form:
This 'Rate Equation" reflects the strong dependence of NO formation on temperature (exponential). It
also shows that NO concentration is only directly proportional (i.e., linear) to N2 concentration and to the
residence time in the high temperature zone. Finally, NO varies with O2 by the square root of O2.
The other equation of importance in understanding Thermal NOx formation is the equation which
approximates the "Maximum" or "Equilibrium" NO concentration. For any given N2, O2 concentration
and temperature there is an upper limit or "Maximum" NO concentration from chemical thermodynamic.
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This "Equilibrium" concentration is approximated as follows:
This equation, like the rate equation, reflects the strong dependence of NO formation on temperature
(again, it's exponential). The "Equilibrium" NO or upper limit is directly proportional to the N2 and O2
concentration and its magnitude is very dependent on high temperature.
These two equations permit us to demonstrate the strong dependence of NO formation on temperature
and time in the high temperature zone. At lower temperature the "Equilibrium" NO or upper limit is
relatively low and the NO reaction proceeds very slowly. So slowly, that the time for the products to
reach equilibrium is much longer than the residence time of the products in the temperature combustion
zone. At these lower temperatures and short residence time, the reaction is "Frozen" and does not
proceed very far toward equilibrium. With high temperature the NO reaction rate is much faster, and in
addition, the "Equilibrium" or upper NO limit is considerably more toward equilibrium in the time the
products are in the high temperature combustion zone. The following tabulation illustrates the effect of
higher temperatures on the "Reaction Rate" and "Equilibrium" NO levels.
Temperature °F Equilibrium NO ppm Time to reach

Equilibrium
1500 10 81.6 years
2250 500 1.25 days
3000 2400 2.08 minutes
3300 3200 5.06 seconds
4000 8600 .0106 seconds
From the two equations it can be seen that NO formation can be reduced by four approaches:
1. Reduce the nitrogen level at peak temperatures.
2. Reduce the oxygen level at peak temperatures.
3. Reduce the peak temperature.
4. Reduce the time of exposure at high temperature.
Since it is not possible to control or modify the nitrogen level in the combustion air, the primary methods
of Thermal NOx control focuses on the other three approaches. Knowing what to reduce allows COEN to
determine how to design a low NOx burner.
21
COEN low NOx burner
Fuel NOx
The relative contribution of fuel bound nitrogen to the total NOx emission can be significant and can
predominate for fuel with high nitrogen levels as previously discussed. The nitrogen content of distillate
oils is usually less than .01% but can exceed .1% to .8%, while the majority of residual oils are in the
range of .25 to .45%
A fraction of the total fuel nitrogen is normally converted to NOx. The percentage of fuel nitrogen to
NOx conversion decreases as nitrogen increases. For instance, for a fuel oil with .05% fuel bound
nitrogen, the conversion of fuel nitrogen to NOx is 65 to 70%. For an oil with .4% bound nitrogen, the
conversion is 40 to 45%. Although fuel NOx emissions increase with increasing fuel nitrogen contents
the emission increase is not proportional.
The optimum environment for minimizing fuel NOx emissions is to generate a temperature fuel rich (i.e.
very little oxygen) primary zone with a residence time sufficiently long to minimize the number of
nitrogen atoms liberated to form NOx with oxygen. The carbon and hydrogen have the stronger affinity
for the oxygen than the nitrogen does. Minimizing the oxygen (by being sub-stoichiometric) allows the
hydrocarbon molecules to start breaking down (combustion) and this eventually liberates the bound
22
nitrogen. But with the little amount of available oxygen, the odds are that a nitrogen atom liberated will
meet with another atom of nitrogen liberates to make a molecule of nitrogen. Once the NOx reactions
have reached a minimum the combustion air is slowly added downstream in the furnace to allow burnout
without significantly increasing the "Thermal" NOx component of the total emission.
The fuel gas to the burner is made up of produced gas recovered from the Well Pads and the VRU. This
is augmented as required by sweet natural gas from the pipeline in area 7. The following is referring to
05-SG-531A but is similar with the B, C and D. The fuel gas from area 7 is letdown in pressure in 05-
PCV-3056. Downstream of the valve are High and Low Pressure shutdown transmitters (PAHH-3062,
PALL-3060). The gas flow is then measured by FI-3050, which feeds into the flow controller to the inner
and outer spuds logic but has no directly associated High Flow shutdown as mentioned in earlier
documents (Note: FAHH-3050 does not exist. 05-FIT-3050 associated Bad PV is what tripped the Steam
Generators).
Next is the positive isolation shutdown system, two in-line shutdown valves (XV-3054 & XV-3057), with a
vent in between (XV-3056). On a shutdown the two inline valves will close and the vent will open giving
full, positive, isolation. All three of these valves have open/close indicators in the DCS. Next in line is a
manual Ball Valve (HV-3050), also with remote open/close indication.
The line then splits. Flow to the outer burner ring (FV-3052) is controlled from the control logic. There
is a high pressure shutdown (PAHH-3064) downstream of the valve. Flow to the inner burner ring
passes through FV-3051, which is controlled from the control logic. High pressure shutdown (PAHH-
3063), downstream of the control valve protects against over firing the burners.
The steam generator management system has five levels of control:

• Level one is the modulating control e.g. Feed-water flow. Fuel gas Combustion Air which is done by
the plant distributed control system (DCS).
• Level 2 is the Burner/flame management control which is done at each steam generator unit local
panel. Each steam generator unit requires local start by the operator. Steam generator start is not
done from the central control room.
• Level 3 is the emergency shutdown which is done by the plant safety system.
• Level 4 is the physically built-in safety devises such as pressure safety valves (PSV).
• Level 5 is a newly installed BMC - Boiler Master Control installed 2011 to control the header pressure.
Another major variable managed by the steam generator control system is the fuel / air ratio. The flue
gas exiting the steam generator stack is analyzed for excess oxygen. At least 2% excess oxygen is
required to ensure efficient combustion of the fuel gas. The excess oxygen controller manipulates the
air flow control valves (at the inlet to the combustion air blower) and the fuel flow control valves.
Combustion Control
The Process Control System (PCS) is responsible for controlling the fuel valves and air dampers to ensure
proper combustion given a target steam quality and inlet flow. The method by which the control system
is detailed in the TIW Western Inch (vendor) document titled "Outline Manual Modulating Control -
Alternative Methods for Direct-Fired Oilfield Steam Generators". Specifically, "Method 3 - Reactive Heat
Balance Calculation" has been implemented for the Surmont steam generators. With this method, the
23
control system continuously calculates the heat input required to convert the supplied feedwater flow to
a specified steam quality output and adjusts the fuel flow and air flow accordingly.
As part of the calculations, the control system uses the heating value of the produced gas to
be used as fuel to the burners. Since there is no online measurement of the heating value
(e.g. gas chromatograph), the control system will be programmed to take an operator entered heating
value. Future BTU analyzer installation is planned.
IMPORTANT: If the manually entered heating value does not match the actual fuel gas used,
the control system will calculate the fuel required incorrectly, which could lead to potentially dangerous
consequences as described in the TIW vendor documentation.
Inner/Outer Spuds Bias Control
There are two fuel control valves controlling fuel to the main burner, one controlling fuel to the outer
spuds and one to the inner spuds. The Plant Control System wilt be programmed initially to control both
valves at the same position based on the Fuel Controller. During commissioning it will be established,
empirically, what is the relationship between the inner and outer spud valve control. This relationship will
then be fed into the Plant Control System as a linearization from one valve to the other.
Air/Fuel Controllers Cross Limiting
To prevent the occurrence of an unacceptable air/fuel ratio deviation, the combustion air controller and
fuel controller will be cross-limited. The cross-limiting will be achieved by using the target air to fuel ratio
in conjunction with the real-time values to generate a limiting setpoint for both the combustion air
controller and fuel controller. In the case of the combustion air controller, the actual fuel flow will be
used to calculate an acceptable air flow setpoint for the given fuel flow. The higher of actual and target,
or the safer, will be used as the setpoint for the combustion air controller.
In the case of the fuel controller, the actual air flow will be used to calculate an acceptable fuel flow
setpoint for the given air flow. The lower of actual and target, or the safer, will be used as the setpoint
for the fuel controller.
Air/Fuel Ratio Deviation Shutdown
In general, all shutdowns for the steam generator will be initiated by the BMS. However, since the Plant
Control System is responsible for the air to fuel ratio control, there is a necessity for the Plant Control
System to initiate a shutdown in the event the actual air to fuel ratio exceeds acceptable limits. As part
of the heat balance equations described in section 3.7, the Plant Control System will produce a
prescribed air to fuel ratio within the design limits of the steam generator. The Plant Control System will
compare the actual air to fuel ratio to this prescribed ratio and generate an alarm, then shutdown if the
two ratios differ significantly from each other.
Initially, the alarm setpoint will be 5% and shutdown will be 10% difference between acceptable and
actual air to fuel ratios. Note: This shutdown has been bypassed since 2007. When ramping a
generator up or down, the air/fuel cross limiter always maintains an 'Air Excess' condition; ramping up,
air increases followed by fuel. When ramping down, fuel decreases first, followed by air. In either
24
condition, you will have a positive air condition that may exceed the limits, and the shutdown is
instantaneous. The BMC project calls for a review with Automation and TIW for proper fix or removal.
Steam Depressurization
If the flow of boiler feed-water to the steam generators is suddenly interrupted, the tubes will quickly
overheat. Even if the flame is immediately shut down, there is sufficient heat remaining in the gases and
refractory lining to damage the boiler tubes. In less than one minute, the temperature of the tubes can
exceed the 427°C (800°F). At this temperature, graphite crystals can start to develop in the tubing
metallurgy. Depressurization must commence immediately if boiler feed-water supply is disrupted;
otherwise metallurgical damage to the carbon steel tubes may require costly replacement of the steam
generator internals.
Steam generator depressurization will be accomplished using the steam header transmitters
05-TIT-3036 and 05-PIT-3009 and the blowdown pressure control valve 05-PV-3009.
Depressurization or "BlowDown" Logic
During most shutdown conditions of the steam generator, BFW flow will be maintained as will
combustion air flow. There are a few situations where there will either be no BFW flow or no combustion
air flow, primarily these are; Plant BESD, Plant ESD, Fire, H2S or Combustible gas detected in the steam
generator building or plant power failure, all of which will stop all rotating equipment in the steam
generator building.
The definition of a "blowdown" scenario for a steam generator is when the steam discharge temperature
is at saturation temperature or higher and there is a sudden loss of BFW flow or combustion air flow to
the steam generator (note this is different from the definition of "Blowdown Emergency Shutdown" or
BESD which applies to the entire plant).
The control system will monitor the steam header discharge temperature (05-TI-3036) and compare it to
the saturation temperature. If the totalized BFW flow or the combustion air flow drops below their
respective tow Low flow setpoints after the steam header discharge temperature has achieved saturation
temperature and is still within 5°C or above, the control system will activate the "Blowdown".
Blowdown of the steam generator will be accomplished by driving the pressure control valve 05-PV-3009
to a pre-determined position when a "blowdown" situation occurs. The position will be based on relieving
the pressure fast enough without sending more steam into the blowdown header than it is sized for.
The valve will remain at the blowdown position until the steam header pressure has dropped below
3000kPag, after which the operator has control of the blowdown valve once again.
25
Principles of Operation - Surmont Phase 1 QLG Low NOx 48 Burner
General
The COEN QLG Burner is specially designed to attain low NOx emissions when firing gaseous fuels, and
is especially suited for refinery VC heaters due to the removable gas spuds. This design does not rely on
high amounts of flue gas recirculation (FGR) to attain low emissions. The burner can also fire oil, or
both oil and gas simultaneously.
Gas Firing
The QLG Burner features two gas zones. These are the central core zone which helps to stabilize the
overall flame and a main gas zone where gas fuel burns after being mixed with furnace gas induced by
the gas jets. The overall mixing pattern created by the burner is such that it is capable of operating with
excess air down to a typical 10 to 15%. The ratio of gas flow to the two zones is adjusted at startup to
control the NOx and CO and stabilize the flame. When firing gas, the core air damper is closed by
pulling the lever down (or out if horizontally fired).
Oil Firing
For oil firing or combination oil/gas firing, the core air damper is opened by pushing the lever up (or in if
horizontally fired). The air entering through this damper provides additional air to the base of the oil
atomizer tip to reduce the formation of carbon or coke on the tip. The oil flame appearance is
characterized by alternate orange and dark streaks. The overall flame shape can be control to a certain
extent by oil cap design.
Understanding the QLG Design and Operating Characteristics - Gas Firing
Fuel Distribution
• For most applications the nominal high fire design fuel split is 15/85 between the Inner Fuel Zone
(Core spuds) and the Main Fuel Zone.
• Shifting the fuel distribution by +- 5% from the nominal design values may require the spuds to be
changed to optimize the orifice trajectory and/or optimize the spud pressure for turndown.
Core Zone
• The purpose of the core flame is to anchor the inner flame. For this reason, the burner must not be
operated without the core flame.
• The nominal design fuel input for the Core Spuds is 15% at high fire.
Main Flame Zone
• The Outer Spuds are designed to inject fuel between and downstream of the air slots in the
distribution plate to lower the NOx emissions. The low pressure created between the high velocity
air/fuel mixtures exiting the slots promote mixing of the Main Flame Zone with the Inner Flame Zone.
26
Excessive Air
• The optimum excess O2 envelope corresponds to 5 to 7% at low fire and 2 to 5% at high fire.
Economizer
The BFW is first heated in the convection section by flue gas leaving the steam generator. The
convection tubes are finned to enhance heat transfer. These finned tubes are shielded from radiant heat
by shock tubes. The steam generation takes place in the radiant section of the boiler (combustion
chamber) by absorbing radiant heat from the burner flames. The radiant section has the highest tube
wall temperatures. The shock and radiant tubes do not have fins.
20 rows of tubes are in the Convection Section for Steam Generators B/C and D.
In A Steam Generator the entire Economizer is different due to being replaced by a different type
purchased from EnCana (Cenovus). This Convection Section is slightly different in its configuration.
Heater Design Pressures Pressure Temperature Pressure Temperature

Steam Relief Valve set at 1633 psig 1682 psig 11260 kPa 11597 kPa
External Outlet Piping & Flanges 1633 psig 601 oF 11260 kPa 316 kPa
Radiant Coil at Outlet 1638 psig 691 oF 11294 kPa 366 kPa
Radiant Coil at Inlet 1795 psig 691 oF 12377 kPa 366 kPa
Convection Coil 1826 psig 664 oF 12590 kPa 351 kPa
Inlet Piping (After main FCV) 1879 psig 400 oF 12952 kPa 204 kPa
Pump Discharge to Main FCV 2655 psig 400 oF 18306 kPa 204 kPa
Flange Rating Inlet 1500# ANSI 1500# ANSI
Flange Rating Pump Outlet 1500# ANSI 1500# ANSI
Flange Rating Steam Outlet 1500# ANSI 1500# ANSI
Average Heat Flux Pressure Pressure

Radiant Coil 16569 BTU/sq.ft/hr 5.23 W/cm2
Bare Convection Coil 17769 BTU/sq.ft/hr 5.60 W/cm2
Lower Finned Convection Coil 7065 BTU/sq.ft/hr 2.23 W/cm2
Upper Finned Convection Coil 1008 BTU/sq.ft/hr .32 W/cm2
Heat Release 12192 BTU/sq.ft/hr 126.14 W/cm2
Pressure Drop Through Heater 273 psig 1882 W/cm2
Tube Wall Quantit Tube

Heating Coil Information Material Area
Dia. Thickne y of Length
Metric Spec. m2
mm ss mm Tubes m
Radiant Coil 88.9 7.6 SA-106-C 132 18.9 727.0
Bare Convection Coil 88.9 7.6 SA-106-C 96 4.27 114.4
Lower Finned Convection Coil 88.9 7.6 SA-106-C 48 4.27 389.0
Upper Finned Convection Coil 88.9 7.6 SA-106-C 336 4.27 5617.5
Material: Carbon Steel 114mm refractory Lined
Convection Tubesheets
4267 mm spacing
27
Tube Wall Tube
Heating Coil Information Material Quantity Area
Dia. Thickness Length
Imperial Spec. of Tubes ft2
In. in ft.
Radiant Coil 3.5 0.300 SA-106-C 132 62 7825.0
Bare Convection Coil 3.5 0.300 SA-106-C 96 14 1231.5
Lower Finned Convection Coil 3.5 0.300 SA-106-C 48 14 4187.1
Upper Finned Convection Coil 3.5 0.300 SA-106-C 336 14 60466.8
1
Material: Carbon Steel 4 /2" refractory Lined
Convection Tubesheets
4267 mm spacing
Note: The Material Spec. has been changed in replaced damaged tubes to Spec. P-22. This
change has increased the operating range of the tubes that have been changed only.
Steam Generator A Convection Section Tube Layout (EnCana(Cenovus) Purchased Economizer)
28
Steam Generator B/C/D Convection Tube Layout
PSV inspection frequency, set pressures
Steam Generator Outlet PSV Pressure and Inspection Frequency

Inspecti
on
Location PSV Set Pressure
Frequen
cy
Steam Generator A 05-PSV-3006 11234.5 kPag (11232) 1 year
Steam Generator A 05-PSV-3007 11565.5 kPag (11569) 1 year
Steam Generator B 05-PSV-3506 11234.5 kPag (11232) 1 year
Steam Generator B 05-PSV-3507 11565.5 kPag (11569) 1 year
Steam Generator C 05-PSV-4006 11234.5 kPag (11232) 1 year
Steam Generator C 05-PSV-4007 11565.5 kPag (11569) 1 year
Steam Generator D 05-PSV-4506 11234.5 kPag (11232) 1 year
Steam Generator D 05-PSV-4507 11565.5 kPag (11569) 1 year
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2.3: Purpose of Operation/Start up Procedure
Steam, created from the Once through Steam Generators (OTSG), is injected into the oil sands formation
through the top well. The heat liquefies the bitumen, allowing it to flow to the production well, located
beneath the steam-injection well. The bitumen, along with the condensed water from the steam, flows
to the surface wellhead.
Detailed Start-Up procedure (Taken from SSOP # 12228754 SG-531 A/B/C/D)
1. Unit Operator to NOTIFY Control Room Operator of your intention to fill the Steam Generator.
2. Open the MOV 05-XV-3502 valve body equalization valve.
3. Unit Operator ensures that the 4” inlet and outlet block valves are OPEN on 05-PV-3509 (SG-
531B Blowdown valve).
4. Unit Operator ensures that the 8” block valve on the High Pressure Steam Line downstream of
05-XV-3502 (SG-531B Steam Gen Outlet Valve) is OPEN.
5. Unit Operator ensures that a High-Pressure Boiler Feedwater pump is on line, circulating hot
Boiler Feedwater through the pump.
6. The Control Room Operator is to ensure that MOV 05-XV-3500 (SG- 531B Steam Gen BFW Inlet
Valve) is CLOSED and that it is in “LOCAL” control.
7. The Control Room Operator is to ensure that 05-PV-3500 (SG-531B Steam Gen BFW Inlet Control
Valve) is in MANUAL and is OPEN at 3-4%.
8. The Control Room Operator is to ensure that the 6 pass-flow-control valves 05-FN-3501 to 3506
are in Manual at 25% open.
9. The Control Room Operator is to enter a FLOW SETPOINT of 55m3/h into the “TARGET VALUES”
on the DCS.
30
10. The Control Room Operator is to ensure that 05-PV-3509 (SG-531B Blowdown valve) is in
MANUAL and that it is OPEN 100%.
11. The Control Room Operator is to ensure that MOV 05-XV-3502 (SG- 531B Steam Gen Outlet
Valve) is CLOSED and that it is in “LOCAL" control.
12. 8” manual valve on the BFW inlet to the steam gen should be CLOSED. Slowly crack OPEN this
valve until the section between this valve and MOV 05-XV-3500 is pressure equalized (charged)
13. Unit operator can OPEN the MOV 05-XV-3500 slowly to 100% then put valve into REMOTE.
CAUTION: There will be a pressure drop of 16,000kpa across the MOV 05-XV-3500. Care must be taken
to open this MOV very slowly. Control room to monitor HP BFW pump discharge pressure and minimum
flow controller.
14. Control room operator can slowly open the steam gen BFW inlet valve (PV-3500) in 1%
increments until all of the air has been vacated from the 6 passes. Then a 5000kpa inlet pressure can be
achieved by manipulating 05-PV-3509 (SG-531B Blowdown valve)
15. When 5000 kPa is achieved, Control Room Operator puts 05-PV-3500 (SG-531B Steam Gen BFW
Inlet Control Valve) in AUTO with a set point of 5000 kPa. If PV-3500 is seen to be hunting, unit
operator to notify control room and opening the PV incrementally may stabilize.
16. Control Room Operator establish a total flow of 55m3/hr through pass flow valves then put all 6
Pass Flow Control valves on “CASCADE”.
WARNING: THE MAXIMUM DIFFERENTIAL PRESSURE ON THE PASS CONTROL VALVES MUST NOT EXCEED 5,000 KPA.
CONTROL ROOM OPERATOR CAN CLOSE MOV 05-XV-3500 (SG-531B STEAM GEN BFW INLET VALVE), IF 05-PV-3500 (SG-531B STEAM
GEN BFW INLET CONTROL VALVE) DOES NOT STABILIZE.
17. Unit Operator CHECK the Generator and related piping for leaks and other abnormalities when
flows and pressures have been established
18. For WARM-UP CIRCULATION on Steam Generator SG-531B allow water to flow through the Steam
Generator until the BFW inlet temperature 05-TI-3000, Radiant Tube Skin Temperatures 05-TI-3511 –
3516, Convection Skin Temperatures 05-TI-3508 – 3510, and the Convection Outlet Temperatures 05-
TI-3501 – 3506 are all within the same temperature range.
19. Control Room Operator put E-531B (Steam Gen Combustion Air Heater Temp Controller) in Auto
with a setpoint of 100°C.
20. Unit Operator CONFIRM that Combustion Air Pre-heater system, E-531B is in service, with glycol
circulating under temperature control through TV-3538.
21. Unit Operator CONFIRMS that the Steam Generator Combustion Air Fan Motor KM-531B is
energized and ready for service, lockout devices removed.
CAUTION: CONTROL ROOM OPERATOR TO ENSURE THAT ONE HVAC IS RUNNING FOR EVERY ONE-STEAM GENERATOR THAT IS TO BE
ONLINE OR IS ONLINE. THERE IS A HVAC SYSTEM IN SERVICE SUPPLYING AIR TO THE BUILDING TO PREVENT A NEGATIVE PRESSURE.
22. Control Room Operator put K-531B (Steam Gen Combustion Air Fan) into “AUTO”.
31
23. Control Room Operator should open up the “START-UP”, “BMS LIMITS”, as well as the “BMS
FIRST OUT” screens to watch the start-up progress.
24. On the “START-UP” screen each step will turn green and then begin to time down as they are in
progress.
25. On the “BMS LIMITS” screen each limit will turn green as the limit is made.
26. On the “BMS FIRST OUT” screen the condition that shut the Steam Generator down will turn red.
27. In the SG-531B “START-UP” screen Control Room Operator select “READY” under the
“PERMISSIVE TO START SELECT” label.
28. When all the required limits are satisfied the “BURNER READY TO START” will turn green.
29. To start the sequence the Unit Operator must press the “BURNER START” touch button.
30. The “ACCEPT” and “CANCEL” will now highlight and the Unit Operator must press the “ACCEPT”
touch button to start the Steam Generator.
.
STEP TIME
CONTROLS IN PURGE POSITION 120 seconds
PRE-PURGE IN PROGRESS 150 seconds
PRE-PURGE COMPLETE -----
CONTROLS TO LIGHT OFF POSITION 120 seconds
PREPARING FOR PILOT IGNITION 5 seconds
PILOT IGNITION IN PROGRESS 10 seconds
PILOT PROVING DELAY IN PROGRESS 5seconds
PILOT IN OPERATION – OPEN SUPERVISORY 240 seconds
- THE UNIT OPERATOR MUST OPEN THE
SUPERVISORY VALVE IN LESS THAN 4
MIN.
MAIN IGNITION IN PROGRESS 10 seconds
MAIN IGNITION COMPLETE – HOLD AT LIGHT 15 seconds
OFF
BURNER FIRING AND MODULATING ----
31. On SG-531B Steam Generator Main screen the “BMS HAS NOT RELEASED TO MODULATE AIR/
FUEL” will be green, underneath on the pull down go from “HOLD LOW FIRE” to “MODULATE”.
32. In the “TAGET VALUES” Control Room Operator increases the “TARGET QUALITY” from 0% to
5%.
33. When the “Main Fuel Flow” approaches the “Calculated Fuel Gas Flow Setpoint” Control Room
Operator increase the “TARGET QUALITY” another 5%.
32
34. As the back end pressure 05-PV-3509 (SG-531B Steam Outlet Pressure Controller) starts to
increases when steam is starting to be made, increase the pressure on 05-PV-3500 (SG-531B Steam Gen
BFW Inlet Control Valve) 500kPa at a time.
35. Repeat steps 34 and 35 until the desired quality is achieved. Perform field steam quality checks to
verify quality. DO NOT EXCEED 75% QUALITY.
NOTE: MANUAL STEAM QUALITIES NEED TO BE COMPLETED ONCE THE STEAM GENERATOR IS STARTED AND RE-DONE AFTER ANY
SUBSEQUANT TRIP OR RE-START TO CONFIRM STEAM QUALITIES.
36. Ensure that condensate is fully drained from 1” drain valve downstream of the steam outlet MOV
05-VX-3502. With SG-531B running to Sludge Pond SU-401, slowly open the 1” bypass around MOV 05-
XV-3502 (SG-531B Steam Gen Steam Outlet Valve) to slowly warm up V-502B HP Steam Separator B
outlet valve.
CAUTION: WHEN OPENING MOV 05-XV-3502 (SG-531B STEAM GEN OUTLET VALVE) YOU MUST ENSURE NOT TO OPEN THE MOV TO
FAST. ALLOW TIME FOR THE DIFFERENTIAL PRESSURE TO EQUALIZE ACROSS THE VALVE. FAILURE TO DO SO WILL RESULT IN A STEAM
GENERATOR TRIP.
37. When pressure is equalized and the H.P. Steam Separator is up to temperature, the unit operator
is to begin opening MOV 05-XV-3502 (SG-531B Steam Gen Outlet Valve) 1-2% at a time, each time
allowing the differential pressure to equalize. Continue until MOV 05-XV-3502 (SG-531B Steam Gen
Outlet Valve) is open 100% The MOV 05-XV-3502 needs to be opened to 100% while controlling the
temperature and pressure throughout the ramp up with the Blow down Valve 05-PV-3509. Keep the
Steam Generator at low rates during the warm-up phase. Controlling the pressure this way will allow the
pressure and temperature to be controlled throughout the entire Steam System during the warm up.
Damage to the MOV 05-XV-3502 may occur if it is used to throttle steam flow during the warm up
phase.
Desired warm up rate is 40C/hr. Crack the 1" bypass at first to slowly the system. Continue to open the
1" bypass until warm up rate slows b30C/hr. When the 1" bypass is fully open, then begin opening the
MOV the warm up back to the 40C/hr rate. Once the temperature and pressure differential OTSG Outlet
and the CPF Steam Header have come close to equalization MOV should then be opened to 100% at this
point the Blow Down Valve OTSG can be used to control the overall Steam Pressure to meet the
recommended warm up rates.
CAUTION: UNIT OPERATOR TO BE AWARE OF THERMAL EXPANSION, WATER HAMMER, AND LEAKS.
38. The Unit Operator is to confirm that there is an established flow of steam out of the HP steam
separator drain to sludge pond.
39. Unit Operator to open the 2” by-pass valves around the H.P. Steam Separator outlet valves to
begin warming steam header up to the low point pump out.
40. Ensure vac truck or containment is set up to hold condensate.
Continue this step until the header has been warmed up right out to the boundary block valve at the
well pad.
33
41. Start opening the first block valve at the H.P. Steam Separator outlet as wellpad is ready to
accept steam, refer to SSOP for wellpad start-up.
42. Control Room Operator can slowly start pinching in on 05-PV-3509 (SG-531B Steam Outlet
Pressure Controller) to maintain a pressure drop of less than 5000kpa across the pass flow valves.
43. Warm-up system as per engineered warm-up rate.
44. The Control Room Operator can increase 05-PV-3500 (SG-531B Steam Gen BFW Inlet Control
Valve) set point in 500kPa increments up to 11200kpa. ALLOW TIME IN BETWEEN EACH ADJUSTMENT
FOR THE CONTOL VALVES TO SETTLE OUT. The BFW Inlet must be above the header pressure 9653kPa
45. Drain Riser Downstream of MOV 05-XV-3502 (SG-531B Steam Gen Outlet Valve) through 1”
drain.
CAUTION: WHEN OPENING MOV 05-XV-3502 (SG-531B STEAM GEN OUTLET VALVE) YOU MUST ENSURE NOT TO OPEN THE MOV TO
FAST. ALLOW TIME FOR THE DIFFERENTIAL PRESSURE TO EQUALIZE ACROSS THE VALVE. FAILURE TO DO SO WILL RESULT IN A
STEAM GENERATOR TRIP.
46. Open bypass around steam outlet MOV XV-3502 to equalize pressure.
47. Control room can then open the steam outlet MOV XV-3502.
CAUTION: UNIT OPERATOR TO BE AWARE OF THERMAL EXPANSION, WATER HAMMER, AND LEAKS.
48. Control Room Operator can slowly start pinching in on 05-PV-3509 (SG-531B Steam Outlet
Pressure Controller) until Steam Generator Back end pressure transmitter 05-PIT-3509 is at a greater
pressure than the Steam Header Pressure.
49. Once the Steam Generator SG-531B is in the Header, the Control Room Operator can put 05-PV-
3509 (SG-531B Steam Outlet Pressure Controller) on Manual at 0%.
50. The Control Room Operator can put 05-PV-3509 (SG-531B Steam Outlet Pressure Controller) on
AUTO with a setpoint of 10200kPa.
34
2.4: BMS (Burner Management System)
Honeywell’s Burner Management System (BMS) is a safety system for oil and gas companies that
enables the safe start-up, operation, and shut down of the multiple-burner furnace section of a boiler.
The solution increases personnel safety and improves furnace protection with its sequencing and
interlocking control design. BMS is an integral part of the Experion Process Knowledge System (PKS)
offering a single source operator interface. The system can expand to include the engineering, controller,
and “burner front” products and services that, when combined, form a superior BMS solution. The BMS
system is designed to safely perform the functions of:
• Automatically placing burners and igniters in service,

• Monitoring flame conditions, and
• Removing burners and igniters from service.
The BMS communicates to the DCS via the Control Net directly to the Safety Control Module (SCM) SCM-
0501 located in MCC 500. The information is displayed on the Operator Workstation for visualization and
control. Each Steam Generator has its own BMS. Any Signals which have control functionality are
communicated via hardwire between the Plant Control System and the BMS.
The DCS is essentially responsible for combustion control and the BMS looks at the High and Low limits.
The start up sequence for the Steam Generator is BMS controlled with input from the DCS but when the
Steam Generator is released from low fire to Modulate the DCS takes over the combustion control and
the BMS watches for the High and Low Limits.
Signals which are for indication only are communicated via ControlNet communications protocol (soft
link) from the BMS to the Plant Control System graphical interface, the operator can view most
information that is displayed locally on the BMS panel at each Steam Generator. Sensors that are
duplicated between the two systems will not be shown twice on the same operating graphic. Instead,
the operator can view any redundant BMS information from the BMS status screen.
Since the local BMS panel has alarming capability, the individual alarm annunciation with
acknowledgement is not duplicated in the control room. Instead, there are two alarm types which will
annunciate in the control room whenever there is any BMS alarm locally. One alarm will annunciate a
common "Alarm Only" alarm. After receiving the common alarm, the operator will need to navigate to
the steam generator graphic BMS alarm and observe, from a list of alarms, which alarm is active.
The second alarm to annunciate in the control room will be the "Shutdown" Alarm. The "Shutdown"
Alarm will be the First Out trip as determined by the BMS local control system. The control room alarm
system will specifically describe the First Out condition. Subsequent shutdowns or alarms will NOT be
annunciated in the plant control system.
There is an external watchdog which independently monitors the heath of the programmable controller
processor. Failure mode(s) addressed by the feature include:
- Failure of the internal processor clock.

- A memory failure in the processer.
- The processor looses communication with I/O modules.
35
- The processor ceases to execute the program.
In the BMS system, all pressure, flow and temperature permissive are made with transmitters with 4-
20mA signals to analog input modules for the PLC.
The following table shows the minimum and maximum values (in engineering unit) for the transmitter
ranges that have been set for each unit input signal to the PLC.
Min. Max.
No. Tag Input Parameter Value Value Unit
(4mA) (20mA)
1 FIT-3001 Feedwater Flow, Pass 1 0 27.3 Sm3/hr
7 Steam quality (from DCS) 0 100 %
8 PIT-3011 Steam Header Pressure (High) 0 20000 kPag
9 FIT-3016 Purge Air Flow (Low) 0 135850 Sm3/hr
10 PDIT-3023 FD Fan Differential Pressure (Low) 0 6.25 kPag
11 PIT-3003 Radiant Chamber Pressure (High) 0 6.25 kPag
12 PIT-3015 Instrument Air Pressure (Low) 0 1000 kPag
13 PIT-3062 Gas Pressure (High, downstream) 0 1000 kPag
14 PIT-3060 Gas Pressure (Low, upstream) 0 1000 kPag
15 PIT-3063 Inner Spuds Pressure (Differential) 0 200 kPag
16 PIT-3064 Outer Spuds Pressure (Differential) 0 200 kPag
o
17 TIT-3030 Steam Temperature, Pass 1 0 500 C
o
o
o
o
o
o
23 TIT-3041 Stack Temperature (High) 0 400 C
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The next table shows the setpoint & alarm process values (in engineering units) that have been entered
in the PLC.
No. System Parameter Value Unit

1 Feedwater Flow Low Trip Threshold 6.3 Sm3/hr
2 Feedwater Flow Deviation High Alarm Threshold *See Note 4 %
3 Feedwater Flow Deviation Low Alarm Threshold * See Note -2 %
4 Feedwater Flow Deviation Low Trip Threshold *See Note -4 %
5 Steam Header Pressure High Trip Threshold 10150 kPag
6 Minimum Purge Air Flow 101888 Sm3/hr
7 FD Fan Differential Pressure Low Trip Threshold 1.562 kPag
8 Radiant Chamber Pressure High Trip Threshold 2.5 kPag
9 Instrument Air Pressure Low Trip Threshold 520 kPag
10 Main Gas Pressure High Trip Threshold 275 kPag
11 Main Gas Pressure Low Trip Threshold 140 kPag
12 Steam Temperature High Trip Threshold Saturation + 5 oC o
C
13 Steam Temperature High Alarm Threshold Saturation + 2 oC o
C
o
14 Stack Temperature High Trip Threshold 315 C
o
15 Stack Temperature High Alarm Threshold 235 C
16 Spuds Differential Pressure High Trip Threshold 50 %
17 Spuds Differential Pressure High Alarm Threshold 40 %
18 Inner Spuds Pressure High Trip Threshold 125 kPag
19 Outer Spuds Pressure High Trip Threshold 125 kPag
*Note
The formula to calculate the Feedwater pass deviation shutdown and alarm condition is:
Threshold x [ 1 + ( 80 - Q ) / 30 ]
Where Q is the steam quality percentage sent by the DCS. The quality input from the
DCS was changed from the original design after the Steam Quality transmitters froze in
the winter of 2008. The quality percentage is sent from the "Target Ramped" PV Tag#
05-AIX-3102/3602/4102/4602 for A/B/C/D Steam Generators respectfully.
BFW lnlet Flow Limiters
There are three BFW inlet flow limiters acting on the system at all times. The first limiter is a constant
based on the overall design of the system which must never be exceeded in all conditions. The second is
a pass flow limiter which ensures the individual pass flows are maintained within an acceptable range
that also acts as a backup to the first limiter. The third BFW limiter is an erosion velocity-energy limit
based on current quality and discharge pressure measurements. The operator will not be allowed to
enter a flow setpoint which would exceed any of the above limits. The lowest of the three limits and the
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operator entered setpoint will be the controlling flow setpoint. These limiters apply in both the pressure
control case and the flow control case.
BFW Inlet Control Valve Velocity Limiter
Since there are two loops acting on the BFW inlet valve there is a velocity limiter, or output ramp, which
occurs downstream of the two feedback controllers. The velocity limiter (part of 05-FN-3000) ensures
smooth transitions when switching between flow and pressure control as well as when there is a
dramatic setpoint change to either controller.
Note: If the valve final element control is put into Manual and the valve position is directly controlled by
the operator, then the velocity limiter is disabled. In this case, it is up to the operator to ensure safe
valve movement is maintained. Large manual valve movements will cause flow imbalances between the
individual flow passes, and can cause the steam generator to trip on flow deviation. The velocity limiter
initial rate is set to 100% per minute, which means the full stroke of the valve will not occur faster than
one minute. The ramp rate will be adjusted during commissioning as required.
BFW Inlet Pass Flow Control
The BFW inlet flow is designed to be equally distributed to each of the six flow passes. The pass flow
balancing is accomplished with individual closed loop feedback flow controllers on each of the passes.
The setpoint for each of the flow controllers is one-sixth of the total flow as determined by the totalized
flow 05-FN-3007. Since each flow valve is meant to simply flow balance and not flow control the entire
BFW inlet, the valves are clamped to a minimum position. The minimum position to be clamped at will
ultimately be determined during commissioning, however the initial range of the valve will be 40 -100%
open.
Pass flow Controller Bias
Each pass will have its own steam quality calculated at the discharge. Based on the online steam quality
value and manual sampling, the operator can adjust a bias on any of the flow pass controllers from the
flow controller faceplate. This purpose of modifying the bias will be to increase or decrease steam quality
on an individual pass. The bias will directly affect the setpoint of the individual closed loop pass flow
controller. The bias values will be initially set to zero.
Pass Flow Deviation
Redundant, individual pass flow measurement is intended to be used for shutting down the steam
generator as part of the BFW pass flow deviation algorithm as discussed in the Burner Management
System. In the event that one pass has a flow rate that is too high, or too low, relative to the other
passes, the BMS will shut down the steam generator.
Online Steam Quality Measurement
Flow nozzles in the discharge piping can be used to monitor the steam quality online. The calculations
for steam quality require:
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- The inlet flow meters (per pass),
- The outlet differential pressures (per pass),
- The steam discharge header pressure and,
- The steam discharge temperature
Since all of the above instrumentation is wired to the Process Control System (PCS), the PCS calculates
the steam quality for each pass. The combustion control does not use the online steam quality
calculation; however the result of the steam quality calculation will be displayed for the operator (05-
AIX-3102). The equations for calculating steam quality are not reproduced in this document, they are
provided by the vendor for programming directly into the control system. Maintenance personnel can
refer to the program's online documentation for the equations should they need to be referenced or the
vendor documentation.
There will be two means of adjusting or tuning the online steam quality calculation:
1. The discharge flow meter coefficient [Kd], which is based on the discharge flow meters and is
provided by the vendor.
2. The linear multiplier factor [Cfj.
Both tuning factors must be adjusted by qualified personnel within the Plant Control System
programming environment. Tuning will be done during operation, at a steady state, using manual quality
sampling The Online Steam Quality Measurement is not meant to replace manual sampling. The online
steam quality measurement can drift with time, and may need to be re-tuned at different operating
conditions (i.e. at turndown) if it has been determined through manual sampling that the steam quality
is outside of acceptable parameters, then it is up to the operator to take corrective action.
39
DCS graphic of the BMS limits
40
2.5: Start-Up Permissive
In order for the start-up of the Once through Steam Generators certain parameters or permissives need
to be met.
Steam Generator Parameters for Start-up
41
2.6: Steam Sample Collectors
A steam quality sample is required to verify or calibrate the DCS Steam Quality readings for individual
OTSG steam flow passes and/or determine whether adjustments are required to DCS Steam Quality
Targets. Steam Qualities are normally done once per shift or as required for trouble shooting or
calibration.
An outlet sample can be drawn from each pass to monitor the quality of the steam. The sample will
consist of the water phase of the discharge steam collected from the sample separator. The samples are
routed through a glycol cooled, sample cooler (E-532 A1 to A6). The concentration of total dissolved
solids (TDS) in the sample is measured and compared to the TDS measurement of the BFW. Steam
quality can then be calculated from the ratio of the TDS concentrations.
Steam Collector
The steam enters the inlet to the collector and contacts an inner pipe which helps promote coalescing of
the steam condensate. The steam passes through the holes in the two baffle plates and provides
pressure for the condensate to flow to the sample cooler. Condensate collects on the bottom of the
Sample Collector and flows through the larger opening at the bottom of the baffles.
42
43
1) Diagram representing a Steam Quality Train
If you open the Sample Valve for too long and steam starts to blow out, the Sample Separator may
empty. This could plug the bottom hole with debris. This may also plug the Sample Outlet Valve due to
the pressure drop and steam flashing leaving TDS deposits on the valve seat.
Periodic blow downs (at least once per week) of the sample collectors are required to prevent organics
and debris from plugging the holes in the sample collectors. Plugging of the sample collector will result
in erroneous reading of the steam quality. In extreme cases the Sample Collector will require
replacement due to prolonged service without blowing down of the sample collector. Note: blowing
down of the sample lines must be done by a trained and competent operator.
Sample Collector Baffles Plugged
Glycol cooled, sample cooler (E-532 A1 to A6).Dual Tube Coil Sample Cooler.
44
The concentration of total dissolved solid (TDS) in the sample is measured and compared to the TDS
measurement of the BFW. Steam quality can then be calculated from the ratio of the TDS
concentrations.
Instructions for testing conductivity with Ultrameter 6P II Portable Water Quality Meter
1. Confirm that there is a good flow of sample from the coolers you will be drawing samples from, with
no flashing taking place.
2. Rinse the conductivity cell 3 times with the sample to be tested.
3. Refill the conductivity cell with the sample to be tested.
4. Press the COND Key and the conductivity units will appear on the right side of the display screen in µs
(micro Siemens/cm). The value will continue to change rapidly at first then will eventually stabilize.
5. Write down this value.
5.2.1 Test and record a sample of Boiler Feed Water from the BFW Sample Cooler using the above
instructions
5.2.2 Use the following formula to determine the quality of each pass sample tested.
5.2.3 Record the results in the Steam Quality Log Sheet and report the results to the Control Room
Operator.
5.2.4 Rinse the Ultrameter II 6P conductivity cell out with de-ionized or clean water.
Note: Blowing down of the sample line, cooler and collector is important for a proper representative
sample. This should be done with proper PPE and all other necessary precautions to protect yourself
and others in the area. The sample lines should be checked periodically for flow to prevent plugging of
the system. The duration of the blow down should be sufficient to remove any possible sedimentation
from the system.
45
Chapter 3: Auxiliary Equipment (Centrifugal pump)
3.0: Low Pressure Feedwater pumps
P-510 A/B/C
The Low Pressure boiler feedwater pumps used in Surmont 1 operations are centrifugal pumps.
Centrifugal pumps basically consist of a stationary pump casing and an impeller mounted on a rotating
shaft. The pump casing provides a pressure boundary for the pump and contains channels to properly
direct the suction and discharge flow.
The pump casing has suction and discharge penetrations for the main flow path of the pump and
normally has small drain and vent fittings to remove gases trapped in the pump casing or to drain the
pump casing for maintenance.
Most centrifugal pumps are not self-priming. In other words, the pump casing must be filled with liquid
before the pump is started, or the pump will not be able to function. If the pump casing becomes filled
with vapors or gases, the pump impeller becomes gas-bound and incapable of pumping. To ensure that
a centrifugal pump remains primed and does not become gas-bound, most centrifugal pumps are located
below the level of the source from which the pump is to take its suction. The same effect can be gained
by supplying liquid to the pump suction under pressure supplied by another pump placed in the suction
line.
At Surmont Phase 1 we current have 2 LP BFW Pumps and space for a 3rd (which is stored vertically in
place in the Water Treatment BU-400). They are Vertical 4 Stage Turbine Pumps with Thrust Pot
(Thrust Bearing).
46
47
48
49
50
51
52
53
54
55
56
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3.0.1 LP BFW specifications
Specifications for P-510 A/B:
CAPACITY: NORMAL (m3/hr) 307 RATED (m3/hr) 337
SUCTION PRESSURE MAX / RATED (kPag) 103
DISCHARGE PRESSURE (kPag) 3,345
DIFFERENTIAL PRESSURE (kPa) 3,345
DIFFERENTIAL HEAD (m) 351* NPSHA (m) 4.92 at suct. C.L.
PROCESS VARIATIONS 12.6 at 1st stage impeller
PUMPING TEMPERATURE NORMAL (°C) 80 MAX (°C) 90 MIN (°C) 4
3.0.2 LP BFW Theory of Operation
The LP boiler feedwater pumps provide the necessary flow and pressure to charge the High pressure
boiler feedwater pumps with enough suction pressure to start. The low pressure pumps also provide the
required pressure to flow through the boiler feedwater heaters. Both low pressure pumps will need to
be started before a second high pressure BFW is started.
Simple process flow of Feedwater
LP BFW PUMP
BFW Tank HP BFW PUMP
Heat Exchangers
58
Start-Up procedure SSOP
1. Field operator: confirm valve line up of the pump: 4” block valve on the minimum flow line
downstream 05-FV-1030, Glycol supply and return lines on the pump seal coolers and10’’ suction
block valve are all in the open position. 8’’ Discharge Block valve should only be opened slightly off
the valve seat.
2. Field operator: Prime pump through ¾” drain on the pump discharge.
3. Field operator: Prime seal coolers through ¾’’ vents.
4. Field operator: Ensure pump motor breaker is energized.
5. Field operator: Notify control room pump is ready to start.
6. Control room operator: open 05-FV-1030 to 150 m3/hr for minimum flow.
Low Low alarm is set at 120m3/hr.
7. Control room operator: Start Pump. (Note: pump can be only started remotely.)
8. Field operator: listen for any abnormal sounds.
9. Field operator: Slowly open 8“discharge block valve.
Place P-510A Pump Online
10. Panel operators to ensure all alarms are enabled on DCS.
11. Visually inspect P-510A pump to ensure normal operation.
12. Ensure all car seals are in place and recorded.
This procedure is complete when:

• P-510A/B LP Boiler Feed Water Pumps Isolation Checklist is signed off.
• The selected online pump is started and operating normally.
• Area is safe, clean and tidy.
Shutdown procedure SSOP
1. Field operator: notify control room which pump is to be taken out of service.
2. Control room operator: make necessary adjustments on the DCS to allow the pump to be taken
out of service. I.e.) Reduce rates on a steam generator or reduce load on a H.P BFW pump. One LP
BFW pump will not supply enough flow for both HP BFW pumps. The minimum flow valve 05- FIC-1030
should be positioned to ensure that the minimum flow is maintained following one LP pump being
shut down.
3. Panel operator to stop P-510A pumps using hand switch 05-HS-1035.
4. Field operator: close 8” discharge block valve after pump is shutdown.

• P-510A/B LP Boiler Feed Water Pumps Isolation Checklist is signed off.
• The selected pump for shutdown is stopped.
• Area is safe, clean and tidy.
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3.1: High Pressure Feedwater pumps
The high pressure boiler feedwater pumps are designed to flow feedwater to the Steam Generators to
produce steam. The water flows at a high pressure and temperature (12,000 kPa/170°C).
3.1.1: HP BFW specifications
CAPACITY: NORMAL (m3/hr) 338 RATED (m3/hr) 372

SUCTION PRESSURE MAX / RATED (kPag) 4,064 / 2,625
DISCHARGE PRESSURE (kPag) 13,580
DIFFERENTIAL PRESSURE (kPa) 10,955
PUMPING TEMPERATURE:
NORMAL (°C) 185 MAX (°C) 205 MIN (°C) 4
Model: DMXD
Size: 6X11 DMXH 8 Stage Pump
The 6 is the pump discharge size
The X is the separator
The 11 is the nominal impeller size
The DMXH is the pump type (Single Suction, High Pressure)
The 8 is the number of stages (depending on size they can go from 2 to 14 stages)
The DMX is a multistage Single or double suction, opposed impeller, horizontally split volute pump. At
Surmont the pump is single suction.
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Design of Major Parts
Casing
The casing provides for immediate containment of the liquid being pumped, while directing the flow of
liquid from the suction nozzle to the impellers and subsequently through the volute to the discharge
nozzle. The casing halves are sealed by the use of a gasket and are joined together by stids, which are
installed in the lower half casing and fastened with washers and cap-nuts.
Impellers
The impellers are single suction, enclosed type, and one-piece construction and are dynamically
balanced. They are fitted with renewable impeller rings (front and back), which are held in place by
headless set screws.
The impellers are keyed and have a shrink fit to the pump shaft. They are held in axial position by a
split ring.
Casing Rings
Casing rings are positioned over the impeller front rings. These rings are tubular and renewable.
Channel Rings
Renewable cast channel rings are positioned over the impeller back rings. They divide the casing into
stages, These rings are horizontally split and are held together by shoulder screws.
Center Sleeve
A renewable type center sleeve is used under the center bushing. The center sleeve is tubular and
keyed to the shaft via the impeller key.
Center Bushing
The renewable center bushing is horizontally split, the two halves are held together by socket head cap
screws and taper dowel pins. It is held in position by the rasied annular ring of the bushing engaging
the annular groove in the casing. The center bushing divides the casing at the center (back to back)
impellers.
Throttling Sleeve
Renewable type throttling sleeve is used under the throttling bushing. The throttling sleeve is tubular,
keyed, has a shrink fit to the shaft, and is held in position by a split ring.
Throttling Bushing
Renewable type throttling bushing is used. It is held in position by the raised annular ring of the
bushing engaging the annular groove in the casing. The throttling bushing, in conjunction with the
throttling sleeve, allows pressure to be bled off through the balance line, so that pressure on the Seal
Chamber is balanced. The throttling bushing also balances the axial thrust of the pump rotor.
Shaft
The high strength shaft is ground over its entire length to close tolerances. The shaft is designed to
transmit the required power without vibration and is stepped at each impeller fit for ease of assembly
and disassembly.
Seal Chambers
The Seal Chambers are cast integral with the casing. Your pump is typically shipped with the mechanical
seal already installed.
The mechanical seal is designed to suit each application. This creates the correct seal loading face when
seal gland is bolted in place.
Cartridge type mechanical seals are preset at the seal manufacture's facility and require no field settings.
The seal installation should be checked before startup.
Bearing Sleeves
61
The bearings are carbon steel backed, Babbitt lined, sleeve-type insert bearing. The bearing inserts are
mounted in the bearing housings and kept from rotating by means of stop pins. The bearing inserts are
renewable.
Thrust Bearing
The Kingsbury thrust bearing is of the equalizing type, having six thrust shoes on each side of the thrust
collar, and is consequently capable of transmitting the thrust load in either direction. The thrust is
transmitted through the thrust collar to the shoes, by the shoes to the shoe supporting elements, and
then to the bearing housing and the foundation.
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AC Motor
The H.P. BFW Motor is a Reliance Electric B-3651. It is suitable for Class1, Group D, Class 11, Group F &
G, Division 2 application.
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Historical Information Timeline
During startup there were numerous issues with the operation of these pumps. This is a timeline that
was built from an RCA detailing the fauilures.
The seal cooling system was suspected in being inadequate as well as our operating procedures. Seal
construction materials have been changed from the original design as well. Instrumentation around the
seal system has been added to properly measure the seal cooling efficiency.
67
3.1.2: HP BFW Theory of Operation
Start up procedure
P-520A/B HP Boiler Feed Water Pumps Pre-Fill Steps

1. Unit Operator to NOTIFY Control Room Operator of your intention to fill the HP BFW Pump.
2. Control Room Operator is to ensure that Lube Oil System is running.
3. Unit Operator to check bulls eyes, pressure gauges, and temperature gauges on the lube oil
system.
4. Control Room Operator to ensure that one of the LP BFW Pumps is running and re-circulating
back to the T-501 BFW Tank.
5. Control Room Operator is to ensure that LP BFW Header is pressurized by observing pressure on
05-PI-1200/1250. Unit operator is to observe this pressure at local gauge. REFER to LP BFW SSOP
for Pressurizing Header.
Priming P-520A/B into an empty header.
6. Slowly crack open the 10” suction chain valve.
WARNING: AFTER SLOWLY CRACKING THE 10’ VALVE ALLOW SUFFICIENT TIME FOR THE PRESSURE TO EQUALIZE ACROSS THE
VALVE.
7. After the pressure is equalized across the 10” valve – fully open suction valve.
CAUTION: THE VENT FOR THE HP BFW PUMP CASING DISCHARGES OUTSIDE OF BUILDING. THE SECOND UNIT OPERATOR
THEREFORE MUST BE OUTSIDE TO OBSERVE THAT ALL THE AIR HAS BEEN REMOVED FROM THE CASING.
8. Vent the pump by opening the 2” vent on the top of the casing. When sufficient air has been removed the
unit operator located outside can inform the unit operator to close the 2” vent.
9. Ensure the seal cooler is vented on the seal water side and the glycol cooler side to remove any entrained
air.
10. To vent the High Points on the discharge piping open the 1” valve upstream of FO-1203 then
open the 2” gate valve downstream of FO-1203 on the warm up line to the blow down header.
This is a discretionary step if starting the pumps after a large outage
11. Open the 6” chain valve downstream of the minimum flow valve FV-1200 or FV-1250 on Pump
B.
12. Control Room Operator is to crack open minimum flow recirculation valve FV-1200/1250. This is
to ensure proper operation
13. The HP BFW Pump P-520A is now air free and ready to be started.
Priming P-520A/B into a charged header.
14. To Prime P-520 A/B into a charged header refer to steps1 thru 11.
15. Open the 1” valve upstream of FO-1203 then open the 2” gate valve downstream of FO-
1203 on the warm up line to the blow down header to vent any trapped air in the discharge piping.
This may be a long time period as per vendor recommendations
16. When all air is expelled close the warm-up water line.
17. Open the 6” chain valve downstream of the minimum flow valve FV-1200 or FV-1250 on Pump
B.
18. Control Room Operator is to crack open minimum flow recirculation valve FV-1200/1250. This is
to ensure proper operation
19. Re-vent the casing prior to starting the pump.
68
20. Ensure warm-up line was open long enough to warm the pump casing and displace the
entire volume of the cold suction leg piping
21. The HP BFW Pump P-520A is now air free and ready to be started.
P-520A/B HP Boiler Feed Water Pumps Pre-Start Checks.
22. Control Room Operator is to ensure that one LP BFW Pump is running. The number of LP BFW
Pumps running must match or exceed the number of HP BFW Pumps.
23. Control Room Operator will observe the HP BFW Pump suction pressure 05-PI- 1200/1250.
When the pressure is above the minimum suction pressure for the HP BFW Pump of 2400kPa the
Control Room Operator will be able to initiate a start.
24. Control Room Operator will place P-520 HP BFW Pump Minimum Flow Valve 05-FV-1200 /
1250 into Auto with a set point of 255 M3/hr for pump A and 270 M3/hr for pump B (current
settings). Keep B flow above A to reduce fluid harmonics issue.
25. Control Room Operator will place P-522A/B HP BFW Pump Aux Lube Oil pump into “Auto” (If
not started in hand, ensure it starts when the start pulse is given). Starting P-520A/B HP Boiler Feed
Water Pumps.
26. Control Room Operator initiates a start by selecting start on the “Pump Control” drop down
menu.
27. The DCS will automatically start the Auxiliary Lube Oil Pump.
28. The DCS will automatically close the P-520 HP BFW Pump Minimum Flow Valve 05-FV-1200 /
1250.
29. The DCS will issue a start command to the HP BFW Pump motor starter when the following
conditions are met:
• The lube oil pressure 05-PI-1231 is above set point 80kPa
• The P-520 HP BFW Pump Discharge Valve 05-XV-1200 / 1250 is closed
• The P-520 HP BFW Pump Minimum Flow Valve 05-FV-1200 / 1250 are
closed.
• The pump casing / header differential temperature of <15°C is met. If
the above conditions are not met, the HP BFW Pump start sequence will be aborted after
a 20 second period.
30. The DCS will stop the Auxiliary Lube Oil Pump after the “RUN STATUS” is received from the HP
BFW Pump Motor Starter.
31. Open the 2 valves on the 1 inch equalization line around 05-XV- 1200/1250. This will pressure
up P-520 A/B to operating pressure.
32. Communicate to the Control Room that you are ready to open the discharge MOV.
33. Open the MOV in manual slowly over a recommended minimum of 15 minutes in stages of
5%. Have the control room monitor the water flow to the steam generators. If needed, stop opening
the MOV to allow the inlet flows to stabilize on the steam generators.
34. Open the MOV all the way. The HP pump is now in service.
35. Close the MOV equalization valves and the pump warm up lines.
36. Ensure all the vent/bleed and drain valve plugs are installed.
Visually inspect P 520A pump to ensure normal operation.

• P 520 A/B HP Boiler Feed Water Pumps Isolation Checklist is signed off.
• The selected online pump is started and operating normally.
69
• Area is clean and all tools and equipment have been returned to their proper storage areas.
3.1.3: Lube oil skid
The purpose of the lube oil skid to keep the pump and motor bearings lubricated with oil while the pump
is shutdown. Once the main pump has been energized and is pumping feedwater, the lube oil skid can
be shutdown. ***Refer to High Pressure Boiler feedwater start-up procedure for
more details***
3.1.4 GE Bentley Nevada Continuous Vibration/Temperature Monitoring System.
The Bentley Nevada 3500 Series Machinery Protection System is used for our Asset Condition Monitoring
on the 05-P-520 A/B High Pressure Boiler Feedwater Pumps. The Bentley Nevada 3500 continuously
monitors Temperature, Vibration, Axial and Radial movement or position. In addition to providing
shutdown due to operating conditions outside of normal operating parameters it provides continuous
monitoring and alarms that can help anticipate mechanical failures.
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Vibration is measure mils Peak to Peak
Vibration Alarms
Radial Hi Hi Alarm -4 to +4.
Radial Hi alarm -3 to +3.
Axial Alarms
Axial Hi Hi Alarm -18 to +18.
Axial Hi Alarm -15 to +15.
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3.2: Associated Heat Exchangers
A heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another.
The media may be separated by a solid wall, so that they never mix, or they may be in direct contact.
The main purpose of the heat exchangers associated with the steam generators is to increase the boiler
feedwater temperature to 175°C (Or as hot as possible). The hotter the feedwater, the more efficient
the steam generators will operate at. Achieving an optimal feedwater temperature is one of the top
priorities at the Surmont facility.
The E-541 is steam condensate/Feedwater shell and tube exchanger. The dual purpose of this
exchanger is: increase feedwater temperature and lower the temperature of the steam condensate
entering the feedwater tank. The exchanger was only designed to accommodate a partial flow of
feedwater (max 214m3/hr).
Specifications
Shell Side (MP Steam Condensate)

Total Fluid rate 44, 563 kg/hr
Temperature in 187°C
Temperature out 90°C
Inlet Pressure 1570 kPa
Tube Side (Boiler Feed Water)

Total Fluid rate 214, 107 kg/hr
Temperature in 79.3°C
Heat Exchanged 18.56 GJ/hr Gross Surface area 146.42 m2
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3.2.2: E-221/211 (Description/Specs)
The E-221/211 is Oil Emulsion/Feedwater shell and tube exchanger. The dual purpose of this exchanger
is: increase feedwater temperature and lower the temperature of the oil emulsion entering the Free
Water Knockout.
Specifications
Shell Side (Oil Emulsion)

Total Fluid rate 319,200 kg/hr (flows are per train)

Total Fluid rate 97,350 kg/hr (flows are per train)
The E-271 is Produced Vapors/Feedwater shell and tube exchanger. The dual purpose of this exchanger
is: increase feedwater temperature and lower the temperature of the produced vapors. This exchanger
was originally designed to handle a majority of the feedwater flow to heat up.
Specifications

Total Fluid rate 91,517 kg/hr

Temperature out 153.8°C
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The E-551 is MP Steam/Feedwater shell and tube exchanger. The dual purpose of this exchanger is:
increase feedwater temperature and lower the temperature and condense the MP steam.
Specifications


Temperature out 183.5°C
The E-552 is Glycol/ MP Steam (Condensate) shell and tube exchanger. The only purpose of this
exchanger is to provide a trim cooling effect on the MP Steam. A majority of the time this exchanger is
not in use. It is utilized only when the out condensate temperature of E-551 is hotter that the desired
setpoint.
Specifications
Shell Side (Glycol)

Tube Side (MP Steam/Condensate)

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The E-502 is Glycol/ MP Blowdown Condensate shell and tube exchanger. The purpose of this
exchanger is to provide cooling on the MP Blowdown condensate. The hot Blowdown flows from V-501
to E-502 then to the disposal system, the WLS or the disposal header. Whatever route (disposal, WLS or
Disposal) the maximum temperature the Blowdown can reach is 80°C.
Specifications
Shell Side (Glycol)

Tube Side (MP Steam/Condensate)

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3.3: Steam Separators (V-502)
A Steam separator, sometimes referred to as a moisture separator, is a device for separating water
droplets from steam.
Steam
Wet Steam
Blowdown
Steam flows from the Generators (SG-531A, B, and C, D) to the steam separators V-502A/B. The steam
leaving the generators isn’t 100% dry steam; it’s actually around 75% steam quality. The excess water
in the steam is dropped out in the steam separators and the steam is sent to the wells for injection.
The excess water or Blowdown is disposed of down hole or recycled back to the WLS (Warm Lime
Softener) inlet.
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3.4: MP Blowdown Flash Drum (V-501)
Condensate is carried out from V-502 steam system. Condensate is supplied to medium pressure Flash
drum operated at 1100 kPa. Steam will be generated because the flash drum operates at a much lower
pressure than the steam separators. Pressure due to flashing is supplied to a steam header to provide
steam energy to various users.
Medium Pressure Steam
Blowdown
Blowdown
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3.5: FD Fan, Motor, Wind Box and Burner
Combustion Air and Fuel Inlet Controllers
The combustion air controller controls the amount of air entering the combustion chamber and the fuel
inlet controller controls the fuel gas in. Both controllers receive their setpoints from the combustion
control calculations as described in section 3.7.
Air/Fuel Controller Predefined Positions
The air and fuel controllers automatically switch to specific positions depending on the state of the steam
generator. For instance, during startup the air and fuel control valves are put to predetermined positions
for specific steps of the sequence. Each individual controller's predefined positions in the sequence are
described below. Offline - When the steam generator is not in start-up, and all post-purge timers have
timed out, both controllers will be put into an "Offline" state. For the combustion air controller this
means the inlet air louvers are fully closed and for the fuel controller this means both fuel gas valves are
fully closed.
Air Flow to Purge Position - As part of the startup sequence, the BMS sends a "Controls to Purge
Position" command to the Plant Control System, prior to light-off (Step 9 of the start-up sequence). At
this point, the forced draft fan is started and the combustion air controller is fixed to run at 100% open
and remain at this position until the purge cycle is complete. The fuel controller remains at fully closed.
Air and Fuel to Light Off Position - After the purge step is completed, the BMS sends a "Controls to
Light-Off Position" command to the Plant Control System (Step 10 of the start-up sequence). At this
point, the combustion air controller is set to a fixed position somewhere between fully open and fully
closed. The fuel controller is also put to a fixed position. There are limit switches located on both the
forced draft fan louver position and fuel valve positions to provide confirmation back to the BMS that the
controllers are in the correct position for light-off. The positions for light-off for each individual steam
generator will be determined as part of the commissioning procedure.
Air and Fuel to Modulating Control - Presuming that the main flame has been established in
accordance with the BMS sequence of operation, the next command to the Plant Control System is
"Controls — release to modulation" (Step 19 of the start¬up sequence). At this point, both the
combustion air controller and the fuel controller will be put into their fully automatic modes, which will
modulate based on the algorithm described in section 3.7.
Air Flow to Last Position - Following a shutdown, the BMS will send the "Hold air flow at last position"
signal to the Plant Control System. The combustion air controller will maintain its current valve position
as long as this signal is energized.
Air Flow to Post Purge Position - Following a time limit as described in the COEN startup manual, the
BMS will then de-energize the "Hold air flow at last position" signal and energize the "Controls to post-
purge position". The combustion air controller will run fully open until this signal is de-energized.The
combustion air controller controls the amount of air entering the combustion chamber and the fuel inlet
controller controls the fuel gas in. Both controllers receive their setpoints from the combustion control
calculations.
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The air and fuel controllers automatically switch to specific positions depending on the state of the steam
generator or its stage of start-up. For instance, during start-up the air and fuel control valves are put to
predetermined positions for specific steps of the sequence. Each individual controller's predefined
positions in the sequence are described below. Offline - when the steam generator is not in start-up,
and all post purge timers have timed out, both controllers will be put into an "Offline" State. For the
combustion air controller this means the inlet air louvers are fully closed and for the fuel controller this
means both fuel gas valves are fully closed.
Air Flow to Purge Position - as part of the start-up sequence, the BMS sends a "Control to Purge
Position" command to the DCS, prior to the light-off (step 9 of the start-up sequence). At this point, the
forced draft fan is started and the combustion air controller is fixed to run at 100% open and remain at
this position until the purge cycle is complete. The fuel controller remains at fully closed.
Air and Fuel to Light-Off Position - After the purge step is completed, the BMS sends a "Control to Light-
Off Position" command to the DCS system (Step 10 of the start-up sequence). At this point, the
combustion air controller is set to a fixed position somewhere between fully open and fully closes. The
fuel controller is also put to a fixed position. There are limit switches located an both the forced draft
fan louver position and fuel valve positions to provide confirmation back to the BMS that the controllers
are in the correct position for light-off. The positions for light-off for each individual steam generator will
be determined as part of the commissioning procedure.
Air and Fuel to Modulation Control - Presuming that the main flame has been established in accordance
with the BMS sequence of operation, the next command to the Plant Control System is "Controls -
release to modulation" (Step 19 of the start-up sequence). At this point, both the combustion air
controller and the fuel controller will be put into their fully automatic modes, which will modulate based
on the algorithm.
Air Flow to Last Position - Following a shutdown, the BMS will send the "Hold air flow at last position"
signal to the DCS. The combustion air controller will maintain its current vavle position as long as this
signal is energized.
Air Flow to Post Purge Position - Following a time limit as described in the COEN startup manual, the
BMS will then de-energize the "Hold air flow at last position" signal and energize the "Controls to post-
purge position". The combustion air controller will run fully open until this signal is de-energized.
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Chapter 4: Chemicals
4.0: Filming Amine
Filming amines are various chemicals that form a protective layer on the condensate piping to protect it
from both oxygen and acid attack. The filming amines should be continuously fed into the steam header
with an injection quill based on steam flow. The two most common filming amines are octadecylamine
(ODA) and ethoxylated soya amine (ESA). Combining neutralizing and filming amine is a successful
alternative to protect against both acid and oxygen attack.
Filming amines are long chain organic compounds which, when added to the steam line, volatilize with
the steam and then deposit in the form of a protective coating over metal surfaces that come in contact
with the steam and the condensate. They inhibit corrosion simply by imposing a waterproof barrier
between the metal and the condensate. Corrosive agents which may be present in the condensate
(dissolved oxygen and carbon dioxide, for example) are rendered ineffectual by the amine film that
keeps water from directly touching the metal.
No tests are necessary in the control of filming amine feed. Chemical dosage is adjusted based on the
steam load, so that the amount used is just sufficient to form and maintain a protective film of amine on
all the metal surfaces that are contacted by condensate. Although the effectiveness of the treatment can
be determined by corrosion test coupons (installed at suitable locations in the condensate system) the
best indication of effective results is obtained by the evidence of reduced maintenance and repairs to the
systems.
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Chapter 5: Boiler Feedwater
5.0: Boiler Feedwater Tank purpose
The purpose of the feedwater tank is to store soft water for the steam generators. The importance of
the feedwater tank is often underestimated. Most items of the plant are duplicated, but it is rare to have
two feed tanks and this crucial item is often the last to be considered in the design process.
At maximum steam rate, the feedwater tank at Surmont phase 1 will last about 7 hours (if the tank is at
full capacity).
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5.0.1: BFW Tank Specifications
Capacity (m3) 5,128 (32,280 bbl)
Design Temp. 93°C
Size (dia X ht) 21.13m X 14.64m
Chapter 6: Air Make-Up Units
6.0: Air Make-Up Unit description/purpose
Air Make Up Unit
An air handler, or air handling unit (often abbreviated to AHU), is a device used to condition and
circulate air as part of a heating, ventilating, and air-conditioning (HVAC) system. An air handler is
usually a large metal box containing a blower, heating or cooling elements filter racks or chambers,
sound attenuators, and dampers. Air handlers usually connect to ductwork that distributes the
conditioned air through the building and returns it to the AHU. Sometimes AHU’s discharge (supply) and
admit (return) air directly to and from the space served without ductwork.
The air drawn from inside the steam generator building and used for combustion must be replaced. Air
makeup units are equipped with blowers to move replacement air into the building from outside. Each air
makeup unit is equipped with a heater to ensure that the indoor temperature remains at about 20°C.
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These heaters were designed to heat ambient air from -39°C to +20°C. A typical midrange AMU duty of
9.36 GJ/h is required to heat 470,500 kg/h of air from 0°C to 20°C with the steam generators operating
at full capacity. The temperature is locally controlled to 20°C using heating glycol but are started from
the DCS. There are 4 air make-up units (AH-505 A/B/C/D).
Combustion air for the steam generators is drawn from inside the steam generator building. The air is
heated from about 20°C to 80°C. About 28.14 GJ/h of heat is required to warm 470,500 kg/h of air
when the steam generators are operating at full capacity.
Additional "Dog Run Heaters" have been installed in the steam Generator Building on the Water and
Steam side do to past freezing issues of our transmitters. They are gas fired heaters. Steam Operators
must ensure the dog run doors remain closed during the winters to prevent
The Steam Generator building utilizes natural ventilation for building cooling by using a 5 section ridge
vent and a series of floor level dampered louvers. Each ridge vent section is matched with selected
damper sections to provide localized cooling of specific areas of the building by 5 strategically located
thermostats.
Filters have to be installed during certain seasons to avoid debris flying into the unit. Filters and screens
are checked on a regular basis to ensure everything is functioning properly.
SPECIFICATIONS
REQUIRED AIR FLOW (kg / hr) _______________________ 124,500 (Each Unit)

AIR TEMPERATURE - IN / OUT (oC) ___________________ -39 / 20
STATIC PRESSURE (Pag) ___________________________ 351
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Chapter 7: CEMS (Continuous Emissions Monitoring System)
7.0: CEMS Purpose/History
A continuous emissions monitor is basically a flue gas analyzer designed for fixed use and to monitor
permanently. The Canadian government passed legislation requiring the measurement of several
different components in the flue gas.
The CEMS Legislation, or Code, was developed by members of the “CEMS Code Working Group” which
was coordinated by Alberta Environmental Protection (AEP). This Code establishes requirements for the
installation, operation, maintenance, and certification of continuous emission monitoring systems. These
requirements will ensure effective measurement, recording, and standardized reporting of specified
emissions and other parameters. In addition, the code establishes requirements for alternative
monitoring systems and for the quality assurance and quality control of continuous emission monitoring
data.
Each facility shall maintain raw data for a period of at least 3 years and summary data for a period of at
least 10 years. The media for storage of raw data shall be designated by the facility and documented in
the facility QAP (Quality Assurance Plan). Raw data shall be made available for inspection if requested by
Alberta Environmental Protection.
CEMS
RATA testing and purpose. CEMS environmental limits i.e. NOx, CO.
CEMS Limits
Value Limit Condition
This is the only CEMS Limit that is regulated. This
was raised from 7.1 kg/hr during commissioning
11.0
NOx and start-up due to an error in the ERCB
kh/hr(kg/hr)
assessment calculation. This was corrected the
limit we use today.
Note: Steam Operators are responsible to review the CEMS report, sign it and file it for regulator
purposes. CEM data is stored for 10 years. The CEMS and QAP (Quality Assurance Plan) must be
evaluated every 12 months.
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DCS Limits
CO This is a DCS initiated trip on a High High CO
2000 ppm
HH condition
CO H 1000 ppm Pre - Alarm for trip
O2 H 10% High Alarm
O2 L 1% Low Alarm
This is a DCS initiated trip on a Low Low O2
O2 LL 0.5%
condition
RATA (Relative Accuracy Test Audit) is performed to test the validity of facility emission data. It
compares data from the CEMS System to an independent reference method data. The data is compared
over the same time period multiple times to completely evaluate the CEM System Performance
Typical parameters monitored for CEM RATA test programs are:
Oxygen (O2)
Carbon Dioxide (CO2)
Carbon Monoxide (CO)
Oxides of Nitrogen (NOX)
Sulphur dioxide (SO2)
Stack Gas Velocity
Stack Gas Volumetric Flow Rate
Stack Gas Temperature
Stack Gas Pressure
The Continuous Emissions Monitoring System (CEMS) is on Steam Generator “A” exhaust stack only.
The CEMS will continuously measure and record the Oxides of Nitrogen (NOx) emissions, stack
volumetric flow rate and flue gas temperature. The measured emissions from the Steam Generator “A”
exhaust Stack will be used along with the fuel gas measurement to calculate the emissions from the
other three steam generator exhaust stacks which use the same fuel gas. The proposed CEMS meets the
monitoring requirements of Surmont Phase 1 – Alberta Environmental Protection and Enhancement Act
(EPEA) Approval No. 48263-00-01.
1.1.1 Pollution Control Equipment
The NOx emissions will be minimized by the design of the burner and monitoring of the combustion
temperature under normal operation. The burners are a “Low NOx” design by COEN and the NOx
reduction technique is staged combustion.
Factors that may affect the Operation of the Monitoring System

The CEMS will be installed on the exhaust stack of the Steam Generator “A”. The monitoring system has
been designed to minimize or eliminate interferences from normal process operations. Factors that may
affect the operation of the monitoring system are therefore related to unexpected failures and not
related to design issues. These factors include:
• loss of utilities (i.e., power, instrument air, etc.) to the CEM system;
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• severe weather that would not allow for safe performance of preventative maintenance or repair
activities of stack mounted sample acquisition equipment;
• catastrophic failure of any of the CEMS related components; and
• fouling of the sample handling system (including the probe, filter element, etc.).
ID
1.67 m
5'-6"
Top of Stack
2.92 m
9' - 7"
3.23 m
10 '- 7"
CEMS Probe Elevation
0.3 m
1' - 0"
11.46 m
37' - 7"
Reference Method Ports Elevation
8.23 m
27' - 0"
Last Disturbance Elevation

27.0 m
88' - 7"
Schematic Only
Not to Scale
15.54 m
51' - 0"
Steam Generator "A"
Pollutants and Parameters to be Monitored

The gas that will be monitored is NOx concentration of the flue gas. Stack gas temperature and
differential pressure (sensed by a K-Type Thermocouple and S-type pitot tubes) at the CEMS port
location will be measured and used to calculate the volumetric flow in the stack. The NOx concentration
will be recorded as Nitrogen Dioxide (NO2) in units of parts per million (ppm) by volume (v) on a wet
basis. Stack volumetric effluent flow rate will be determined on a wet basis and corrected to volume at
standard conditions of 25°C and 760 millimeters of mercury pressure (mm Hg). The volumetric flow rate
will be reported in units of thousand standard cubic metres per hour (e3m3/h). Stack flue gas
temperature at the CEMS port elevation will be recorded in units of degrees centigrade (°C). Differential
pressure generated by the pitot tubes will be recorded in units of millimeters (mm) of water column.
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Mass emission rate of NOx will be calculated from the measured concentration and flow parameters.
The mass emission rate will be recorded in units of kilograms per hour (kg/hr) of NO2.
Sample Conditioning
The CEMS utilizes extractive dilution sample conditioning technology to draw a sample from the stack
and prepare it for analysis of the Nitric Oxide (NO) and NO2 content. The sample will be extracted from
the stack through a stainless steel probe. The extracted sample will pass through a particulate filter and
will then be diluted with clean, dry, conditioned instrument air at a dilution ratio of approximately 100:1
to reduce the sample dew point to less than 0°C. The dilution ratio is precisely controlled using a critical
sampling orifice operated at sonic velocity. The particulate filter and dilution module are located in a
heated and temperature controlled enclosure mounted to the CEMS sampling port on the stack. The
temperature of this enclosure is operated above the dew point temperature of the non diluted stack gas
preventing condensation. The relatively low sample extraction rate minimizes the loading on the filter
and the subsequent dilution of the sample reduces the level of any corrosive or condensing components
of the flue gas to where they do not cause fouling of the sample transport line. The dilution of the stack
gas also reduces any potential interfering gas species (there are none expected in this application) to a
level that is not detectable by the analyzer. The diluted sample is at a slight positive pressure which
eliminates any influence of minor leaks in the sample transport system. The conditioned gas sample is
transported down an inert and heated (freeze protected) line to the analyzer located in the shelter at
ground level. The extracted sample is presented to the NOx analyzer and the analyzer outputs will be
multiplied by the dilution ratio to normalize the values back to stack conditions. The NOx measurement
system will have a full scale of 90 ppmv wet which is 1.5 times the maximum expect NOx concentration
(60 ppmv wet) when the emission limit of 11 kg/h is reached at the maximum expected volumetric flow
rate in the stack. The 100:1 dilution ratio will create a NOx concentration of approximately 0.6 ppmv
wet to the analyzer when the stack gas is actually 60 ppm. This concentration is well within the
operational range of the NOx analyzer which has a lower detection limit of 0.4 parts per billion (ppb) and
can be operated with full scale ranges of 0.05 to 100 ppmv.
Operating Principles of the Analyzers

The NOx analyzer is a model 42C NO/NO2/NOx analyzer manufactured by Thermo Environmental
Instruments. The analyzer uses Chemiluminescence technology to detect NOx in the sample. This
technology virtually eliminates interference from other gas species and measures NOx in the expected
range of 0 to 0.6 ppmv after dilution.
Stack gas temperature is measured using a K-Type thermocouple mounted in the CEMS probe. The
millivolts (mv) generated by the thermocouple are linearized using a temperature transmitter that
provides an analog output representing the stack temperature at the CEMS port elevation. The
temperature transmitter is an Omega Canada Inc. Model Ci1653 transmitter that will be located in the
CEMS shelter. The transmitter will be calibrated for a range of 0 to 325°C which is approximately
1.5 times the maximum expected flue gas temperature.
S-Type pitot tubes, built to the specifications of the Alberta Stack Sampling Code (AEP 1996), are used
to determine the stack gas velocity. The pitot tubes are mounted in the CEMS probe and the moving
stack gas causes a differential pressure to be produced. Impulse lines within the umbilical connect the
pitot tubes to a differential pressure transmitter in the analyzer shelter. The differential pressure
transmitter is a Rosemount Model 3051CDO which converts the differential pressure to a milliamp analog
output representing the measured differential pressure. The initial range of the transmitter will be set at
0 to 50.8 mm water column (2” W.C.) which is approximately 1.5 times the maximum expected
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differential pressure. A timed blow back of the pitot tubes with high pressure instrument air keeps the
impulse lines and sensing tips from fouling. The differential pressure signal is held at the last valid value
during the blow back period. The blow back and signal recovery sequence duration is two minutes and
the blow back sequence is initiated automatically by the data acquisition system (DAS) every four hours.
CEMS Data Collection and Manipulation
CEMS data will be collected, validated and stored using a Personal Computer (PC) based DAS. The DAS
scans the analog inputs continuously and produces one- minute averages from the scanned values.
Various data status indicators are checked to validate the one-minute averages. The one-minute
averages are used to produce 15 minute averages and if all four 15 minute averages for an one-hour
period meet the data validation requirements then the one-hour average is generated from the four 15
minute averages. This method meets the Alberta CEMS Code (AEP 1998) requirement of producing
hourly averages from four equally space data points per hour. This data collection and validation
technique is used on all measured parameters. The DAS stores the one-minute averages as a soft copy
in a secure data base. These averages are used to provide a daily summary report which is printed
automatically each day. The stored one-minute data can be used at any time to recreate hourly, daily,
monthly, or quarterly summaries. The DAS will also initiate and monitor the daily calibration drift tests
for the gas analyzer and will capture the zero and span responses. These responses will be compared to
the appropriate gas value and the difference will be calculated as a percent of the analyzer full scale.
The DAS then compares the calibration drift to the allowable limits set out in Section 5.1.3 (d) Table 15
of the Alberta CEMS Code (AEP 1998). The DAS provides status indication of “OK”, “Warning”, “Out of
Control One Day”, or “Out of Control Five Day”. The DAS invalidates data as required by Section 5.1.3
(d) of the CEMS Code (AEP 1998) for any out of control events. The daily calibration drift test results
are stored as a soft copy and are also printed automatically each day. The DAS then makes zero and
span corrections on the NOx concentration input after the calibration drift test is completed and the
drifts are calculated and recorded. The DAS allows for manual initiation of status flags such as
“Calibration” and “Maintenance” to invalidate data collected during time of service or repair on the CEMS.
These status indicators appear next to the data on reports.
The DAS is consists of a data logger and PC. The PC performs the data display functions, data storage
and data reporting functions. The data logger collects the CEMS data, validates the data and performs
any required calculations or manipulations. The data logger controls calibration relays and initiates and
monitors automated calibration drift tests. The data logger is also capable of providing analogue
outputs to other recording devices or displays. The data logger can function independent of the PC and
will record and store data until the internal buffer is full and then data is overwritten. In this application,
the logger will be able to store several days of data in the event that the PC is out of service for any
reason. The PC polls the logger every 10 seconds and updates the operator display and data archive but
in the event of a PC failure the CEMS will continue to operate normally and there will be no data loss
from the logger until the memory buffer is full.
The data logger is located in the instrument rack in the CEMS shelter and the PC is located in the plant
control room. Access to the data logger configuration and control is via the PC.
A CEMS specific Quality Assurance Plan (QAP) prepared in compliance with the requirements of Section 5
of the Alberta CEMS Code (AEP 1998) is being developed. The final draft QAP will be completed by the
CEMS installation date and then reviewed after the CEMS installation to make changes to reflect the
actual site specific conditions.
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Number of Analyzers and Acquisition Points
Each CEMS will consist of one (1) NOx analyzer, one (1) Differential Pressure transmitter, one (1) CEMS
Level Temperature transmitter and thermocouple and one (1) S-type Pitot tube flow sensing element.
The gas extraction probe, thermocouple and picot tubes are combined into a single assembly that
mounts to one port on the stack. The gas extraction point, the stack gas temperature measurement
point and the differential pressure measurement point will be located within the centroidal area of the
stack (since the stack inside diameter is less than 2 m) and 0.3 m (1’ downstream (above) of the
reference method ports.
The Alberta CEMS Code (AEP 1998) defines the sample extraction location requirements as follows:
3.1.2 Point CEM Systems
The measurement point shall be (1) no less than 1.0 m from the stack or duct wall, or (2) within or
centrally located over the centroidal area of the stack or duct cross section.
Centroidal area means a concentric area that is geometrically similar to the flue, duct or stack cross
section and is not greater than 1% of the stack or duct cross-sectional area.
This CEMS will sample and analyze for NOx on a continuous basis and will monitor temperature and
differential pressure on a continuous basis.
Equipment Manufacturers and Model Numbers
Equipment Model No. Manufacturer

CEMS (Overall System) G400PD Global Analyzer Services Limited,
Calgary
NOx Analyzer 42C Thermo Environmental Instruments
Data Acquisition System ICIS III WTC (Western Telecomputing Inc,)
Sampling Umbilical SU Stak Pak O’Brien Canada
Differential Pressure 3051CD0 Rosemount
Flow Sensing Element S-Type Pitot Tube Global Analyzer Services Limited,
Calgary
Stack Gas Temperature Ci1653 Omega Canada Inc.
CEMS Shelter n/a Senex Engineering, Calgary
Expected Normal and Maximum Analyzer or Flow Rate Readings

The expected normal analyzer and flow rate readings are 50 ppmv wet for NOx, 195°C for flue gas
temperature and 96 (e3m3/h).
Table 1 of the Alberta CEMS Code (AEP 1998) requires that the full scale of NOx analyzer be set at
1.5 times the approval limit. The analyzer concentration range has been set at 90 ppmv wet for NOx
which is 1.5 times the maximum expected NOx concentration of 60 ppmv when the approval limit of
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11 kilogram per hour (kg/h) is reached. The approval states a mass emissions limit only and does not
give a ppm limit.
The maximum expected temperature and maximum expected flow rates in the stack are 217°C and
102 e3m3/h and the analyzer full scales for these parameters are 325°C and 150 e3m3/h, respectively.
The full scale values are based on approximately 1.5 times the maximum expected value for temperature
and flow.
Process and Pollution Control Equipment Operating Parameters
There are various operating parameters that could affect the level of NOx emissions from the stacks,
including:
• Steam Generation Load
• Function of the staged combustion system
• Ambient Air Conditions
The above and many other parameters are displayed and recorded by the plant distributed control
system.
Calibration, Operation and Maintenance Procedures and Schedules
Calibration of the gas analyzer will be conducted using gases injected into the sampling system probe
upstream of all connections and sample conditioning apparatus. This method verifies the analyzer
calibration and the entire sampling system. Span gases will be NO in a balance of nitrogen certified to
NIST traceable standards and zero gas will be clean, dry, instrument air which has been conditioned by
passing through a potassium permanganate and anhydrous Calcium Sulphate (CaSO4) scrubber.
Calibration of the flow monitor differential pressure and temperature subsystems will be conducted using
primary standards such as an inclined manometer or using test equipment certified to have accuracy at
least two times better than the calibration tolerance being checked as per section 5.1.3(b) of the Alberta
CEMS Code (AEP 1998). The flow monitor final output for volumetric flow will be calibrated against
reference method testing as set forth in the Alberta Stack Sampling Code (AEP 1996).
Calibration of the DAS will be conducted using test equipment and signal calibrators certified to have
accuracy at least two times better than the calibration tolerance being checked.
Maintenance procedures will be those provided by the equipment manufacturer and detailed in the CEMS
specific QAP.
The detailed procedures for calibration will be provided in the CEMS specific QAP.
The schedule for the calibration and maintenance activities is as follows:
Gas Analyzer Daily Calibration Drift Test
Daily Inspection
CEM System Daily Inspection

Weekly Checks
CEMS System Quarterly Preventative Maintenance
Flow Monitor Twice per Year Calibration Drift Test on subsystems.

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The actual procedures used will be fully documented in the CEMS specific Quality Assurance Plan. The
schedules provided herein are based on the manufacturer’s recommendations. The CEMS will be
reviewed over the first few months of operation and schedules will be adjusted as needed.
Record Keeping
All CEMS data collected by the DAS will be backed up to a secure storage media on a regular basis and
will be kept for 10 years. This data includes all gas concentration, differential pressure and temperature
readings as well as the calculated flow and mass emissions value. This data also includes the results of
the daily calibration drift test on the gas analyzers and all data status flags. All CEMS daily data reports
and calibration drift reports will be printed in hard copy daily and retained which will provide a secondary
archive of the CEMS data.
All manually recorded data such as daily CEMS inspection, preventative maintenance, corrective action,
RATA results, CGA results, annual evaluation reports and all other reports as required by the Surmont
Project’s EPEA Approval No. 48263-00-01 and the Alberta CEMS Code (AEP 1998) will be kept in hard
copy for a minimum of three years and made available for inspection on request.
All record keeping requirements and methods will be detailed in the CEMS specific QAP.
93
94
Chapter 8: Utility Steam System
Utility steam is available at several locations in the facility. The steam can be used for equipment
cleaning and thawing activities. Most buildings in the CPF have a utility station within it.
During the colder months, the utility steam stations are kept on all the time allowing a trickle of
steam/condensate to flow. This allows continuous flow of steam in the utility header and negates any
chance of freezing.
The utility steam header pressure operates at a much lower pressure than the main steam
header, usually around 700 kPa.
95
Chapter 9: Blowdown system
The steam generators only produce steam at about 80% quality. Meaning, around 20% of what the
steam generators create is water. This extremely hot water can be utilized for heat energy exchange and
can be flashed off to create utility steam.
The excess Blowdown is then transferred to 3 possible locations:
1.) Recycled to WLS – The excess Blowdown is cooled through E-502 and shipped to the Warm
Lime Softener. The rate at which it is injected into the WLS is dependant on the total flow inlet of the
WLS.
2.) Pond – Shipped to the pond, and left to settle over time, eventually recycled back into the
system via the De-oil tank.
3.) Disposal Well – Pumped underground to a disposal well
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9.3: Disposal System (wells & pumps)
If the WLS (Warm Lime Softener) and the pond cannot handle anymore flow then the excess Blowdown
gets pumped underground to one of three disposal wells. Although the disposal rates vary from day to
day, the ideal disposal rate is about 50m3/hr.
Chapter 10: Glycol System and Heater
The Burner Management System (Fireye E-110) controls the safe startup and shutdown of the burner,
and monitors the safety interlocks during operation, in accordance with eSA B149.1, CSA B149.3 and
NFPA 8SA. The system initiates its cycle by a heat demand as determined by the Operating Modulating
Temperature Controller. Upon a call for heat, the system checks the operating limits to ensure safe
operation and then begins a startup sequence. The sequence provides a start blower signal and then
proceeds to a high fire purge. After the high fire purge is proven, by end switches on the air damper, the
low fire position is re-established and proven by the end switches. The control then initiates pilot trial for
ignition and, if successful in lighting, the pilot proceeds to main flame trial for ignition. If the main flame
signal strength is proven, by
the flame scanner, the Burner Management system releases the combustion control to modulate the
firing rate to meet the heat demand of the system.
The tight wound helical coil heater is the optimum constant phase heater available in its size range (0.5
– 50 mmbtu/hr). The primary use is for Glycol but can be used with other mediums. The Helical coil
has several design features which have contributed to its selection as the heater of choice for many end
users.
DESCRIPTION SET POINT INSTRUMENT TAG

Media Operating Temperature Control 100°C TIC-1432
Media Operating Temperature Limit 110°C TSH-1432
Media High High Outlet Temperature 120°C TSHH-1432
High Stack Temperature 400°C TSHH-1431
Low Fuel Gas Pressure 35 kPag PSLL-1439
High Fuel Gas Pressure 66 kPag PSHH-1440
Low Combustion Air Pressure Switch 3.7 kPad PDSLL-1447
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Low Heater Differential Pressure
[Flow Media Flow) 38.6 kPad PDSLL-1431
Main Fuel Gas Regulator 69 kPag PCV-1436
Pilot Fuel Gas Regulator 7 kPag PCV-1446A
Main Fuel Gas Safety Relief Valve 103 kPag PSV-1437
H-601 Specifications
IN OUT
TOTAL FLUID kg / h 282,000 282,000
TOTAL VAPOUR kg / h N/A N/A
TOTAL LIQUID kg / h 282,000 282,000
DENSITY (liquid) kg / m3 1049 1034
VISCOSITY (liquid) cP 1.88 1.22
SPECIFIC HEAT (liq/vap) kJ/kg°C 3.332 3.421
TEMPERATURE °C 79 100
OPERATING PRESSURE kPag 800 Not less than 700
The glycol circuit was designed to be a self-balancing heat management system. It consists of a
cooling circuit and a heating circuit. Both circuits are driven by one set of glycol circulation pumps
(P-601A/B/C). These pumps are designed to run hot; with typical operating temperatures in the
70°C to 120°C range.
Figure 4.1-1 Glycol Cooling Circuit
Glycol
Expansion Drum
Glycol
Aerial Cooler
40 °C Glycol to
Glycol Process Cooling Loads
Circulation Pumps
Cooling
Circuit
Heating Bypass
Circuit Valve Header
Returns
PDC Bleed
Valve
Hot Glycol To
Glycol Heating
Circuit
98
The glycol cooling circuit is illustrated in Figure 4.1-1. The cooling circuit draws just enough flow
to meet process cooling needs. Glycol will only flow through the aerial cooler at the rate
demanded by the process heat exchangers. If cooling is not required, then glycol will
automatically bypass the cooling circuit. Residual heat will remain in the glycol until it is used by
utility heating demands (tracing, tank heaters, buildings, combustion air heaters, etc). This
conserves energy by dissipating heat only when necessary.
The glycol heating circuit is illustrated in Figure 4.1-2. The heating circuit draws just enough flow
to meet the utility heating demands (tracing, tank heaters, buildings, combustion air heaters, etc).
This minimizes fuel consumption at the glycol trim heater (H-601) if the returns from the cooling
circuit are below 100°C.
Figure 4.1-2
Glycol Expansion
Glycol Heating Circuit Drum
To Glycol PDC
Circulation
Pumps Heating
Circuit
Bypass
Valve
Hot Glycol From

Header
Bleed Coolant Return
Valve
Header
Hot Glycol to Utility Heat Consumers

99 Glycol
Trim Heater
Normally there should be more than enough recovered process heat to meet all of the utility
heating demands. There should be no reason for the glycol trim heater (H-601) to be operating
when the aerial coolers are wasting significant amounts of heat to atmosphere. The returns from
the cooling circuit should be hotter than the set-point for the temperature controller in the trim
heater. During normal operating, glycol will flow through the trim heater but the burner should be
on standby.
1.1.1.1 Glycol Mixture
The process conditions are too hot to allow the use of ethylene glycol. The glycol system
for the Surmont facility was designed to operate with a solution of 60wt% triethylene
glycol in water. This mixture must contain chemical inhibitors and detergents to:
Inhibit corrosion.
Prevent sludge formation.
Prevent foaming in the process piping and equipment.
Inhibit oxidation (the glycol makeup tank is open to the atmosphere).
Inhibit thermal degradation at operating temperatures up to 210°C.
The glycol mixture should withstand the high process temperatures that are expected in
some areas of the facility. The mixture will become very viscous at 0°C and may freeze if it
100
is allowed to cool below -25°C. Operators should consider draining and isolating some of
the bays in the aerial cooler (E-601) during winter conditions.
The material safety datasheets should be reviewed before attempting to work with, handle,
transfer, or clean up the triethylene glycol solution. Chemical additives and degradation
products in the solution may increase toxicity. Extreme care must be exercised when
servicing the glycol filters. Proper personal protective equipment must be worn to prevent
direct contact with the solution or its vapours. Maintenance, safety, and spill response
procedures must be prepared prior to filling the glycol system. These procedures are
beyond the scope of this document.
1.1.1.2 Glycol System Balancing
The cooling circuit has been designed for a substantial range of operating conditions and
process transitions. Ambient temperatures over 28°C will reduce this operating envelope
and may require production cutbacks.
For the most part, the glycol system will automatically balance itself. During normal
operation, there will be excess flow that bypasses the cooling circuit and merges with the
cooling returns (06-PDV-1038). The mixed cooling returns then feed the heating circuit.
Likewise, there is a bypass valve around the heating circuit which should normally be
flowing (06-PDV-1401).
When the plant is operating at design capacity, two of the three glycol circulation pumps
will be operating (P-601A/B/C) and the cooling circuit bypass valve should throttle between
15% and 50% open (06-PDV-1038). If the cooling circuit bypass valve closes further, then
the cooling system is near its operating limit. If the bypass valve goes completely closed,
then glycol-cooled exchangers will start to compete for coolant, and operator intervention
is required to avoid a plant upset. An alarm will be tripped if the valve goes completely
closed (06-PZAC-1038).
If the cooling system bypass valve (06-PDV-1038) continuously operates more than 50%
open, it may be feasible to turn off one of the glycol circulation pumps (P-601A/B/C). This
would reduce electricity consumption, but would require the operator to closely monitor the
operating status of the glycol circuit. Leaving the pump on will not cause any problems.
The heating circuit bypass valve (06-PDV-1401) will have a wider operating range than the
cooling circuit bypass valve (06-PDV-1038). Depending on the time of year, utility heating
demands, and plant operating status, the heating circuit bypass valve will operate
anywhere between 10% and 100% open. It should be feasible to operate with only one
glycol circulation pump operating when the plant is shut down for maintenance.
1.1.1.3 Glycol Circulation Pumps
42-PID-06-002-1
Glycol system is equipped with three 50% duty pumps (P-601A/B/C). The plant was not
designed to accommodate steam generation or bitumen production without the glycol
system being in service. The spare glycol pump helps assure reliability of the system and
operability of the plant.
The glycol circuit provides coolant to a number of process heat exchangers. Several of
these heat exchangers operate at very high temperature. The pressure generated by the
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glycol pumps prevents the coolant from boiling in these heat exchangers. If the glycol
pumps suddenly stop, then the coolant pressure will drop from about 1100 kPag to about
400 kPag. The coolant will immediately flash and will continue to boil until the residual
process heat is dissipated. This can cause the problems listed below.
Vapour will displace coolant into the glycol expansion drum (V-710). The expansion drum
will flood and spill over into the flare system (through 07-PCV-1032 into V-702). The
flare system may be needed for other upsets occurring in the plant, so the extra liquids
in the flare system will be detrimental. Liquids in the flare knockout drum are
automatically pumped to the slop or skim tanks. Glycol-contaminated liquids can
stabilize emulsions so they are detrimental to the skim tank and slop system.
Water hammer and cavitation will occur in the glycol circuit as migrating vapours merge
with cooler glycol. This could cause costly equipment damage and leaks.
Heat exchangers could trap pockets of vapour and liberated dissolved gases. Vapour-locked
exchangers would have to be vented. This will delay restart.
A sudden stoppage of the glycol circulation pumps poses a number of safety and
environmental threats. Several measures were incorporated into the plant design to
mitigate the risks. These measures are listed below.
1) Time delay on Blow-down Emergency Shutdown (BESD): The glycol system should
continue to operate for at least five minutes after a shutdown is tripped. This will
maintain coolant pressure while residual process heat is dissipated. After the high-
temperature exchangers are allowed to cool off, it should be safe to stop the glycol
circulation pumps (P-601A/B/C).
2) Emergency power to the glycol circulation pumps (P-601A/B/C): Coolant flashing will
occur as soon as the glycol pumps stop turning. Immediately switching at least one
of these pumps (261 kW) to the emergency power supply will help keep the coolant
moving. Flow is needed to dissipate residual heat. The pressure generated by the
pump should help keep the coolant from boiling. This will reduce water hammer and
cavitation damage in the glycol system and the glycol-cooled exchangers. Keeping
the glycol pump running on emergency power for five minutes should be sufficient
to help manage the problem. Running one of the pumps on emergency power can
also help avoid freeze-up during a prolonged winter power outage.
3) The low-low level shutdown on the glycol surge drum (06-LALL-1033 on V-601) will
cause the glycol circulation pumps (P-601A/B/C) to stop, but not be locked out. The
operator can immediately restart one of the pumps to protect the rest of the plant.
Depending on the circumstances, the operator can choose to sacrifice one of the
glycol circulation pumps to cavitation damage in order to save more costly
equipment, preserve safety, and protect the environment.
The glycol pumps (P-601A/B/C) operate at fixed speed. The system has been designed to
keep the pumps operating near their best efficiency point at all times.
During normal operation, two glycol circulation pumps should be running (P-601A/B/C).
When production is shut down, the glycol circuit can operate on one pump. The system is
equipped with an alarm (06-PZAC-1038) that will notify the operator if the glycol flow rate
is unable to meet process cooling demands. The alarm is tripped if the cooling circuit
bypass valve (06-PDV-1038) goes fully closed. This helps reduce the risk of a nuisance
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shutdown if the operator forgets to turn on the second glycol circulation pump. If the alarm
is tripped, the operator must immediately start another glycol circulation pump to avert a
plant upset.
The section on glycol system balancing provides additional information on when it may be
appropriate to operate with only one glycol circulation pump. If the cooling circuit bypass
valve goes fully closed (06-PZAC-1038) with two glycol circulation pumps operating (P-
601A/B/C), then there is a serious problem with the plant heat balance. This condition is
most likely caused by severe fouling in some of the process heat exchangers. Operating all
three glycol circulation pumps at the same time should only be considered as a temporary
measure to avert an emergency shutdown while ramping down production. It can also buy
time to help operators identify the cause of excessive coolant consumption.
A fouled water-cooled exchanger can often pass excessive heat loads downstream to a
glycol-cooled exchanger. The trim coolers have a moderate margin of surplus capacity, but
the plant heat balance is sensitive to fouled exchangers. All exchangers must be kept
relatively clean to ensure optimum energy efficiency and operability.
If a glycol-cooled exchanger is fouled, the temperature controller will automatically
compensate by increasing the glycol flow rate. A fouled exchanger can often be identified
by the glycol discharge temperature. If the glycol temperature higher than the normal
value shown in the line list, then the exchanger is probably okay. If the glycol leaving the
exchanger is colder than the line list suggests, then the exchanger probably needs to be
cleaned. It the temperature is normal and the temperature control valve is near wide-open,
then the problem is likely in an upstream heat exchanger. If the glycol circulation pumps
(P-601A/B/C) cannot meet the increased flow demands, then the process heat exchangers
will start to compete for a short supply of coolant. The third glycol pump can be turned on
temporarily to stabilize the plant while production is cut back. The fouled exchanger should
be taken out of service and cleaned as soon as possible.
A flow control override (06-PDYC-1038; 06-FIC-1038) provides minimum flow protection
for the glycol circulation pumps (P-601A/B/C). The control logic should be programmed to
automatically adjust the flow control set-point based on the number of pumps in operation
(06-YI-1040/1042/1044). The minimum flow requirement for each pump is 172 m3/h. The
cooling circuit bypass valve (06-PDV-1038) normally operates on differential pressure
control (06-PDIC-1038). However if the flow rate falls below the minimum requirement for
the pumps, then the flow controller (06-FIC-1038) takes over the valve.
Each glycol circulation pump (P-601A/B/C) is equipped with a ¾” warm-up bypass valve.
When the pump is on standby, this valve allows a small slipstream of warm glycol to
bypass the check valve. Hot glycol will trickle backward through a pump back to the pump
suction header. It is important to keep the standby pump warm at all times unless it is
undergoing maintenance. The following problems can occur if the standby pump is allowed
to cool off.
Thermal shock and expansion can lead to deformation and stress cracking in the pump
case, piping, and fittings.
Sudden exposure to hot glycol can cause the impellor to expand quicker than the volute.
The rotating components may come into contact with stationary features due to close
clearances in the pump. This can destroy the pump and lead to costly downtime.
103
Each glycol circulation pump (P-601A/B/C) is equipped with a seal leak detector (06-PIT-
1040/1042/1044). If there is significant leakage past the primary seal, then elevated
pressure will be detected in an interstitial chamber. This will trip an alarm that will shut
down the pump (06-PAHH-1040/1042/1044).
Each glycol circulation pump (P-601A/B/C) is equipped with motor winding temperature
protection. If the windings in the electric motor become too hot, then a local high-
temperature shutdown switch will be tripped (06-TSHH-1040/1042/1044). The shutdown is
triggered locally at the motor protection relay.
A low-low level alarm will be tripped if the liquid level in the glycol surge drum (V-601)
drops below 500 mm. At this level, the pumps may start to cavitate. The low-low level
alarm will automatically stop the glycol circulation pumps (P-601A/B/C) but will not lock
them out. Due to the critical need to hold pressure in the glycol circuit (discussed above),
the operator can immediately restart one of the pumps.
1.1.1.4 Glycol Surge Drum

42-PID-06-002-1
MANUFACTURER: HEATECH
CAPACITY: SIZE (GJ/hr) 2286 mm I.D. x 6100 mm 30m3
DESIGN TEMPERATURE (°C): Full Vacuum @ 200/-40
DESIGN PRESSURE (kPa): 1600
OPERATING PRESSURE (kPa): 400 @ 110°C
The entire glycol system has a design pressure of 1600 kPag. This includes the glycol surge
drum. The relief valve on the surge drum is set at a pressure which is much lower than the
vessel design pressure (06-PSV-1035 set @ 750 kPag). This was done to address concerns
about the pumps operating during an over-pressure upset. Keeping the suction side of the
pumps from exceeding 750 kPag should prevent the discharge pressure from exceeding
the design limit of the downstream piping and equipment.
A blanket gas regulator on the glycol surge drum (06-PCV-1030 on V-601) will keep the
pressure in the system from dropping below 350 kPag. Thermal effects and liquid level
movements will cause the pressure in the vapour space to fluctuate. If the pressure drops
below 350 kPag, then blanket gas will be fed into the vessel. If the pressure exceeds 500
kPag, then excess pressure will be bled off through a backpressure valve (06-PCV-1032) to
the flare system. The vessel is not expected to bleed off a significant amount of vapours,
so there was no need to tie the unit into the vapour recovery unit (VRU).
104
The glycol surge drum (V-601) is equipped with a redundant level transmitter and local
level gauges. The level readings should be compared periodically to ensure the transmitters
are operating properly. The transmitter bridles are traced to prevent high viscosity or
freezing in the sensing lines.
1.1.1.5 Glycol Filter

42-PID-06-002-1
Some of the glycol that passes through the glycol circulation pumps (P-601A/B/C) is filtered
and sent back to the glycol surge drum (V-601). The glycol filter (FL-601) was designed to
handle a 50 m3/h slipstream of glycol at normal temperatures up to 120°C.
The glycol filter (FL-601) is equipped with 10-micron disposable filter cartridges. Operators
must exercise extreme caution when servicing the filter. It normally operates at high
temperatures. Opening the filter without first cooling it down can cause the contents to
suddenly boil over. This could cause a serious injury or fatality. The filter contents must be
cooled to below 60°C (06-TG-1036), and the filter must be isolated before attempting to
open the filter chamber.
A supply of cold glycol has been piped to the filter inlet (G-BAB-2-0396). Before servicing
the filter, it must be cooled off by closing the inlet from the pump discharge header then
opening the filter cool-down supply valve. Cold glycol must be allowed to flush through the
filter for several minutes to thoroughly cool the housing and internals. The temperature
gauge (06-TG-1036) should drop to 40°C and should remain there after the flow of cold
glycol is turned off. After it has been confirmed that the filter and its contents have
stabilized at a safe temperature, the unit must be isolated.
The glycol filter (FL-601) must be isolated using double block and bleed before the
chamber is opened for service. Both valves in line G-BAA-3-0009 must be closed and the
sample connection must be opened (with plug removed) to monitor for leaks. The same
must be done for the inlet line G-BAA-3-0008. The plug should be carefully removed from
the vent valve on the top of the filter chamber. The vent valve should be cracked open
slightly to check for residual pressure. Some of the glycol should be drained from the filter
chamber into a clean pail. This will help minimize messy spills when the lid is opened and
the spent cartridges are pulled.
After new filter cartridges have been installed, the glycol that was drained into the clean
bucket can be poured back into the filter chamber. Do not pour contaminated glycol back
into the system. After sealing and securing the lid back onto the filter chamber, residual air
must be vented. With the vent valve cracked open, the upstream bleed valve should be
closed and cold glycol should be fed into the filter. After the air is displaced, the filter can
be put back into service. The bleed valves and vent valve must be closed and plugged, and
the block valves should be opened to route hot glycol from the pumps through the filter.
The valve for the filter cool-down supply should be checked to ensure that it is closed.
The glycol filter helps remove mill scale and construction debris from the glycol circuit. The
filter elements will probably have to be changed several times soon after initial plant
startup.
105
Over time, the filter cartridges will accumulate debris and will have to be replaced. The
control scheme used for the bypass valves in the glycol circuit precluded the use of a
differential pressure gauge to indicate filter status. The differential pressure across the
filter will remain constant regardless of how clogged the cartridges become. The filter
status is indicated by flow rate (06-FIT-1036). The flow rate through the filters should
normally exceed 50m3/h. The cartridges should be replaced if the flow rate drops below 30
m3/h (06-FAL-1036).
1.1.1.6 Glycol Aerial Cooler

42-PID-06-003-1,2
Recovered process heat is used to meet utility heating demands such as tracing, tank
heating, combustion air preheating, and building heat. During peak production, the
recovered process heat is expected to exceed utility heating needs. The surplus heat is
discharged to the atmosphere using the glycol aerial cooler (E-601). The glycol circuit is
configured with bypasses to avoid unnecessary fuel consumption at the glycol trim heater
(H-601) and unnecessary loads on the aerial cooler (E-601).
Each bay of the glycol aerial cooler (E-601) is equipped with two fans. One fan operates
with on/off control. The second fan operates on variable frequency drive (VFD). The speed
of the VFD-driven fan is controlled based on the temperature of the glycol leaving the bay.
If natural convection is sufficient to cool the glycol to below 40°C, then neither fan will
operate. If forced convection is required, then the VFD-driven fan will modulate to the
speed necessary to cool the glycol to 40°C. The operator will have to switch on the second
fan if the VFD-driven unit cannot sustain the target glycol temperature.
During cold winter operating conditions, the operator may need to shut down some of the
bays in the aerial cooler (E-601). Even with the fans turned off, natural convection through
the cooling fins may dissipate more heat than the process excess can supply. The glycol
will become very viscous if it is over-cooled. Some of the slower-flowing tubes could freeze
up if the glycol mixture cools below -25°C.
Operators should isolate and drain some of the cooling bays if the cooling capacity is not
required and cold weather is anticipated. Isolation valves, vents, and drains have been
provided to facilitate this work. It is recommended that nitrogen or utility gas be used to
displace the glycol from the isolated bays. Allowing air to enter the tubes is discouraged.
It may be feasible to displacing the glycol from the cooling bays into the rest of the system
using higher pressure nitrogen or utility gas (using a blow-casing technique). This would
eliminate the need for a tank truck, but would raise the level in the glycol surge drum (V-
601). It could also lead to gas bubbles trapped in glycol-cooled heat exchangers and piping
pockets. These gas bubbles will have to be vented to avoid a process upset.
The glycol aerial cooler (E-601) was not designed to dissipate peak heat loads during very
hot summer conditions. If the aerial cooler is unable to cool the glycol to 40°C, then
production must be cut back to protect the plant heat balance. Spraying water onto the
aerial cooler is not an acceptable method for improving the cooling performance. Under no
circumstances should utility water be sprayed on the outside of the cooling fins when the
106
aerial cooler is in operation. Applying utility water to the hot tubes can lead to fouling of
the cooling fins, corrosion, and thermal stress damage.
1.1.1.7 Cold Glycol Distribution System

42-PID-06-005-1,2,3,4,5
During normal operation, most of the glycol leaving the glycol circulation pumps (P-601
A/B/C) will flow through the aerial cooler (E-601) then on to the glycol-cooled equipment.
A portion of the glycol will bypass the cooling circuit through a pressure differential control
valve (06-PDV-1038). The controller that manipulates this valve (06-PDIC-1038) should
always be set at 400 kPa differential. This control valve has two functions.
4) The primary function is to sustain a constant differential pressure between the
coolant supply header and the coolant return header (06-PDIC-1038). This ensures
that all glycol-cooled equipment has enough differential pressure at all times to
overcome frictional losses through the piping, equipment, and control valves. It
helps stabilize the operation of control valves and ensures responsive temperature
control at the glycol-cooled exchangers.
5) The secondary function is to meet the minimum flow requirements of the glycol
circulation pumps (P-601A/B/C). A minimum flow override (06-PDYC-1038; 06-FIC-
1038) takes over control of the valve (06-PDV-1038) to ensure the flow rate does
not drop below the minimum requirement of the pumps. The set-point for the
minimum flow rate controller (06-FIC-1038) will depend on the number of pumps in
107
operation. The controller must be programmed to detect the number of pumps in
operation (06-YI1040/1042/1044) and automatically adjust the flow controller set-
point accordingly.
The cooling circuit bypass valve (06-PDV-1038) is equipped with a soft valve position
indicator (06-PZI-1038). The valve should normally throttle between 15% and 50% open
(See the section on glycol system balancing for further information). If the valve goes fully
closed (06-PZAC-1038), then the operator must start up another glycol circulation pump
(P-601A/B/C) to stabilize the glycol-cooled heat exchangers.
If the cooling circuit bypass valve goes fully open (06-PZAO-1038), then the cold glycol
distribution pressure will be a bit higher than normal. This is not a serious problem. The
flow rate – pressure relationship will follow the pump curve until the system head matches
the pump head. The operator should turn off one of the glycol circulation pumps to reduce
power consumption.
The glycol should normally leave the pumps at about 1200 to 1350 kPag. The actual
operating pressure will depend on the blanket pressure in the glycol surge drum (V-601)
and the operating head of the circulation pumps (P-601A/B/C). The pressure drop through
the aerial cooler and distribution headers will vary with:
Glycol flow rate
Glycol operating temperature
Number of cooling bays in operation.
Generally, the coolant supply should reach the glycol-cooled equipment at a temperature
below 40°C and a pressure no less than 1000 kPag. The system was designed for a 300
kPa pressure drop through the glycol-cooled exchangers and their associated temperature
control valves. The glycol return header should operate at about 800 kPag. During normal
operation, the return temperature should be between 110°C and 120°C (06-TI-1400).
Clean exchangers will show higher return temperatures. Lower temperatures indicate that
some of the exchangers may be fouled. The normal temperatures provided in the line list
can serve as a guide for identifying fouled exchangers and heat management upsets.
When production is shut down, the glycol system will remain on line to provide freeze
protection and bitumen viscosity control. The temperature of the glycol flowing to the trim
heater (H-601) will typically drop down into the 70°C to 90°C range (06-TI-1400).
Additional details are provided in the section on hot glycol distribution.
The cooling loop is the dominant influence in the design of the glycol circuit. The glycol
circulation pumps were designed to generate the flow required to handle peak cooling
loads (in addition to the marginal recycle through the filters).
Three 50% duty pumps were installed. Two of these pumps must be running during
normal operation at peak production. The glycol circulation pumps will be operated at fixed
speeds, so the flow rates will be relatively constant. This ensures that coolant will always
be available to meet the demands of glycol-cooled exchangers without operator
intervention. Excess capacity will simply flow through the bypass valves.
108
1.1.1.8 Glycol Header Bleed Valves
The end of each main glycol supply header is equipped with a ¾” globe valve that
discharges into the return header. These bleed valves should remain slightly open at all
times. They help sustain a minimal flow of glycol through the headers.
The coolant supply network is not insulated. Continuous flow through the branches is
needed to help prevent dead-legs in the system. Sustained circulation is needed to help
keep the piping network pipe from dropping below the minimum allowable metal
temperature (-29°C). The glycol header bleed valves must not be left fully closed in the
winter.
Bleed valves have been installed at the end of each hot glycol distribution header. These
valves must remain slightly open to prevent stagnant zones in the distribution network.
Stagnant zones can cool off leaving slugs of cold fluid in the piping. When the slugs of cold
fluid move through the system, they can cause thermal shock in the piping network. Even
though the plant is well equipped with expansion loops, sudden and drastic temperature
changes should be avoided whenever possible. A readily available supply of hot glycol also
helps ensure stable and reliable operation of automated heat users such as the fuel gas
heater (E-701).
During some operating conditions, the glycol system may accumulate too much heat. This
will become apparent if the glycol circulation pumps start to operate hotter than normal
(06-TI-1038). If the temperature of the glycol leaving the pumps (P-601A/B/C) exceeds
125°C, then some of the accumulating heat will have to be dissipated. Opening the bleed
valves at the ends of the cold glycol distribution to wide open is one of the methods that
can be used. This helps increase the flow of glycol through the aerial cooler (E-601), which
is the most effective unit for expelling waste heat.
1.1.1.9 Glycol Trim Heater
MANUFACTURER: HEATECH
CAPACITY: SIZE (GJ/hr) 20 (5.56 MW)
FLOW RATE: (kg/hr) 282,000 (305,000 w/o FIRING)
DESIGN TEMPERATURE (°C): 200/-29 @ 2068 KPag
SUCTION TEMPERATURE (°C): 79
DISCHARGE TEMPERATURE (°C): 100
DESIGN PRESSURE (kPa): 1600
OPERATING PRESSURE (kPa): 800 IN, NOT LESS THAN 700 OUT
NUMBER OF PASSES: 4 PARALLEL
BURNER: LOW NOx
42-PID-06-004-1
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The primary function of the glycol trim heater (H-601) is to provide utility heat during a
production shutdown. The unit will have a wide operating envelope that depends on
everything from weather conditions to fluid inventories in the process tanks. After
production reaches steady state condition, there should be sufficient waste process heat to
meet all utility heating demands.
The utility heat consumers (tracing, tank heaters, building heaters, air makeup units,
combustion air heaters, and fuel gas heater) were all designed to operate with a glycol
supply temperature of 100°C. Using a lower set-point on the glycol trim heater burner
control may cause problems in the plant. During normal operation, when production is near
the design capacity of the plant, hot glycol should be available even without firing the
burner in the trim heater. Due to the abundance of waste process heat, glycol
temperatures may often reach 120°C in the hot glycol distribution system.
To conserve energy and reduce operating costs, the glycol heating circuit was designed to
avoid unnecessary heating of the glycol. Only the flow required by utility heat consumers
will pass through the glycol trim heater (H-601). Excess glycol flow will bypass the heating
circuit through a pressure differential control valve (06-PDV-1401) and return to the glycol
surge drum (V-601).
Controls
Process Temperature
The burner in the glycol trim heater (H-601) will be controlled to keep the glycol discharge
temperature at 100°C, this is the primary variable in the control system. This temperature
is sensed by a Duplex RTD mounted in the outlet manifold of the heater. The RTD is wired
to an operating modulating temperature controller and to a high limit temperature
controller. A second relay output on this controller prevents the burner from going to the
high fire position until a predetermined temperature is obtained (low fire hold). A third
relay output, the "operating" control, recycles the burner on high temperature when
demand is lower than the modulation turndown. A fourth output retransmits a 4-20 mA
representation of the outlet temperature as sensed by the RTD. The High limit
temperature controller is a safety that will shut down the heater if the operating
temperature has been exceeded. Normally it is set to 20 C above the set point of the
operating temperature controller. This set-point can be adjusted a few degrees to allow
operators to optimize the performance of the heat management system. During normal
operation, the returns from the cooling circuit should be hotter than 100°C, so the burner
will typically remain on standby. The hot glycol will simply pass through the heater as it
feeds the hot glycol distribution system.
Burner Management System (BMS)

The Burner Management System (Fireye E-110) controls the safe startup and shutdown of
the burner and monitors the safety interlocks during operation, in accordance with CSA
B149.1, CSA B149.3 and NFPA 85A. The system initiates its cycle by a heat demand as
determined by the Operating Modulating Temperature Controller. Upon a call for heat, the
system checks the operating limits to ensure safe operation and then begins a startup
sequence. The sequence provides a start blower signal and then proceeds to a high fire
purge. After the high fire purge is proven, by end switches on the air damper, the low fire
110
position is re-established and proven by the end switches. The control then initiates pilot
trial for ignition and, if successful in lighting, the pilot proceeds to main flame trial for
ignition. If the main flame signal strength is proven, by the flame scanner, The Burner
management system releases the combustion control to modulate the firing rate to meet
the heat demand of the system.
Throughout the entire sequence of operating, the Burner Management System monitors
the firing system for safety. Should the firing rate exceed the heat demand, the burner will
shutdown and run through a post-purge sequence designed to evacuate any spent furnace
gasses from the heater.
The BMS uses an Expanded Annunciator (Fireye E300) to increase the interlock supervision
of the BMS; by wiring the interlock switches into the Expansion Module, The BMS display
automatically acts as a "first-out" Annunciator for these interlocks.
Limit Circuit
The 06-H-601 is wired through a series of limits. These limits act as check points or safety
interlocks, to insure the heater is operating safely. The standard limit circuits are:
DESCRIPTION SET POINT INSTRUMENT TAG

Media Operating Temperature Control 100°C TIC-1432
Media Operating Temperature Limit 110°C TSH-1432
Media High High Outlet Temperature 120°C TSHH-1432
High Stack Temperature 400°C TSHH-1431
Low Fuel Gas Pressure 35 kPag PSLL-1439
High Fuel Gas Pressure 66 kPag PSHH-1440
Low Combustion Air D/P Pressure 3.7 kPag PDSLL-1437
Switch
Low Heater Differential Pressure (Low 38.6 kPag PDSLL-1431
Media Flow)
Main Fuel Gas Regulator 69 kPag PCV-1436
Pilot Fuel Gas Regulator 7 kPag PCV-1446A
Main Fuel Gas Safety Relief Valve 103 kPag PSV-1437
Heater Outlet Safety Valves (x2) 1600 kPag/1640 PSV-1430A/PSV-
kPag 1430B
111
112
113
114
115
116
117
INSPECTION SCHEDULE
DAILY
1. Visually check flame for good combustion.
2. Visually check stack for any traces of smoke.
3. Check electrical panel for burned out bulbs.
4. Check temperature setting on burner control switches.
MONTHLY
1. Clean lens on flame scanner.
2. Check all pressure gauges.
3. Check burner control switch by turning below fluid temperature.
4. Check fan wheel for dust build-up.
YEARLY
1. Remove ignition electrodes, or gas pilot. Check for carbon.
2. Dust out electrical panel with low-pressure air hose.
3. Check all safety limits for proper working order.
118
The glycol trim heater (H-601) has a minimum flow requirement of 107 m3/hr. If the flow
rate drops below the vendor-specified minimum while the burner is operating, then tubes
may be damaged in the unit. Low flow can also lead to hot spots that could degrade the
glycol solution. Glycol degradation can lead to equipment fouling and corrosion problems. A
minimum flow bypass valve (06-FV-1401) was installed to help avoid these problems. The
set-point for the minimum flow controller (06-FV-1401) should be consistent with the
minimum flow specified in the vendor documents for the trim heater.
1.1.1.10 Hot Glycol Distribution System

42-PID-06-006-1,2,3,4,5,6
Utility heating loads (such as tracing, building heat, tank heaters, etc.) were designed on
the basis of a 100°C glycol distribution temperature. This is the set-point for the glycol trim
heater. The trim heater should fire up during a production shutdown when recovered
process heat is unavailable.
During normal operation, the returns from the glycol-cooled heat exchangers should be
between 110°C and 120°C. Some of the hot glycol returns are routed to the trim heater
(H-601) and distributed to utility heat consumers. If the glycol entering the trim heater is
colder than normal, the burner in the trim heater will fire up to ensure the glycol fed to
heat consumers remains above 100°C. This would be the case during a production
shutdown.
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When the plant is operating at full capacity, much of the hot glycol returning from the
glycol-cooled process heat exchangers will not be needed by the utility heat consumers
(tracing, building heat, tank heaters, etc.). The excess flow bypassed the glycol heating
circuit through a differential pressure control valve (06-PDV-1401). The controller that
manipulates this valve (06-PDIC-1401) should always be set at 400 kPa differential. This
control valve ensures that there is a steady driving pressure available to move hot glycol
through the heating circuit. The following pressure drop allowances were made during the
design of the plant.
Maximum 100 kPa pressure drop through the glycol trim heater (H-601)
Maximum 100 kPa pressure drop through the utility heating equipment
Maximum 200 kPa pressure drop through temperature control valves and piping.
The glycol heating circuit bypass valve (06-PDV-1401) will operate anywhere between 10%
and 100% open. The valve operation depends on the time of year, utility heating demands,
and plant operating status. The normal pressure in the hot glycol distribution and return
headers depends on flow rates, elevation, and location in the plant. The normal pressures
given in the line list are approximate, but the can be used as a guide to help identify
problems in the glycol circuits.
Generally, the glycol pressure at the inlet to the trim heater (H-601) should be about 800
kPag. After losing about 100 kPa through the trim heater, the hot glycol will be distributed
to heat consumers at about 700 kPag. The actual hot glycol distribution pressure will
depend on a number of factors such as:
Glycol flow rate
Glycol temperature
Blanket pressure in the glycol surge drum (V-601)
The pressure in the heating glycol return header is dictated by frictional losses in the piping
and the pressure in the glycol surge drum (V-601). The pressure in the headspace of the
surge drum is controlled between 350 kPag and 500 kPag.
1.1.1.11 Reducing Glycol Circulation Pump Operating Temperature

During some operating conditions, the glycol system may accumulate too much heat. This
will become apparent if the glycol circulation pumps start to operate hotter than normal
(06-TI-1038). If the temperature of the glycol leaving the pumps (P-601A/B/C) exceeds
125°C, then some of the accumulating heat will have to be dissipated. Operators can use
the following measured to reduce the operating temperature of the glycol circulation
pumps:
Fully open all of the bleed valves at the end of every cold glycol distribution header. Doing
the same to the hot glycol distribution system will not help.
Switch the glycol filter (FL-601) to cool-down mode. Shut off the hot glycol flow and open
the filter cool down valve in line G-BAB-2-0396.
Open the manual glycol throttling valves at the numerous sample coolers and pump seal
flush coolers around the plant (be careful not to overcool pumps where viscosity could
become a concern).
120
These steps can help increase the flow of glycol through the aerial cooler (E-601), which is
the most effective means for expelling waste heat.
1.1.1.12 Glycol Makeup Tank
42-PID-06-001-1
MANUFACTURER: Universal Industries Corp.
CAPACITY: SIZE 80m3
DESIGN TEMPERATURE (°C): -29
DESIGN PRESSURE (kPa): 1.7/0.215 vac @110°C
OPERATING PRESSURE (kPa): Atm @ 20°C
The glycol makeup tank was sized to accommodate two Super-B-Train truckloads of glycol
solution with room for freeboard and tank bottoms. Its primary function is to facilitate the
initial charging of the glycol circuit prior to startup. It also provides an inventory of glycol
for topping up the system if there are losses due to leaks, maintenance activities, or
changes in steady state operating temperatures.
The glycol makeup tank allows the level in the glycol expansion drum to be adjusted. As
production ramps up, the plant will warm up. This will cause the temperature in the glycol
circuit to increase. The glycol will expand until a steady state operating condition is
achieved. Normally the glycol surge drum will accommodate this expansion. However, it
may be necessary to adjust the level in the surge drum to avoid tripping level alarms. The
piping has been configured to allow some of the glycol to be drained from the surge drum
back into the makeup tank (globe valve in line G-BAA-0025).
The glycol makeup tank can be used to store glycol drained from a large heat exchanger
during maintenance. A tank truck will be required to make the transfer. It is important that
the tank truck be thoroughly cleaned before draining the heat exchanger. If the glycol is
contaminated by residual oil, acid, or chemicals in a dirty tank truck, then it must not be
transferred to the glycol makeup tank. Returning contaminated glycol into the system could
cause serious and costly damage to equipment and piping in the plant.
The glycol makeup tank is equipped with a heating coil. The heating coil helps keep the
triethylene glycol solution from becoming too viscous in the winter. Freezing the tank
contents is not a major concern. At subzero temperatures, ice crystals will form in the
solution. It is unlikely that the tank contents will freeze solid, but as the ice crystals thaw,
some glycol-water segregation can occur. Operators should set the manual valve for the
heating coil so that the tank contents remain at about 20°C throughout the year.
The glycol makeup tank (T-601) also serves as a pop tank for the glycol surge drum
pressure safety valve (06-PSV-1035 on V-601). A number of relief scenarios will send
vapour or boiling glycol through the PSV. The tank is needed to capture any liquids passing
through the PSV. The emergency venting manway on top of the tank was sized to
accommodate high vapour rates from the PSV. This emergency vent must not be blocked
or bolted down under any circumstances.
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1.1.1.13 Glycol Makeup Pump
42-PID-06-001-1
The primary function of the glycol makeup pump is to fill the glycol circuit before initial
startup. It can also be used to top up the system after it is put into operation. Normally the
pump will provide sufficient pressure to top up the glycol circuit without depressurizing the
glycol surge drum.
The pump operates on simple on/off control. The minimum flow bypass (06-FO-1001)
allows the pump to be started without opening the valve to the glycol surge drum (V-601).
This allows the glycol makeup tank (T-601) to be circulated to mix the contents before
topping up the surge drum.
Operators must check the temperature of the glycol in the makeup tank before starting the
pump. If the glycol entering the pump exceeds 80°C, then the pump could suffer cavitation
damage.
1.1.1.14 Plant Heat Balance
Some of the glycol-cooled exchangers have surplus capacity to help improve the plant
operating envelope. There will be several situations where the demands of the water-
cooled exchangers will exceed the available supply of boiler feed water (cooling water).
The operators will have to adjust the controller set-points to ration the water supply and
shed some of the heat to the glycol-cooled exchangers.
The heat exchangers listed below were sized to help ensure that they can handle excess
heat passed on by the water-cooled exchangers. These glycol-cooled exchangers have a
limited margin of excess capacity. They can handle normal process fluctuations, minor
upsets, and can often allow one of the water-cooled exchangers to be bypassed for
service. They cannot handle the heat loads that would occur during full production with a
drastic turndown of boiler feed water flow. If half of the steam generators are suddenly
shut down, then the production rate will have to be choked by about 40 or 50%.
E-212, E-222
E-215
E-601
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Chapter 11: Instrument Air
Instrument / Utility Air System (Area 07)
Inlet Operating Temperature °C 28 Max, 0 Normal, -41

Minimum
Discharge Operating Pressure kPag 862 Max, 760 Normal,

758 Minimum
Discharge Operating Capacity sm3/h 1014 Max, 1014

Normal, 1014 Minimum
Discharge Operating Temperature °C 31 Max, 20 Normal, -

31 Minimum
Pre-Filter Nominal Removal Rating 0.01 Micron
After Filter Nominal Removal Rating 1 Micron
Instrument Air Package

42-PID-07-003-1
Instrument air packages are provided at the main plant and at each well pad. The
instrument air system supplies pressurized air throughout the plant for pneumatic
instruments. Actuators of control and shutdown valves are constantly supplied with
instrument air. Utility Air is drawn from the Instrument Air Header System. Use of utility
air around the plant must be monitored and controlled during normal plant operations to
avert the possibility of drawing too much air from the system.
The instrument air compressors (K-710A/B) are oil-flooded rotary screw units. They draw
ambient air from outside the utility building and compress it to approximately 760 kPag.
The compressors are controlled by local PLCs. Under normal circumstances, one
compressor can meet the all of the plant instrument air demands. The second compressor
should normally remain on standby as a 100% spare. If air demand is high both
compressors may operate. Either compressor may be selected to run as the lead unit. This
selection can be made locally using a switch located on the air compressor package. The
selection can also be done remotely through the DCS. The lead unit starts and stops as
required by air demand. The lag machine starts automatically if the lead machine is unable
123
to keep up with air demand. The lag unit stops automatically when system pressure is back
in the normal range.
The maximum discharge pressure of the compressors is 862 kPag based on flow and
horsepower restrictions.
The air compressor packages include after-coolers (E-710A/B). Cooled air from the
compressor packages is sent directly to the instrument air dryer trains. Each dryer train is
rated for 100% of the output from one compressor package (i.e. there is one 100% spare
drier train). One of the drier trains can be isolated and kept on standby. The air is filtered
as it enters the drier train (FL-710A/B). There is an auto drain with a manual bypass on
each filter.
The filtered air is routed to the dual tower air dryer (DR-710A/B). The drier reduces the
dew-point of the air to below -50°C. Each dryer consists of two packed bed towers that
contain desiccant. One bed is used to dry the instrument air, while the other bed
undergoes regeneration. Before the desiccant in the active drying bed becomes saturated
with moisture, automated switching valves reroute the airflow. The spent desiccant is
regenerated using a heat-less method. The tower is depressurized and a slipstream of dry
air is fed backward through the bed. One drying bed is on line at all times while the other
undergoes regeneration.
Immediately downstream of the dryer is a moisture detector (07-AI-1228). This detector
will indicate if there is a problem with the desiccant regeneration cycles. A dew-point
analyzer has been installed upstream of the dry air receiver (07-AE-1251 upstream of V-
711). This analyzer monitors the moisture content of the instrument air in terms of dew
point. If the dew-point exceeds -40°C, then an alarm will be tripped (07-AAH-1251).
Allowing moisture into the instrument air network can lead to water and ice accumulation.
Water can upset the performance of I/P transducers, actuators, solenoid valves, and other
intricate instruments. During winter, the water can freeze up the instruments and can
damage components.
The dried air is passed through an after filter (FL-711A/B). This filter captures any
desiccant dust that may be carried out of the air dryers. Each filter has an auto drain with a
manual bypass.
General Description
QSI compressors are single stage, positive displacement, and fluid filled- flooded rotary
screw type compressors containing two precision-machined rotors. A motor directly drives
the male rotor through a flexible drop out type coupling with no step up or step down
gearing used. The male rotor has four lobes that mesh with a female rotor consisting of
six flutes. Both rotors are housed in a single cast iron cylinder. The unit has an inlet port
at the power input end and a discharge port at the opposite end.
Most models are equipped with a positive displacement fluid pump mounted to the
compressor to circulate fluid through the system. Models without a fluid pump use positive
pressure in the reservoir to circulate the fluid.
All components are attached to a heavy-duty steel frame.
Controls and indicators are arranged on a control panel. Acoustical cabinets are available
to reduce sound levels.
124
The Compression Cycle
The compression cycle of a rotary compressor is a continuous process from intake to
discharge with no reciprocating mechanism starting and stopping as found in reciprocating
compressors. The compressor consists of two rotors in constant mesh, housed in a
cylinder with two parallel adjoining bores. The male drive rotor has four lobes that mesh
with six flutes in the female rotor. All parts are machined to exacting tolerances.
As the rotor rotates, (male-clockwise as viewed from the power input end) air is drawn into
the cylinder through the inlet port located at the power input end. A volume of air is
trapped as the rotor lobes pass the inlet cut off points in the cylinders. Compression
occurs as the male rotor rolls into the female flute, progressively reducing the space
thereby raising the pressure. Compression continues until the lobe and flute pass the
discharge port. The compressed air is then discharged into the air/fluid reservoir. There
are four complete compression cycles for each complete rotation of the male rotor.
125
Air Flow
With the compressor operating, a partial vacuum is produced at the compressor inlet. Air entering
via the compressor air filter flows through the air inlet valve into the rotor housing where it
is compressed, then discharged into the air/fluid reservoir. Compressed air passes through
the complete system then through a minimum pressure check valve to the service
connection.
Cooling System
Fluid Coolers
Fluid coolers may use either air or water as a cooling medium. At Surmont Phase 1 we use Air-
cooled fluid coolers. The following descriptions point out the major differences between
the two types of coolers.
Air-cooled Fluid Coolers
The air-cooled fluid cooler and aftercooler are the finned aluminum tube, one piece design. Ambient
air is forced through the fins by a motor driven fan, cooling the fluid and air in the tubes.
To maintain proper compressor operation, the ambient air temperature should not exceed
the temperature of 110°F. The cooler fins must be kept clean at all times. Fluid leaving the
126
receiver passes through a thermal mixing valve before traveling on to the cooler. The
purpose of the thermal valve is to maintain a minimum fluid discharge temperature at the
compressor of approximately 180°F.
Water-cooled Fluid Coolers
Water-cooled fluid coolers are the shell and tube design. Fluid passes through the shell transferring
its heat to the water flowing through the tubes. Fluid leaving the cooler does not pass
through a thermal mixing valve as in an air-cooled unit, but goes directly to the fluid filter
and the compressor. Fluid discharge temperature at the compressor is maintained by a
water temperature regulating valve located in the discharge water line. The water
temperature regulating valve uses a probe to sense fluid temperature and opens and
closes, governing water flow through the cooler.
Aftercoolers
Aftercoolers reduce the amount of water in the discharge air. They are used to lower the
temperature of the discharge air thereby condensing water vapour from the compressed
air. This allows most of the contained water to be trapped and expelled from the unit
reducing water related problems downstream.
Air-cooled Aftercoolers are part of the air-cooled fluid cooler. Cooling air from the fan is blown
through the aftercooler and the fluid cooler.
Water-cooled Aftercoolers are placed in series with the fluid cooler. Incoming water is first directed
through the aftercooler and then on to the fluid cooler.
A combination moisture separator and water trap is provided for collecting and expelling water to the
customer's drain.
Capacity Control System
As the motor starts driving the compressor rotor, air is drawn in, compressed and discharged into the
air/fluid reservoir. When the air pressure in the air/fluid reservoir exceeds the set point of
the pilot valve (normally 110 pisg), the valves opens and passes a controlled volume of air
to the inlet valve air cylinder. Other pressures are available optionally.
The air forces a piston to move within the cylinder, closing the inlet valve. The compressor will
continue to run, matching air demand with air delivery by constantly adjusting the position
of the inlet valve. The inlet valve regulates compressor capacity between 100% and nearly
0% of rated delivery.
When maximum pressure (typically 10 psig above normal full load pressure) has been obtained in the
air system, complete compressor unloading occurs. The pressure switch located in the
control panel sends a signal to the control and the solenoid valve opens, venting the
residual pressure from the blowdown valve. At the same time, control air from the
reservoir check valve is directed through the solenoid to the inlet valve air cylinder. The
inlet valve is held in a closed position preventing the intake of air into the compressor and
serving as a check valve preventing reverse air/fluid flow through the inlet valve and air
filter.
Auto/Dual (Standard)
The Auto/Dual system offers two choices of controlling the Quincy QSI Compressor. With the
selector switch in the Continuous Run position, the compressor operates continuously,
127
matching air demand as the differential pilot valve controls the position of the inlet valve.
When maximum system pressure is reached, the pressure switch opens. Venting the
air/fluid reservoir and, although the compressor continues to run unloaded, no air is
compressed.
When the Auto/Dual mode is selected, the compressor will also perform as above; however, a solid
state timer is activated when the pressure switch contacts open. This timer is adjustable
within a ten (10) minute range. When the timer reached the end of its delay period, the
compressor will automatically shut down and assume a "standby" mode. Upon a drop in
system air pressure, the pressure switch contacts close, restarting the compressor
automatically. The timer should be set, during unit start-up for a minimum of six (6)
minutes.
During the unloading/timing mode, if plant pressure should drop causing the pressure switch contacts
to close, the compressor will continue to operate, resetting the timer and instructing the
inlet valve to reopen.
Auto/Demand (Optional)
The QSI compressor with Auto/Demand controls accommodates external control signals from an
optional Quincy Demand-A-Matic multiple compressor controller.
With the selector switch in the Local mode, the compressor will operate exactly as described in the
previously mentioned Auto Dual description.
In the Remote mode, the compressor's control panel is bypassed in favor of the Demand-A-Matic
multiple compressor controller. The compressor will start, build air, unload and shutdown
on time delay as determined by the Demand-A-Matic controller. With slight modifications,
a compressor equipped with Auto/Dual controls may be converted to Auto/Demand control.
Lead/Lag
This option allows one of two different pressure control settings to be chosen for a given machine. If
the demand is greater than one unit's capability, the second compressor will automatically
turn itself on until the excess demand has been satisfied. Again, working with the standard
Auto/Dual control, the second machine would time out and turn off after the demand
dropped.
Load/No Load (Optional)

In the Load/No Load mode, the compressor does not modulate the inlet valve. The valve is either
fully open or it is closed. If systems demands include regular periods of air usage at less
than full load, a large compressed air storage capability is required with this type of
control. Without adequate storage, rapid cycling may occur. This will cause wide system
pressure fluctuations that may affect the performance of equipment using the compressed
air. Load/No Load works with Auto/Dual control to turn the compressor off during
extended periods of no demand.
Safety Sensors
128
Two high air temperature (HAT) sensors are standard on the QSI units. These sensors protect the
unit by sensing unusually high temperatures and shutting the unit down. One is located in
the discharge line from the compressor to the air/fluid reservoir. The second is located in
the top of the air/fluid reservoir. These sensors are set to trip at approximately 225°F.
The sensors are nonadjustable.
Indicators
129
Main Power on Light - Power from the main disconnect will remain lit as long as there is power to
the unit, regardless of the position of the selector switch.
High Discharge Air Temperature Light - Lit when there is a high discharge temperature.
Fluid Filter Change Light - Indicates excessive pressure differential across the fluid filter. It is
used to determine fluid filter change intervals.
Air/Fluid Separator Element Differential Light - Indicates excessive pressure differential across
the air/fluid separator element.
Air Intake Filter Service Light - Indicates when the filter element needs to be cleaned or
replaced.
Gauges
Hour meter
Air Pressure Gauge
Air Outlet Temperature - The normal reading is 170°F-190°F.
Percent Capacity Gauge - Percent capacity of the unit or how much air is being used.
Pre-start checks
- The area around the Compressor should be clean of debris.
- Check fluid level in the Air/Fluid Reservoir.
- Check the Fan and Fan mounting for tightness
- Manually rotate the compressor through enough revolutions to ensure no mechanical restrictions
- Check pressure connections for tightness.
- Check to see if all relief valves are in place.
- Check to make sure all panels and guards are in place and mounted securely.
- Check fuses, circuit breakers and thermal overloads for proper size.
- Close the main power disconnect switch and job the starter switch button to check the rotational
direction of the compressor.
- Check the fan rotation (air flows through the coolers).
Fluid Scavenging System
130
Fluid from inside the separator element is returned to the inlet valve or airend by a scavenger tube
positioned inside the separator element, through an orifice and tube connected to the
compressor. Failure to keep the orifice clean will result in excessive fluid
carryover. Cleaning of the orifice should be performed as follows:
- When no fluid is seen moving through the sight glass.
- When excessive fluid carryover is detected.
- Every fluid change.
- Once per year
Air Filter
A heavy-duty air filter is standard on all QSI models. It is a two stage, dry type element. The first
stage is cyclonic. Centrifugal air flow spins the larger dirt particles to the outside walls of
the filter canister. In the second stage, air passes through the filter element with an
efficiency of 99.9% as tested by SAE J7266 test code specifications. Removal and
replacement of the element is accomplished by unscrewing the wing nut and exchanging
the element. Replacing the element must be done carefully to ensure the element is
seated correctly on it's mounting base.
Control Line Air Filter
An automatic draining control line filter is used. Draining occurs only when the compressor is in the
unloaded condition.
Lubrication
Most QSI compressors are equipped with a positive displacement fluid pump mounted to the
compressor and directly driven by one of the rotors. Fluid is circulated through the cooler,
fluid filter and into the compressor. In the compressor, fluid is diverted through internal
passages to ensure positive lubrication of the bearings and shaft seal. The remainder of
the fluid is injected at the beginnings stage of the compression cycle to seal clearances and
to cool and lubricate the rotors. Models not equipped with a fluid pump use pressure
differential to circulate the fluid. Positive pressure maintained in the reservoir forces the
fluid throughout the machine.
Fluid Level
Fluid level is monitored by a sight glass or a dial gauge while in operation. Fluid level should be in
the "run" area on the dial gauge or completely fill the sight gauge. DO NOT OVERFILL.
Each unit comes with a fluid level sight gauge, fluid fill opening, and a fluid drain in the reservoir.
The fill plug is drilled to allow some pressure to escape before the plug is completely
removed. If there is air releasing when this is removed then replace it and depressurize
the unit before proceeding.
Troubleshooting
Probable Causes: Failure to Start Corrective Action:

Power not turned "On" Turn the power "On" by closing the main
disconnect switch or circuit breaker.
Blown control circuit fuse Replace fuse. Find and correct cause.
131
Safety circuit shutdown resulting from high See: High discharge air temperature
discharge air temperature troubleshooting guide.
In the Thermal overload relays tripping Reset overload relay and press the start
button.
Low voltage Check the voltage at the entrance meter
and compare to the motor terminals.
Faulty start switch Check power supply to the unit.
Power Failure Replace the relay.
Faulty control relay Check all wiring terminals for contact and
tightness.
Loose wire connections Check HAT switch.
Faulty transformer Check secondary voltage on the
transformer.
Probable Causes: Unscheduled Corrective Action:

Shutdown
High discharge air temperature See: High discharge air temperature
troubleshooting guide.
Thermal motor overload relays tripping Reset overload relay and press the start
button.
Power failure Check power supply to the unit and fuses.
Faulty HAT sensors Contact service tech.
Loose wire connections Check all wiring terminals for contact and
tightness
Faulty control relay Replace relay
Probable Causes: Thermal Overload relay Corrective Action:

tripping
Excessive discharge pressure Lower full load pressure setting at control
panel
Low voltage Check voltage and amperages while
operating at full load pressure.
Loose overload connection TIGHTEN MOUNTING SCREWS ON
THERMAL
OVERLOAD.
Incorrect thermal overload relay setting CHECK MOTOR NAMEPLATE AND COMPARE
TO
OVERLOAD RELAY SETTING.
Loose motor or starter wiring CHECK ALL CONNECTIONS FOR
TIGHTNESS.
Faulty motor CHECK MOTOR STARTER WIRING BEFORE
REMOVING
MOTOR. REMOVE MOTOR AND HAVE
TESTED AT
MOTOR MANUFACTURER REPAIR CENTER.
132
Probable Causes: Low Air Delivery: Corrective Action:
PLUGGED AIR INTAKE FILTER ELEMENT CLEAN AIR FILTER ELEMENT OR REPLACE
WITH NEW
ELEMENT.
EXCESSIVE LEAKS IN THE SERVICE LINES CHECK SERVICE LINES FOR LEAKS WITH
SOAP SUDS.
REPAIR AS NECESSARY.
INLET VALVE NOT FULLY OPEN CHECK FOR BUILD UP OR GUMMING OF
SHAFT.
RESTRICTED FLUID FLOW CHECK FLUID FILTER FOR PLUGGING.
Probable Causes: Low Receiver Corrective Action:

Pressure:
EXCESSIVE AIR DEMAND REEVALUATE AIR DEMAND. INSTALL
ADDITIONAL
COMPRESSORS AS NEEDED.
EXCESSIVE LEAKS IN THE SERVICE LINES CHECK SERVICE LINES FOR LEAKS WITH
SOAP SUDS.
REPAIR AS NECESSARY.
INLET VALVE NOT FULLY OPEN CORRECT IN ACCORDANCE WITH THE
INSTRUCTIONS
IN "INLET VALVE NOT OPENING OR
CLOSING IN
RELATION TO AIR DEMAND" SECTION OF
TROUBLESHOOTING GUIDE.
PLUGGED AIR INTAKE FILTER REPLACE AIR FILTER ELEMENT.
DIFFERENTIAL PILOT VALVE NOT SET DIFFERENTIAL PILOT VALVE TO ACHIEVE
CORRECTLY DESIRED MODULATION RANGE.
AIR PRESSURE SWITCH NOT SET ADJUST AIR PRESSURE SWITCH TO
CORRECTLY ACHIEVE DESIRED
CUT-IN AND CUT-OUT PRESSURE
FAULTY RECEIVER PRESSURE GAUGE CHECK AND REPLACE AS NECESSARY.
Probable Causes: High Receiver Corrective Action:

Pressure:
AIR PRESSURE SWITCH NOT SET ADJUST AIR PRESSURE SWITCH TO
CORRECTLY ACHIEVE DESIRED
CUT-IN AND CUT-OUT PRESSURE. ENSURE
UNLOAD
PRESSURE DOES NOT EXCEED MAXIMUM
OPERATING
PRESSURE.
INLET VALVE NOT CLOSING AT LOWER AIR CORRECT IN ACCORDANCE WITH
DEMAND INSTRUCTION ON
"INLET VALVE NOT OPENING OR CLOSING
IN
133
THIS
BLOWDOWN VALVE NOT RELIEVING CHECK CONTROL SOLENOID AND
RECEIVER PRESSURE BLOWDOWN VALVE.
Probable Causes: High Discharge Air Corrective Action:

Temperature and/or High Fluid
Injection Temperature:
NOT ENOUGH COOLING WATER FLOWING CLEAN COOLER. CHECK WATER SYSTEM
THROUGH FOR
COOLER (WATER-COOLED MODELS ONLY) POSSIBLE RESTRICTIONS, INCLUDING
WATER
TEMPERATURE REGULATING VALVE. CLEAN
OR
ADJUST, IF NECESSARY
INADEQUATE CIRCULATION OF COOLING CHECK LOCATION OF COOLER AND ASSURE
AIR AT THE NO
COOLER (AIR-COOLED MODELS ONLY) RESTRICTION TO FREE CIRCULATION OF
COOLING AIR.
CHECK COOLER FIN AND CLEAN AS
NECESSARY.
Low FLUID LEVEL IN RESERVOIR ADD FLUID TO RECOMMENDED LEVEL.
CHECK FLUID
SYSTEM FOR LEAKS.
CABINET PANELS REMOVED REPLACE ALL PANELS, ENSURE ALL
SEALING
SURFACES AND MATERIALS ARE
SATISFACTORY.
COOLER PLUGGED CLEAN COOLER, FIND AND CORRECT
CAUSE OF
CONTAMINATION.
FLUID FILTER PLUGGED REPLACE FLUID FILTER ELEMENT(S).
EXCESSIVE AMBIENT TEMPERATURES MAXIMUM AMBIENT FOR PROPER
OPERATION IS
LISTED IN DATA SHEET. VENTILATE ROOM
OR
RELOCATE COMPRESSOR.
INCORRECT FAN ROTATION CORRECT ROTATION IS WITH THE FAN
PUSHING THE
AIR THROUGH THE COOLER. REVERSE
MOTOR
STARTER LEADS L 1AND L2.
IMPROPER FLUID USE RECOMMENDED FLUIDS ONLY. REFER
TO
"COMPRESSOR FLUIDS" SECTION OF THIS
MANUAL.
134
CLOGGED AIR FILTER CLEAN OR REPLACE AS NECESSARY.
FAULTY THERMAL VALVE REPAIR OR REPLACE AS NECESSARY.
FAULTY GAUGES CHECK AND REPLACE AS NECESSARY.
AIREND FAILURE CONTACT AN AUTHORIZED QUINCY
DISTRIBUTOR.
Probable Causes: Frequent Air/Fluid Corrective Action:

Separator Clogging:
FAULTY AIR FILTER OR INADEQUATE IF FAULTY AIR FILTER ELEMENTS, REPLACE
FILTER FOR THE THEM. IF
ENVIRONMENT AIR FILTER IS INADEQUATE FOR THE
ENVIRONMENT,
RELOCATE THE INTAKE AIR TO A CLEAN
SOURCE.
FAULTY FLUID FILTER REPLACE FLUID FILTER ELEMENT.
FLUID BREAKDOWN CORRECT IN ACCORDANCE WITH THE
INSTRUCTION IN
"FLUID BREAKDOWN" SECTION OF THE
INCORRECT FLUID SEPARATOR ELEMENT USE GENUINE QUINCY REPLACEMENT
ELEMENTS
ONLY
EXTREME OPERATING CONDITIONS SUCH OPERATE COMPRESSOR AT RECOMMENDED
AS HIGH RESERVOIR PRESSURE AND DISCHARGE
COMPRESSOR DISCHARGE TEMPERATURES, AIR
HIGH TEMPERATURE
AMBIENT TEMPERATURE WITH HIGH
HUMIDITY AND
HIGH RESERVOIR PRESSURE
MIXING DIFFERENT GRADES OR TYPES OF Do NOT MIX DIFFERENT GRADES OR TYPES
FLUIDS OF FLUID.
Do NOT MIX FLUIDS FROM DIFFERENT
MANUFACTURERS.
INCORRECT FLUID FOLLOW FLUID SPECIFICATIONS AS
DESCRIBED IN
"COMPRESSOR FLUIDS" SECTION OF THIS
MANUAL.
CONTAMINATED FLUID CHANGE FLUID. SERVICE AIR FILTER AND
FLUID
FILTER IN ACCORDANCE WITH THE
RECOMMENDED
MAINTENANCE SCHEDULE.
Probable Causes: Fluid Discharge Out Corrective Action:

Blowdown Valve:
Too HIGH FLUID LEVEL IN RESERVOIR ADJUST FLUID LEVEL TO RECOMMENDED
135
FLUID
LEVEL BY DRAINING THE RESERVOIR. USE
FLUID
LEVEL GAUGE AS A GUIDE.
AIRIFLUID RESERVOIR BLOWS DOWN TOO CHECK FOR PROPER BLOWDOWN VALVE
FAST SIZE.
INLET VALVE NOT CLOSING COMPLETELY CORRECT IN ACCORDANCE WITH
INSTRUCTIONS IN
"INLET VALVE NOT OPENING OR CLOSING
IN
THIS
TROUBLESHOOTING GUIDE
Probable Causes: Frequent Fluid Filter Corrective Action:

Clogging:
FAULTY INDICATOR REPLACE INDICATOR ASSEMBLY.
INCORRECT FLUID FILTER USE GENUINE QUINCY REPLACEMENT
FILTERS ONLY.
FAULTY, INCORRECT OR INADEQUATE AIR REPLACE AIR FILTER ELEMENT.
FILTER
FLUID BREAKDOWN SEE FLUID BREAKDOWN SECTION OF THIS
SYSTEM CONTAMINATION CHECK AND CLEAN SYSTEM OF ALL DIRT,
CORROSION
AND VARNISH.
Probable Causes: Excessive Fluid Corrective Action:

Consumption:
Too HIGH FLUID LEVEL IN THE RECEIVER ADJUST FLUID LEVEL TO RECOMMENDED
FLUID
LEVEL BY DRAINING THE RESERVOIR. USE
FLUID
LEVEL GAUGE AS A GUIDE.
PLUGGED SCAVENGER LINE CLEAN SCAVENGER LINE ORIFICE AND
TUBE.
HIGH DISCHARGE TEMPERATURE CORRECT IN ACCORDANCE WITH THE
INSTRUCTIONS
IN "HIGH DISCHARGE AIR TEMPERATURE"
SECTION OF
THIS TROUBLESHOOTING GUIDE.
Low RESERVOIR PRESSURE WITH FULLY RESERVOIR PRESSURE SHOULD NOT FALL
OPEN INLET BELOW 50
VALVE PSIG WHEN RUNNING LOADED. CHECK
SYSTEM
CFM REQUIREMENT AND MINIMUM
136
PRESSURE CHECK
VALVE.
FAULTY OR DAMAGED SEPARATOR CHANGE AIR/FLUID SEPARATOR.
LEAK IN FLUID LINES CHECK FOR LEAKS AND CORRECT.
SEALFA~URE,LEAKS REPLACE SEAL ASSEMBLY AND O-RINGS.
INCORRECT FLUID USE RECOMMENDED FLUIDS ONLY. SEE
COMPRESSOR FLUID SECTION.
Probable Causes: Frequent Air Cleaner Corrective Action:

Clogging:
COMPRESSOR OPERATING IN HIGHLY USE REMOTE AIR INTAKE MOUNTING.
CONTAMINATED ATMOSPHERE
AIR CLEANER NOT ADEQUATE FOR USE SPECIALIZED AIR F~TER. CONTACT AN
CONDITIONS AUTHORIZED QUINCY DISTRIBUTOR.
Probable Causes: Inlet Valve Not Corrective Action:

Opening Or Closing In Relation To Air
Demand:
IMPROPER SETTING OF AIR PRESSURE ADJUST AIR PRESSURE SWITCH TO
SWITCH OR PROPER SETTING
FAULTY SWITCH OR REPLACE SWITCH, IF FAULTY.
EXCESSIVE MOISTURE IN CONTROL AIR SERVICE CONTROL AIR LINE FILTER DAILY.
LINE AT AIR
CYLINDER
IMPROPER FUNCTIONING OF INLET VALVE CHECK PISTON AND CYLINDER BORE.
PISTON REPAIR OR
REPLACE AS NEEDED.
JAMMED AIR INLET VALVE ASSEMBLY CHECK AIR INLET VALVE BUSHING AND
SHAFT.
CHECK PISTON AND CYLINDER BORE.
REPAIR OR
REPLACE AS NEEDED.
FAULTY SOLENOID VALVE REPAIR OR REPLACE AS NECESSARY.
FAULTY SHUTTLE VALVE REPAIR OR REPLACE AS NECESSARY.
LOOSE WIRING CONNECTIONS AT CHECK AND TIGHTEN WIRING TERMINALS.
SOLENOID VALVE/
PRESSURE SWITCH
BROKEN SPRING IN AIR INLET VALVE REPLACE SPRING.
Probable Causes: Compressor Does Not Corrective Action:

Unload When There Is No Air Demand:
INCORRECT AIR PRESSURE SWITCH ADJUST TO PROPER SETTING.
SETTING
FAULTY AIR PRESSURE SWITCH REPLACE SWITCH.
FAULTY BLOW DOWN VALVE REPAIR OR REPLACE AS NECESSARY.
FAULTY SOLENOID VALVE REPAIR OR REPLACE AS NECESSARY.
137
FAULTY DIFFERENTIAL PILOT VALVE REPAIR OR REPLACE AS NECESSARY.
LEAKS IN CONTROL LINES CHECK ALL CONTROL LINE FITTINGS AND
TUBINGS.
LEAKS IN SERVICE LINES CHECK LINES BEFORE MPC VALVE.
Probable Causes: Compressor Does Not Corrective Action:

Revert To Load When Service Line
Pressure Drops To Reset Pressure:
FAULTY AIR PRESSURE SWITCH REpAIR OR REPLACE AS NECESSARY.
LOOSE WIRING CONNECTION CHECK AND TIGHTEN WIRING TERMINALS.
JAMMED AIR INLET VALVE ASSEMBLY CHECK AND REPAIR AIR INLET VALVE.
FAULTY SOLENOID REPAIR OR REPLACE AS NECESSARY. -
F AULTY TIMER CHECK AND REPLACE TIMER.
FAULTY DIFFERENTIAL PILOT VALVE ORIFICE PLUGGED. CLEAN OR REPLACE AS
NECESSARY.
Probable Causes: Compressor Will Not Corrective Action:

Time-out Or Shut Down When
Unloaded (Auto/Dual Only):
F AULTY TIMER CHECK AND REPLACE AS NECESSARY.
LEAKS IN CONTROL LINES CHECK AND REPAIR ANY LEAKS.
LEAKS IN SERVICE LINES CHECK PLANT AIR DISTRIBUTION SYSTEM
FOR LEAKS.
FAULTY AIR PRESSURE SWITCH REPAIR OR REPLACE AS NECESSARY.
FAULTY AIR PRESSURE SENSORS REPLACE AS NECESSARY.
Probable Causes: Excessive Water in Corrective Action:

Plant Air Distribution System:
CLOGGED MOISTURE SEPARATOR/TRAP CLEAN OR REPLACE AS REQUIRED.
INSTALLATION/APPLICATION CHECK OTHER COMPRESSORS ON SAME
SYSTEM.
FAULTY COOLER/LEAKS REPLACE COOLER.
Probable Causes: Pressure Relief Valve Corrective Action:

Exhausting:
DIFFERENTIAL PRESSURE REGULATOR NOT DIFFERENTIAL PRESSURE REGULATOR TO
SET OBTAIN DESIRED MODULATION RANGE.
CORRECTLY
AIR PRESSURE NOT SET CORRECTLY ..READJUST AIR PRESSURE SWITCH SO
THAT THE
COMPRESSOR UNLOADS AT THE DESIRED
PRESSURE.
AIR INLET VALVE NOT CLOSING PROPERLY CORRECT IN ACCORDANCE WITH THE
IN· INSTRUCTION IN
RELATION TO AIR DEMAND "INLET VALVE NOT OPENING OR CLOSING
IN
138
THIS
PLUGGED SEPARATOR REPLACE WITH NEW AIRIFLUID
SEPARATOR.
FAULTY RECEIVER PRESSURE GAUGE CHECK GAUGE FOR ACCURACY AND
REPLACE IF
NECESSARY.
FAULTY PRESSURE RELIEF VALVE CHECK PRESSURE RELIEF VALVE FOR
CORRECT
PRESSURE SETTING. IF VALVE IS STILL
LEAKING,
REPLACE IT.
Probable Causes: Excessive Water Corrective Action:

Content In Fluid:
WATER DRAIN INTERVALS DRAIN WATER AS NEEDED TO REDUCE
WATER
CONTENT IN FLUID BELOW 200 PPM.
DISCHARGE TEMPERATURE TOO LOW CHECK OPERATION OF THERMOSTATIC
VALVE OR
WATER REGULATING VALVE. IF
CONDITION
CONTINUES, CONSULT QUINCY SERVICE
DEPARTMENT.
Maintenance Schedule
Interval: Action:
Periodically/DAILY: MONITOR ALL GAUGES AND INDICATORS
(8 HOURS MAXIMUM) FOR
NORMAL OPERATION.
CHECK FLUID LEVEL.
OBSERVE FOR FLUID LEAKS.
OBSERVE FOR UNUSUAL NOISE OR
VIBRATION.
DRAIN WATER FROM AIR/FLUID
RESERVOIR.
MONTHLY: SERVICE AIR FILTER AS NEEDED. (DAILY
OR WEEKLY
IF EXTREMELY DIRTY CONDITIONS EXIST)
CLEAN AFTERCOOLER AND FLUID COOLER
FINS.
(AIR-COOLED ONLY)
WIPE ENTIRE UNIT DOWN TO MAINTAIN
APPEARANCE.
6 MONTHS OR EVERY 1000 HOURS: TAKE FLUID SAMPLE.
139
CHANGE FLUID FILTER.
CHECK PRESSURE RELIEF VALVE.
PERIODICALLY/YEARLY: Go OVER UNIT AND CHECK ALL BOLTS FOR
TIGHTNESS.
CHANGE AIRIFLUID SEPARATOR.
CHANGE AIR FILTER.
LUBRICATE MOTORS.
TEST PRESSURE RELIEF VALVE FOR
PROPER OPERATION.
CHECK SAFETY (HAT) SHUTDOWN SYSTEM
(CONTACT A QUALIFIED SERVICE
TECHNICIAN)
140
141
Dry Air Receiver
Dry air from the instrument air package is sent to a dry air receiver (V-711). This vessel
maintains a reserve of compressed air to protect the plant from any surges in air demand.
There is sufficient volume in the vessel to shut down the entire plant safely in case of an
emergency. The dry air receiver has a manual drain. Under normal operating conditions,
there should be no water accumulation in this vessel. Operators should periodically crack
open the drain valve to verify that no moisture is getting through the drier trains.
PRE-FILTER
The pre-filter is perhaps the single most important item determining the long-term
performance of a desiccant type air dryer. It is essential that the pre-filter receives
periodic maintenance. Failure to maintain an efficient pre-filter will produce the
following results:
A) Damage to the desiccant, i.e. oil contamination is irreparable and will
directly affect the ability of a desiccant dryer to produce an acceptable dew point.
Replacement is the only solution after contamination.
B) Potential contamination of the after-filter elements which will require
replacement.
C) Contamination of downstream instrumentation.
Pre-Filter Maintenance
Ensure the pre-filter has a functioning automatic drain installed which receives
daily attention. A pre-filter with a differential pressure reading above 5-8 PSID
should be replaced. A pre-filter element has an expected life span of between 6
months to 1 year.
AFTER-FILTER
The after-filter is designed to remove dust caused from desiccant movement, it
will protect instrumentation downstream where even minimal dust is not
acceptable. The after-filter element should be replaced when the differential
pressure is greater than 5-8 PSID. Potential contamination of the after-filter
element will require replacement.
DESCRIPTION OF OPERATION
4.1 HD TYPE DRYER
4.1.1 The Xebec HD dryer has a NEMA cycle time of 10 minutes or 4 minutes
depending upon the air quality desired. In a 10 minute cycle, 5 minutes is
dedicated to drying for each chamber (5 minutes half cycle). In a 4 minutes
142
cycle, the half cycle is then 2 minutes. The cycle timer is factory preset and
is not field adjustable.
4.1.2 Through the 3-way inlet switching valve wet air enters either desiccant
chamber at the inlet (bottom) and is dried as it flows upward through the
desiccant bed. Dry air exits the dryer through the outlet check valve.
4.1.3 At the outlet of each chamber, a portion of the dry air (purge air) is diverted
to the regenerating chamber. The dry air, at near atmospheric pressure,
will remove previously adsorbed moisture as it flows downward through the
desiccant bed exiting through the purge exhaust muffler.
4.1.4 The purge air is controlled by a purge orifices located in the purge line.
Purge orifice(s) are calibrated at the factory based on operating conditions
listed in the Specification and Data section of this manual. If the dryer is
intended to be operating at conditions others than those specified, contact
Xebec Inc. or our nearest representative for adjustments.
4.1.5 Near the end of each half cycle, the chamber being regenerated will be repressurized.
For this to occur, the exhaust valve of the chamber being
regenerated closes while purge air continues to flow. Re-pressurizing the
regenerated chamber to operating pressure before placing it into service
minimizes fluidization of the desiccant and helps prevent desiccant
abrasion which causes desiccant dust to prematurely block pilot and afterfilter
elements.
4.1.6 Chamber switchover takes place when both towers are fully pressurized
to minimize desiccant movement. 3-way solenoid valves control pilot air
directed to the main switching valve actuator (double acting type) and to
the purge exhaust valves.
When switchover is complete, the regenerated tower will be placed into
service and the exhausted tower will begin a depressurization/regeneration
cycle.
DESCRIPTION OF OPERATION (Continued)

4.2 DRYER OPERATING SEQUENCE (No control or alarm options)
The Xebec HD air dryer uses a PLC as its standard control panel. Anytime power
is supplied to the controller, the dryer will begin the sequence of operation at
STEP 1 and continue as follows:
STEP 1 Energize control panel.
Power is turned ON - electrical circuit energized.
The exhaust valves remain closed.
The inlet valve does not change positions.
The repress timer counts down for approximately 40 seconds and then
energizes solenoid valve EV-3 opening the repress valve. (SEE NOTE 1)
STEP 2 Select left chamber drying.
Energize solenoid EV-1 L.
Inlet valve positioned for left chamber drying.
Open right chamber exhaust valve.
De - energize EV-3.
Regeneration timer begins countdown for 4 minutes - 20 seconds.
STEP 3 Right chambers repress.
143
De - energize EV-1 L.
Close right chamber exhaust valve.
Inlet valve remains in current position.
Energize solenoid EV-3.
The repress valve is activated.
The repress timer begins countdown of 40 seconds. (SEE NOTE 1)
STEP 4 Right chamber drying.
Energize solenoid EV-1 R.
Inlet valve positioned for right chamber drying.
Open left exhaust valve.
De - energize EV-3.
Regeneration timer begins countdown for 4 minutes - 20 seconds.

Left chamber repress.
De - energize solenoid EV-1 R.
Close left chamber exhaust valve.
Inlet valve remains in current position.
Energize solenoid EV-3.
The repress valve is activated.
The repress timer begins countdown of 40 seconds. (SEE NOTE 1)
The dryer has completed 1 full cycle and will repeat steps 2 through 5 until power
is removed from the control panel.
4.3 OPERATING SEQUENCE (AUTODEW OPTION)
The Xebec HD air dryer uses a Siemens PLC in its AUTODEW control panel. It
uses a retentive programming that remembers where it was after a power failure.
The program is working as follows:
STEP 1 Select left chamber drying.
Energize EV-1 L.
Inlet valve positioned for left chamber drying.
When 4 seconds have passed, go to STEP 2.
STEP 2 Open right exhaust valve.
Keep energized EV-1 L.
If not in Autodew mode then energize EV-2R.
When regeneration time has passed, go to STEP 3.
STEP 3 Re-pressurize right chamber.
Keep energized EV-1 L.
Energize EV-3 (see Note 1)
When repress time has passed and
PS-1 and PS-2 are ON, go to STEP 4.

Select right chamber drying.
Energize EV-1 R.
Inlet valve positioned for right chamber drying.
When 4 seconds have passed, go to STEP 5.
144
STEP 5 Open left exhaust valve.
Keep energized EV-1 R.
If not in Autodew then energize EV-2L.
When regeneration time has passed, go to STEP 6.
STEP 6 Re-pressurize left chamber.
Keep energized EV-1 R.
Energize EV-3 ( See Note 1 )
When repress time has passed and
PS-1 and PS-2 are ON, go to STEP 1.
NOTE 1: EV-3 and repress valves are used only if dryer operating at pressure
above 120 PSI (G) and / or dryer operating on a timing cycle other
than 10 minute cycle.
NOTE 2: If power failure occurs to the dryer or unit is turned off both exhaust
valves will close. The inlet valve will remain in the same position as
before power was removed. The dryer will re-pressurize both
chambers but continue to dry through the same chamber.
When the power is returned, the control board will return to STEP 1.
See previous pages for STEP 1. The PLC (Autodew option) controller
will return to the step in program before power failure.
NOTE 3: The actual timer setting may differ from the previously noted
sequence. Example: A dryer requiring 30 seconds to re-pressurize
the regenerating chamber will have a regeneration time of 4 minutes
and 30 seconds. The half cycle time will remain at 5 minutes and full
cycle at 10 minutes.
NOTE 4: The regeneration and re-pressurization times should be adjusted by
Xebec trained personnel only. Changing the factory settings will
result in loss of dew point and/or failure to re-pressurize before
changeover.

4.4 ALARMS
4.4.1 Common alarm relay
Common alarm relay comes with any optional alarm. If anyone of the alarms are
activated, the common alarm relay will de-energise and remote a dryer failure
alarm.
4.4.2 Switching Failure Alarm (Optional, Included with AUTODEW option)
Two pressure switches, sensing desiccant chamber pressure, are provided. An
alarm will be activated if both chambers remain at full pressure when
regeneration is required. Furthermore, if pressure in both chambers remain below
set pressure, after depressurization an alarm will be activated. In both cases, the
dryer will continue to cycle.
NOTE: Dryers equipped with AUTODEW and operating in the AUTODEW
mode do not depressurize during the purge cycle (and do not
purge) when an acceptable dew point is maintained. During this
condition the switching failure alarm is cancelled.
4.4.3 High Humidity Alarm (Optional, Included with AUTODEW option)
145
The hygrometer provided has been programmed to initiate an alarm if the dryer
outlet dew point falls below the setting. An alarm light is provided.
4.4.5 Event of probe connection failure
If the hygrometer board to probe connection fails then a fault will observed by the
hygrometer. The high humidity alarm light will come on. The dryer will go into a
fixed cycle mode. The digital display will indicate s -202.
MAINTENANCE SCHEDULE
Xebec Inc. heaterless air dryers will give trouble free operation if the following
maintenance schedule is observed.
DAILY A) Check pre-filter drain operation.
MONTHLY A) Check operating conditions. Check purge rate.
B) Check pressure drop across each filter (to be less
than 35 kPa - 5 PSIG).
C) Check dryer operation schedule (follow program
steps listed in "Description of Operation" section).
EVERY 3 MONTHS A) Check outlet dew point.
B) Blow down relief valves - ear and eye protection
needed.
EVERY 6 MONTHS A) Inspect filter elements. Replace if necessary.
EVERY 12 MONTHS A) Inspect desiccant and replace if badly broken or
contaminated with oil.
B) Inspect check valve seats.
C) Inspect pilot operated air valves.
D) Inspect solenoid valves.
Problem Possible Cause Solution

Loss of dew point 1. Insufficient purge air flow Check purge flow required.
for reactivation or back
pressure on
reactivating chamber.
2. Inlet air pressure below Check this condition, the
the efficiency of this dryer
designed condition. decreases as the working
pressure decrease.
3 Inlet air flow higher than the Check the SCFM flow of
designed condition. air being dried.
4. Liquids entering the wet Check the incoming line.
air inlet. Inspect pre-filters and
be certain that automatic
traps are not clogged.
5. Inlet air temperature the Check the compressor
above after-cooler and cooling
146
designed conditions. system.
6. Desiccant broken and Replace desiccant and
coated with oil. correct the source of trouble.
Check pre-filter.
7 Mufflers dirty resulting in Replace mufflers.
chamber
backpressure.
Excessive pressure drop in 1. Filters dirty. Replace element(s) as
filters required.
Excessive pressure drop in 1 Inlet and/or outlet screen Inspect and clean.
dryer dirty
2 Excessive flow rate. Check the SCFM flow of air
being dried.
Failure to switch 1 No input power. Check wiring.
Check fuse.
2 Defective solenoid valves. Check for burned coil,
Check for plugged or leaking
valve body.
Clean or replace solenoid
plunger as required.
3 No pilot air. Check pilot air line.
Be certain shut-off valve is
open and in-line
filter is clean.
Back pressure on 1 Check valves leaking. Verify O-Ring seats.
reactivating chamber Check for foreign material
under seat.
2 Excessive purge flow. Check required purge flow.
3 Leaking inlet switching Inspect seats and seals.
valve. Clean and replace as
required.
4 Re-pressurization valve Inspect and clean or replace
Failed- open. as required.
5 Depressurizing and purge Replace mufflers.
exhaust mufflers plugged.
AUTODEW (OPTIONAL)
10.1 DESCRIPTION OF AUTODEW
Xebec Inc. heaterless air dryers are designed and selected to provide a specific
pressure dew point performance (generally -40°F PDP (-40°C PDP)) at the most
severe operating conditions specified. (Maximum flow at lowest pressure and
147
highest inlet temperature). The purge flow rate required for the regeneration of
the dryer is calculated and adjusted to achieve this dew point and is based on
these conditions. For example, for dryers operating at 100 PSIG (690 kPa) and
100°F (38°C) the purge flow rate is approximately 15% of the specified maximum
inlet flow.
Substantial savings of purge air can be realized if the inlet conditions to the dryer
are less severe or if the dew point required is higher (wetter) than specified.
Under the following conditions, valuable compressed air normally used during
regeneration will be saved. These savings may be substantial if:
• The inlet flow to the dryer is lower than specified or intermittent. (For example
lower air demand during night shifts or on weekends).
• The inlet pressure is higher than the minimum inlet pressure specified,
consequently the resulting actual inlet flow (ACFM) to the dryer will be lower.
• The inlet temperature is lower than the maximum inlet temperature specified.
The resulting water load to the dryer will be lower.
• The dew point required at certain times of operation might be higher (wetter)
than specified. The DDS system provides a field adjustable dew point setting
over the full range of the meter scale thus savings in purge air can be
realized.
10.2 HOWAUTODEWWORKS
The normal cycle of a heaterless dryer is 10 minutes, Le. each desiccant tower
is in service for 5 minutes, followed by a 5 minute regeneration cycle. This dew
point can be observed on a direct reading digital display, calibrated in degrees
Fahrenheit or Celsius.
HOW AUTODEW WORKS (continued)

Prior to the start of each regeneration cycle, (that is before depressurization of the
desiccant tower to be regenerated takes place), the AUTODEW electronic
controls diagnose the condition of the outlet flow of the dryer. Should the dew
point reading be better than the set point, the purge exhaust valve will not open
and the purge cycle will not take place. This results in saving of the air normally
dumped to atmosphere and saving of the purge air normally consumed during
regeneration.
The inlet valve will continue to change positions based upon the dryers cycle
time.
HAZARDS IDENTIFICATION
A. EMERGENCY OVERVIEW:
Physical Appearance and Odour:
White powder solid, odourless
Warning Statements:
DUSTS IN HIGH CONCENTRATIONS MAY CAUSE SKIN, EYE AND
RESPIRATORY TRACT IRRITATION.
B. POTENTIAL HEALTH EFFECTS:
Acute Eye:
148
Causes foreign body irritation only.
Acute Skin:
Non-irritating. Skin absorption not likely
Acute Inhalation:
Low acute inhalation toxicity. May cause lung irritation, shortness of breath, chest
pain.
Acute Ingestion:
Low acute oral toxicity. May cause constipation.
Chronic Effects:
This product does not contain any ingredient designated by IARC, NTP, ACGIH or
OSHA as probable or suspected human carcinogens.
4. FIRST AID MEASURES
FIRST AID MEASURES FOR ACCIDENTAL:
Eye Exposure:
Hold eyelids open and flush with a steady, gentle stream of water for at least 15 minutes.
Seek medical attention if irritation develops or persists or if visual changes occur.
Skin Exposure:
In case of contact, wash with plenty of soap and water. Seek medical attention if irritation
develops or persists.
Inhalation:
If respiratory irritation or distress occurs remove victim to fresh air. Seek medical attention
if respiratory irritation or distress continues.
Ingestion:
No harmful affects expected. If appreciable quantities are swallowed, call a physician or
poison control center. Do not leave victim unattended.
MEDICAL CONDITIONS POSSIBLY AGGRAVATED BY EXPOSURE:
Inhalation of product may aggravate existing chronic respiratory problems such as asthma,
emphysema or bronchitis. Skin contact may aggravate existing skin disease.
NOTES TO PHYSICIAN
All treatments should be based on observed signs and symptoms of distress in the patient.
Consideration should be given to the possibility that overexposure to materials other than
this product may have occurred.
Treat symptomatically. No specific antidote available.
149
150
Instrument Air Distribution
Instrument air distribution pressure is monitored by two independent transmitters (07-PIT-
1254 and 1255). One transmitter will trip an alarm if the pressure exceeds 900 kPag or falls
below 620 kPag (07-PAH/PAL-1254). This transmitter is also used to provide a low-low
pressure shutdown signal. The second transmitter provides a redundant low-low pressure
shutdown signal. The consequences of a plant-wide shutdown are serious. To prevent a
transmitter failure from tripping a nuisance shutdown, both instruments must show low-low
pressure in order to shutdown the facility (07-PALL-1254 and 1255).
A back-pressure regulator is installed immediately upstream of every utility air station.
These regulators help prevent utility consumers from drawing down the distribution
network pressure to below 520 kPag.
Utility Air
Utility air stations are strategically located around the plant to facilitate maintenance
operations (used mainly for air tools). These stations draw air form the instrument air
system.
Pneumatic tools consume large volumes of compressed air. Instrument air is critical to the
control of the plant. Loss of pressure in the instrument air system can cause a plant-wide
emergency shutdown. To mitigate this risk, each utility air station is equipped with a
safety regulator to limit air withdrawal. These regulators are set at 520 kPag and must not
be bypassed or adjusted. They are needed to prevent high utility air demands from
drawing down the instrument air system below a minimum acceptable threshold pressure.
151
Chapter 12: Fuel Gas Sigma Thermal Bath Heater
Sigma Thermal Bath Heater
152
Unit 201
Equipment
201-FU-801 Fuel Gas Heater

201-BL-801 FD Fan
201-E-802 FD Fan Electric Pre-heater
201-V-802 Fuel Gas Odourizer
General Information
153
Fuel Gas is routed to the Bath Heater 201-FU-801 before the main inlet 07-XV-1000 at the Fuel Gas
riser. The Fuel Gas is passed though the heater and through 201-FG-802 Fuel Gas Odourizer. Fuel Gas
is feed after the heater but before the Odourizer to the Bath Heater for combustion.
Overall it is a very simple operation that is pretty hands off except for clearing the shutdowns/alarms on
the local Allen Bradley. All shutdowns/alarms are very clearly described in text on the local Allen
Bradley. If the heater is down and needs to be reset, you will have to reset the alarm on the HMI as
well as getting the control room to reset the system to get all permissives for a start. After that it is
pretty much hands off and the heater controls itself.
The Odourizer injects a small amount of odorant through a solenoid that is activated based off of flow.
The meter on the pipeline just outside the odorant reservoir (FT-1445) is what activates the solenoid.
201-FU-801 Fuel Gas Heater
Specs
Model: WB-0.70-16-1-2.0-160
Duty: 0.7 MM BTU/HR
Coil Design: 1440 psig @ 250°F
MOC: Tubes: SA 333 GR B
Stack
Flow: 5m3/min (184 SCFM)
Temp: 364°C (687°F) Max
Pressure: ATM
Fuel Gas
Inlet Temperature: 0°C (32°F)
Outlet Temperature: 30/33°C (85/91°F)
Inlet Pressure: 6870/6867 kPag (996 psig)
Gas Flow Inlet to Burner: 38m3/h (1349 SCFH)
Gas Flow Outlet to Burner: 27m3/h (947 SCFH)
Gas Flow Inlet to Heater: 4251 kg/hr (9350 lb/hr)
Gas Flow Outlet to Process: 4251 kg/hr (9350 lb/hr)
Burner
Maxon 4" EB TUBE-O-THERM® burners
EB - External blower: combustion air blower not included with
burner
Rate: 1.35 MM BTU/hr Max, 0.95 MM BTU/hr Normal
For proper burner adjustment, MAXON advises the use of an oxygen content meter. Optimal oxygen
level in exhaust stack should
read between 3 and 4 vol. % dry when measured with the burner operating at the maximum capacity
firing rate.
Typical ignition sequence

154
Pre-purge of burner and installation, according to the applicable codes and the installation’s
requirements.
Combustion air control valve shall be in the minimum position to allow minimum combustion air flow
to the burner.
Pre-ignition (typically 2s sparking in air).
Open pilot gas and continue to spark the ignitor (typically 5s).
Stop sparking, continue to power the pilot gas valves and start flame check. Trip burner if no flame
can be detected from here
on.
Check pilot flame stability (typically 5s) to prove the stable pilot.
Open main gas valves and allow enough time to have main gas in the burner (typically 5s + time
required to have main gas in
the burner).
Close the pilot gas valves.
Release to modulation (allow modulation of the burner).
Above sequences shall be completed to include all required safety checks during the start-up of the
burner (process & burner
safeties).
Expected emissions
TUBE-O-THERM® burners utilize rapid mixing of fuel and air to suppress formation of NOx. Typical NOx
formation from the burner
will be 30-40% less than conventional burners.
Temperature Control and Indication

The system utilizes several “TE’s” (temperature elements) to monitor and control the
various temperature requirements. There are (2) (TE-1411/TE-1430) TE’s located in
the shell of the heater, (2) (TE-1414, TE 1415) on the process outlet header, (1) (TE-
1413) on the process inlet header, and (1) (TE-1416) in the stack. The burner firing
rate is controlled by a temperature controller TC-1416 located in the customers DCS.
The system can control the burner firing rate based on the bath temperature through
TE-1430 and process temperature variables through TE 1414.
All TE’s monitoring liquid or hazardous gases are placed in closed thermowells to
eliminate the risk of a leak.
High Temperature Limits

High temperature limits are used to ensure that the system is not allowed to continue
operation if any of the temperature set points of the temperature limit controllers is
exceeded. The temperature inputs are created from temperature transmitters mounted
in various locations of the heater system. If a TE is to fail or malfunction, the signal will
fail in the high condition causing the burner to shut down and lock out. These burner
interlocks are referred to as a temperature indicating alarm high high.
Burner Management
The burner management system (BMS) continuously monitors all system safeties and
interlocks to ensure safe operation of the burner. It also monitors the condition of the
flame by using an ultra violet scanner to ensure that the fuel is properly burning. If for
any reason the system interlocks or safeties are not satisfied, the BMS will either
155
prevent the burner from being started or shut an operating burner down. If a system
fault is found, the BMS will sound an audible alarm and lock the burner out from firing.
The burner is not able to fire again until the system fault is corrected and the BMS is
locally reset at the control panel. For ease of identifying the problem, the cause of the
shutdown will be indicated on the control panel display.
Burner Modulating Control

Burner Modulating Control is achieved though the clients DCS system. BMS will send a
modulation permissive signal (YS-1405A) to the clients DCS, then rely on the DCS
controller (TC-1430) to adjust the open/close position of TV-1430 A/B which ar
4
mechanically linked together. A description of this control philosophy can be found in
the clients control description document.
Low Fire/High Fire Control

YS-1405B is hard wired from BMS to DCS for low fire/high fire command. This signal
will work together with YS-1405A to force the DCS controller TC-1430 output to be 0%
or 100%. For a low fire command, TC-1430 input signal will be 0%which will
command TV-1430A/B to fully closed. For a high fire command, TC-1430 input signal
will be 100% which will command TV-1430 A/B to fully open.
Burner Management
When the burner selector switch on the control panel is turned on, it is referred to as an
pre-ignition sequence. During the start of an pre-ignition sequence, the BMS monitors
the safety interlocks to ensure they have not been jumpered and are open prior to
proceeding to the next step. Once this has been verified the BMS starts the combustion
air blower motor. When the combustion air motor has started, the BMS checks to ensure
the safety interlocks are satisfied within (10) seconds before proceeding to the next step
of High Fire Purge. High Fire Purge sequence drives the combustion air damper actuator
to the high fire position. Once it reaches the high fire position and is verified by the High
Fire Proof Switch, the BMS begins the Purge Timer and continues to ensure that all
safety interlocks are satisfied.
The BMS will continue to monitor the safety interlocks and shut the system down and
lockout if any of the safeties in the limit string are not satisfied. If all safeties are
satisfied, the BMS continues the Purge Cycle for a pre-determined calculated duration.
The purge time is based on the combustion chamber volume and the volumetric flow
capacity of the combustion air fan. A minimum of four (4) air exchanges must take place
during the purge sequence.
Upon a complete purge cycle, the BMS drives the combustion air damper actuator to the
low fire position. The BMS will not advance to the next cycle until the damper actuator
has reached the low fire position and verifies the Low Fire Switch has been closed. Once
the Low Fire Switch is closed, the BMS energizes the pilot valves (opening the (2) shut
off valves (XV-1432/1434) and closing the (1) vent (XV-1433)) and the ignition
transformer. This is referred to as the Pilot Trial for Ignition (PTFI). The pilot has ten
(10) seconds to establish a flame signal. The flame is detected by the means of an Ultra
Violet Flame Scanner. The minimum acceptable flame signal strength is determined by
the manufacturer of the scanner. However, a reliable pilot will always have better than
156
the minimum acceptable flame signal strength. If a flame signal is not detected or the
strength drops below the minimum acceptable level, the BMS will lockout and shut the
burner down.
After the pilot flame has been established, the BMS de-energizes the ignition
transformer and energizes the main gas valves. At this time the two shut off valves (XV-
1425/1427) open and the vent valve (XV-1426) closes, igniting the main flame. This is
referred to as the Main Trial for Ignition (MTFI). The pilot valves are de-energized after
10 seconds (closing the pilot shut off valves (XV-1432/1434) and opening the vent valve
(XV-1433)) and the BMS monitors the flame signal strength to ensure that the main burner is stable. If
at any time the main burner signal strength becomes too weak the
BMS de-energizes the gas valves (Closing the main shut off valves (XV-1425/1427) and
opening the vent valve (XV-1426)), locks out the system and shuts the burner down.
Upon a successful main burner light off, the BMS automatically turns the burner firing
rate controls over to the clients DCS temperature controller TC-1430 though TS-1405A..
Assuming the conditions are met to allow the burner to modulate, the firing rate
controller adjusts the output of the burner based on actual temperature readings of the
media being heated in relation to the TC set point. This sequence is referred to as
Normal Modulation, a status of this sequence will be displayed in the clients DCS.
Upon completion of a cycle, or should the burner be switched off, the BMS de-energizes
all fuel shut off and vent valves and performs a post purge. The post purge sequence
runs the combustion blower for 15 seconds to evacuate out any remaining fuel that may
be in the combustion chamber. Once the post purge has been completed, the heater
cycles into a Ready Mode awaiting standby for the next heating cycle.
High Bath Temperature – TI 1411

This manual reset limit controller acts as a manual back-up to the Burner Control
deviation alarm explained above. The limit set point is based on the maximum design
parameters of the heater. Should the bath temperature exceed the Set point (59°C) and
preset deviation alarm value, the BMS will shut down the burner and lockout the
system. This safety requires a local manual reset of the BMS.
High Process Gas Temperature – TI 1415
This manual reset limit controller is a protective measure for a run-away burner case by
measuring the process gas outlet temperatures. The limit set point is based on the
maximum design parameters of the heater. Should the process gas temperature exceed
the Set point (57°C) and preset deviation alarm value, the BMS will shut down the
burner and lockout the system. This safety requires a local manual reset of the BMS.
High Flue Gas Temperature – TI 1416
This manual reset limit controller is a protective measure for a run-away burner case by
measuring the stack outlet temperatures. The limit set point is based on the maximum
design parameters of the heater. Should the flue gas temperature exceed the Set point
(385°C) and preset deviation alarm value, the BMS will shut down the burner and
lockout the system. This safety requires a local manual reset of the BMS.
Low Bath Level – LI 1417
The bath level is monitored by a level transmitter located in the liquid level indicator.
This level transmitter ensures the system is sufficiently filled above the process coils for
safe operation. If the transmitter determines the bath level to be below a set level (25
mm or 3% of the level gauge scale), the BMS will shut down the burner and lockout the
157
system. This safety requires local manual reset of the BMS.
Low Combustion Air Pressure – PI 1420
This safety ensures that the burner is receiving adequate air to sustain safe combustion.
This safety is a pressure transmitter located in the combustion air duct which monitors
the pressure of the combustion air for adequate combustion flow. Should this safety
6
trip during any cycle the BMS will shut down and lockout the system, requiring manual
reset. This alarm is not active during Ready Mode so that the system is not locked out
before a pre-purge sequence can start. This alarm set point will be set at 0.75 kPa.
Low Gas Pressure – PI 1424
This safety ensures that there is adequate gas pressure to sustain safe combustion.
Should this safety trip during any cycle the BMS will shut down and lockout the system,
requiring manual reset. This alarm is not active during Ready Mode so that the system
is not locked out before a pre-purge sequence can start. This alarm set point will be set
at 7.5 kPa.
High Gas Pressure – PI 1429
This safety ensures that there is not an excessive amount of gas pressure to sustain safe
combustion. Should this safety trip during any cycle the BMS will shut down and
lockout the system, requiring manual reset. This alarm is not active during Ready Mode
so that the system is not locked out before a pre-purge sequence can start. This alarm
set point will be set at 20 kPa.
Flame Scanner – BE 1437
The Flame Scanner is used by the BMS to determine whether or not there is a flame
present in the combustion chamber. The BMS will lockout in the event that it detects a
flame in the combustion chamber during any of the following cycles:
 eady
R
L ow Fire Purge
 igh Fire Purge
H
 ost Purge.
P
The BMS will lockout should the flame scanner not detect a flame in the following
cycles:
PTFI-Pilot Trial for Ignition
MTFI-Main Trial for Ignition
Auto-Modulation controlled from Loop controllers
Safety Shut Off Valve Proof of Closure
Proof of closure switches XZSC 1425 and XZSC 1427 ensure that the main gas valves are
actually shut prior to lighting the burner. Proof of closure switches XZSC 1432 and XZSC
1434 ensure the pilot valves are closed during automation mode. Proof of closure is
required by the burner management system prior to ignition.
Emergency Stop
The main control panel will contain a panel mounted emergency button (HS-1408) that
will shut down the burner and the blowers in the event of an emergency. A remote estop
(XS-1406) is also available to tie this function in with the clients SIS.
The BMS will not monitor any of the alarms listed above in Ready mode as it will not
initiate any of the alarm checks until the burner light off sequence is initiated.
System Bath Fluid

158
The system is designed to be filled with a 60/40 Triethylene glycol/ water mixture. The
system can be filled using a pre mixed fluid or mixed together at the site. If the fluid is
mixed at site the water must be clean de-ionized water. It is recommended to use a
quality glycol with a rust inhibiting agent to ensure the bath shell and other components
are protected from rust. The fluid is to be tested on a yearly basis to ensure the rust
inhibitor has not degraded to levels that leave the system susceptible to rust. The
system is to be filled from the 8” goose neck on top of the expansion tank. The system
fluid levels should be monitored on a regular basis, if additional fluid is required the
same 8” hatch can be used to fill the system to the proper level.
Checks Prior to Starting

The initial start up of the Indirect Fired Bath Heater should be conducted by a
technician from the Sigma Thermal Field Service Group. The customer should provide
qualified maintenance personnel to assist the technician during the commissioning
process. The following is a list of items to be checked prior to start up.
1) Verify that the mechanical installation has been completed in accordance with
any applicable installation drawings and/or procedures supplied by Sigma
Thermal and/or the site engineers
2) Visually check piping and ductwork installation for compliance with the flow
schematics.
3) Verify that all globe valves, strainers, check valves and control valves have been
installed with the correct flow direction and orientation.
4) Ensure that all piping to the heater and burner are correctly supported and no
undue stress is imposed.
5) Verify that the discharge piping from any relief valves is piped to a safe location.
6) Remove “skillet” at the relief valve inlet flanges from pressure testing.
7) Verify that all drain valves are closed.
8) Open or close all manual valves and/or dampers according to the correct
operating position. Refer to the flow diagrams or contact Sigma Thermal with
questions.
9) Open all pressure gauge and device shut off valves.
10) Verify that the electrical installation is complete and is in compliance with the
electrical schematics and area classification.
11) Check all safety and control devices to verify that they are correctly installed and
have the correct ranges and set points according to the mechanical and electrical
diagrams.
8
3.0 First Firing of the System
1) It is important that a Sigma Thermal technician or representative commission
the water bath heater to ensure safe and correct operation of the equipment. Do
not attempt to commission the heater without direct supervision of a Sigma
Thermal representative.
2) The burner should be started and held at low fire to allow the system to slowly
warm up. The firing rate of the burner is to be manually increased gradually
over 2 to 3 hour span until it reaches high fire.
3) Adjustments must be made to the fuel and air controls to establish the
mechanical limits associated with the low fire and high fire settings. These
159
changes should only be made by a qualified Sigma Thermal approved start-up
technician.
CAUTION: Never attempt to perform any burner tuning without the direct
supervision of a qualified burner technician that has been approved by Sigma
Thermal.
4) Once the initial low fire and high fire settings have been established, the Bath
mode controller can be placed in automatic mode and allowed to modulate.
5) Allow the burner to reach high fire and check the burner settings to insure that
the high fire fuel and air are configured correctly.
4.0 Daily Operation
Routine start ups and operation should only be conducted by personnel that have been
fully trained in the operation of the Sigma Thermal Indirect Fired Bath heater, and are
familiar with all system component manufacturers’ operating instructions.
4.1 Shutdown
1) If the system is in Auto mode, remove the signal from the plant PLC for enabling
process control mode.
2) Turn the burner selector switch to the off position, turning the burner off not
allowing a light off sequence to start.
4.2 Start Up After Routine Shutdown
1) Check that all manual valves are in the correct operational position.
2) Visually inspect system for leaks or other problems.
3) Perform any scheduled maintenance on any equipment in the system per the
manufacturer’s recommendations.
4) Check that the fuel supply is turned on.
5 Energize the control panel.
6) Turn the burner switch on the mian control panel to the “ON” position.
9
7) If all system interlocks and safeties are satisfied, the burner will start and stay at
low fire until the low fire hold set point has been reached. The burner will then
be released to modulate as necessary to achieve and maintain the desired set
point in standby mode. (DCS Performs Temperature Control)
8) Check that all pressure gauges are indicating normal operating pressures.
9) It is recommended that operator attendance be maintained while the system is
being heated up. Under normal operation the system can be monitored
remotely.
10) Operators and/or maintenance personnel should periodically check on the
system throughout their shift for any signs of trouble.
5.0 General System Maintenance
1) Replace any damaged or loose insulation.
2) The burner should only be inspected and serviced by a qualified technician
annually to ensure safe and efficient operation. A Sigma Thermal technician can
be scheduled to perform this and any other service required to the system.
3) Cooling surfaces, slots, cable trays, heater lids and electrical enclosures must be
kept free of dust. Make sure to keep covers to electrical components and doors
to electrical enclosures closed at all times.
4) Inspect the combustion fan for potential wear on the drives and/or bearings.
5) It is strongly recommended that your entire system be thoroughly checked by a
160
Sigma Thermal technician on an annual basis. Our technician will check all of the
above in addition to verifying the correct operation of all safeties and interlocks,
tune the burner and record the emissions data, tune controllers and record their
configuration, train any plant personnel as directed, make recommendations on
anything that may enhance the system operation and provide a detailed report
of all findings.
10
5.1 Maintenance Check List
Refer to system component manufacturers operating instructions and guidelines for
specific scheduled maintenance on the burner, valves, actuators, fans, etc.
DAILY
1) Verify proper operation of pressure gauges. Gauge valves should be closed when
not checking pressure.
2) Visually inspect system for obvious physical damage.
3) Check incoming fuel supply pressure.
4) Listen for any unusual noises or vibration.
5) Confirm operating performance is consistent with prior performance.
WEEKLY
1) Check for any loose linkages or fittings.
MONTHLY
1) Clean any accumulation of dust off of the heater lid and out of any electrical
devices or enclosures.
ANNUALLY
1) Contact Sigma Thermal for a preventative maintenance and inspection of the
entire system. This is critical for the continued safe and efficient operation of
your Indirect Fired Bath Heater.
5.3 Maintenance Log
The following is an example of data that should be recorded at least once per shift on
continuous operations or once per day for non-continuous operations. This information
will be highly useful in creating trends to spot developing problems before they become
emergencies and to facilitate scheduled down time to correct them.
System Caution Notes

Checks Prior to Starting
The initial start up of the Indirect Fired Bath Heater should be conducted by a technician
from the Sigma Thermal Field Service Group. The customer should provide qualified
maintenance personnel to assist the technician during the commissioning process. The
following is a list of items to be checked prior to start up.
1) Verify that the mechanical installation has been completed in accordance with any
applicable installation drawings and/or procedures supplied by Sigma Thermal
and/or the site engineers
2) Visually check piping and ductwork installation for compliance with the flow
schematics.
3) Verify that all globe valves, strainers, check valves and control valves have been
installed with the correct flow direction and orientation.
4) Ensure that all piping to the heater and burner are correctly supported and no
undue stress is imposed.
161
5) Verify that the discharge piping from any relief valves is piped to a safe location.
6) Remove “skillet” at the relief valve inlet flanges from pressure testing.
7) Verify that all drain valves are closed.
8) Open or close all manual valves and/or dampers according to the correct operating
position. Refer to the flow diagrams or contact Sigma Thermal with questions.
9) Open all pressure gauge and device shut off valves.
10) Verify that the electrical installation is complete and is in compliance with the
electrical schematics and area classification.
11) Check all safety and control devices to verify that they are correctly installed and
have the correct ranges and set points according to the mechanical and electrical
diagrams.
First Firing of the System
1) It is important that a Sigma Thermal technician or representative commission the
water bath heater to ensure safe and correct operation of the equipment. Do not
attempt to commission the heater without direct supervision of a Sigma Thermal
representative.
2) The burner should be started and held at low fire to allow the system to slowly
warm up. The firing rate of the burner is to be manually increased gradually over 2
to 3 hour span until it reaches high fire.
3) Adjustments must be made to the fuel and air controls to establish the mechanical
limits associated with the low fire and high fire settings. These changes should only
be made by a qualified Sigma Thermal approved start-up technician.
CAUTION: Never attempt to perform any burner tuning without the direct supervision
of a qualified burner technician that has been approved by Sigma Thermal.
4) Once the initial low fire and high fire settings have been established, the Bath mode
controller can be placed in automatic mode and allowed to modulate.
5) Allow the burner to reach high fire and check the burner settings to insure that the
high fire fuel and air are configured correctly.
Daily Operation
Routine start ups and operation should only be conducted by personnel that have been fully
trained in the operation of the Sigma Thermal Indirect Fired Bath heater, and are familiar
with all system component manufacturers’ operating instructions.
Shutdown
1) If the system is in Auto mode, remove the signal from the plant PLC for enabling
process control mode.
2) Turn the burner selector switch to the off position, turning the burner off not
allowing a light off sequence to start.
Start Up After Routine Shutdown
1) Check that all manual valves are in the correct operational position.
2) Visually inspect system for leaks or other problems.
3) Perform any scheduled maintenance on any equipment in the system per the
manufacturer’s recommendations.
4) Check that the fuel supply is turned on.
5 Energize the control panel.
6) Turn the burner switch on the mian control panel to the “ON” position.
162
Bath Heater Troubleshooting Guide
Problem Possible Cause Solution

Burner won’t start when Set point of the TIC is lower Adjust set point to normal
switched on - continued than the process variable operating
(Actual temperature of the temperature. Do not exceed
fluid) maximum rating
for the process or the heater.
FSG has the burner locked Check FSG display and correct
because a limit or safety fault as
device is not satisfied. necessary. Reset limit (if
applicable) and the
FSG.
Blower motor starter De-energize panel, open panel
overload protector is tripped. door and reset
overload. Close door and re-
energize panel.
Defective temperature Check TIC and replace/repair
controller program if
necessary
No Power Check voltage supply to motor
starters and all
local disconnects.
Remote start/stop permissive Set remote start/stop to
not set to “RUN”. “RUN”.
Blower housing switch or De-energize panel, open panel
other interlock not satisfied. door and reset
overload. Close door and re-
energize panel.
Heat capacity does not Set point is too low. Check the set point of the TIC
meet load requirement. and adjust to
desired operating
temperature.
Defective temperature Check output from TIC and
controller. replace if
necessary.
Combustion air fan inlet is Check combustion air fan inlet
blocked or restricted. and clear any
blockage or restriction. Check
Air filter to see
if it is clogged.
Improper air/fuel ratio to Contact Sigma Thermal to
burner. schedule a
technician.
Only qualified burner
technicians should
attempt to adjust burners.
163
Low fuel/gas supply pressure. Check incoming fuel pressure
and adjust to
required supply pressure
according to the
burner P&ID.
Partially closed valve(s). Check that all manual valves
are fully open.
Defective fuel valve or Check all actuators for proper
combustion air damper operation and
actuator motor. replace as needed.
Loose/disconnected linkage Check all linkage and
or actuator couplings. couplings. Tighten or reinstall
as needed.
Heater is exposed to a Ensure that the heater area is
negative pressure not subjected to
environment. negative pressure. The
combustion air must
be ducted into the burner
from a neutral
pressure environment if the
heater is located
in a negative pressure
environment.
Blower comes on but the System interlock or safety is Check PLC display. Correct the
FSG locks out before the not satisfied. fault situation
burner starts reset the system.
Blower comes on but the High fire switch isn’t Check actuator motor. Check
purge timer never begins closing. linkage/coupling
or cam and tighten or adjust
as needed. Check
switch and replace if
necessary.
Purge cycle completes its Low fire switch isn’t closing. Check actuator motor. Check
timing, but the BMS linkage/coupling
doesn’t advance to Pilot or cam and tighten or adjust
Trial for Ignition (PTFI) as needed. Check
switch and replace if
necessary.
Pilot fails to ignite Insufficient gas pressure to Check incoming fuel supply
pilot regulator. pressure and
correct as needed. Make sure
that all shut off
valves are open.
Damaged or defective pilot Repair or replace regulator as
regulator. needed.
Damaged or defective ignition Replace electrode.
electrode.
164
Defective ignition transformer Replace ignition transformer.
Loose, damaged or Check connector and cable.
disconnected connector or Make sure
ignition cable. connector is securely plugged
onto electrode
and cable is also securely
fastened to the
connector and the ignition
transformer. Make
sure that the cable is not
broken or exposed to
water/moisture.
Defective pilot shut off Replace shut off valve(s).
valve(s)
Incorrect blower rotation. Refer to manufacturer’s
instructions and
correct blower rotation as
needed.
Pilot actually ignites, but Replace flame scanner.
BMS doesn’t recognize Defective flame scanner.
the flame and locks out
on “Pilot Flame Fail”
Pilot lights, but is Improper fuel/air ratio. Contact Sigma Thermal to
unstable and goes out schedule a
before Main Trial for technician for burner tuning.
Ignition (MTFI)
Main burner fails to Insufficient gas pressure to Check incoming fuel supply
ignite during MTFI main gas regulator. pressure and
correct as needed.
Shut off valve(s) closed. Make sure that all shut off
valves are open.
Defective main gas regulator. Repair or replace regulator.
Improper air/fuel Contact Sigma Thermal to
ratio. schedule a
technician for burner tuning.
Only qualified
burner technicians should
attempt to
adjust burners.
Defective main gas/fuel oil Replace main gas valve
valve actuator. actuator.
Faulty operation of main gas Check valves for free
valves. movement. Clear any
obstructions. Replace valves
as necessary.
Dirty or clogged fuel gas Check and clean strainer as
strainer. necessary.
165
Blocked or restricted exhaust. Make sure that no damage
has occurred to the
exhaust duct or stack and that
nothing is
restricting the exit of the
gases.
Weak flame signal Dirty or defective scanner. Clean scanner lens or replace
as necessary.
Poor flame quality. Contact Sigma Thermal to
schedule a
technician for burner tuning.
Only qualified
burner technicians should
attempt to
adjust burners.
Improperly aimed scanner. Make sure that scanner has a
clear
unobstructed view of the
flame.
Burner constantly cycles TIC is in “MANUAL” control Place the TIC in “AUTO” so
on and off mode at an elevated that it
output. automatically adjusts the
output to achieve
and maintain and the set
point.
Not enough “Overshoot” Typically, there should be at
allowance configured in the least 10° F of
TIC. “overshoot” allowance to
prevent excessive
cycling. Some applications will
require more
depending on the load
variations.
Not enough load to Increase load or change to a
accommodate the minimum burner with more
input from the burner. turn down.
(Turn down is the input
difference between
low and high fire)
Actuator, linkage, air damper Correct the condition that has
or gas valve is stuck at the caused the
high fire position. problem or replace the
components.
High temperature limits Defective temperature Check TIC and ensure that it
tripping controller is functioning
correctly. Replace if
necessary.
166
Defective temperature Replace temperature element
element
Set point of limit is lower than Make sure that the set point
maximum operating for the fluid
temperature. temperature limits are set at
least
50° F above the highest
operating
temperature and the stack
temperature limit
is set at least 100° F above
the highest stack
temperature with the burner
at high fire and
the system at full operating
temperature.
Low gas pressure switch Fuel supply pressure is too Check incoming gas supply
is tripping low. and adjust per
burner P&ID.
Shut off valve is Check the valve(s) upstream
closed. of the regulator
and ensure that they are
open.
Defective regulator. Check the regulator and repair
or replace as
necessary.
Improperly sized gas supply Increase the size of the
line or regulator orifice. incoming pipe to
reduce the line losses. Check
the orifice size
for the regulator and compare
to the
manufacturers recommended
size for the
application.
Dirty or clogged strainer. Check and clean strainer.
Defective switch. Replace switch.
Set point is too high. Adjust set point lower than
the minimum gas
pressure downstream of the
main regulator.
High gas pressure switch Dirty or defective regulator. Check regulator for debris that
is tripping may be
preventing it from closing and
also check the
diaphragm for damage. Repair
or replace as
167
necessary.
Set point is too low. Adjust set point higher than
the maximum gas
pressure downstream of the
gas valves.
Combustion air pressure Combustion air fan wheel is Check that the fan wheel is
switch is tripping not spinning. coupled to the
motor shaft or that belts are
not broken or
have come off of the sheave.
Combustion air inlet is Check inlet and clear away
blocked any blockage.
Air pressure sensing tube is Check tubing and ensure that
damaged, disconnected, and it is properly
loose or is plugged with connected and free of any
debris. obstructions.
Combustion air fan rotation is Check manufacturers literature
incorrect. and correct
rotation as directed.
168
169
201-E-802 FD Fan Electric Pre-heater
Specs
Design: 8 KW
Volt: 600/3.60hz
Design air flow: 440 m3/h (259 SCFH)
Design Inlet Temperature: -45°C (-49°F)
Design Outlet Temperature: 4.5°C
Pressure: ATM
Caloritech™ type XDF explosion-proof duct heaters
GENERAL INFORMATION
2.1 DESCRIPTION
Caloritech™ type XDF explosion-proof duct heaters are designed
for heating air or gases that contain potentially explosive substances.
XDF heaters feature the unique Caloritech™ approach to explosionproof
electric heater design, which embodies safety and reliability.
The XDF is a factory pre-wired explosion-proof duct heater.
170
Standard models are available in three duct sizes, with either a
single or double bank of heating modules. XDF heaters are available
as standard units with T3B, T3A, or T2D hazardous area
temperature codes.
2.2 APPLICATION
The XDF is designed specifically for heating industrial spaces where
potentially explosive substances are or may be present.
OVERHEAT PROTECTION
8.1 The heater is equipped one (1) high limit thermocouple
per heating bank to sense the heating element sheath
temperature. Each high limit thermocouple must be wired to a
separate Certified, manual-reset high limit controller in the
control panel.
8.2 In the event of fan failure, excessive dust buildup, or

restricted airflow, the heater temperature may rise, causing the limit
controls to open and break the power supply to the heater.
CYCLING OF THE HEATER ON THE HIGH

LIMITS SHOULD NOT BE PERMITTED. Should
this occur, the system should be inspected to
determine the cause of the cycling, and the
condition must be corrected before regular
operation is resumed.
201-V-802 Fuel Gas Odourizer
Description of Operation
171
The PLC receives input pulses from the volume corrector (known volume of gas flow), the PLC will then
calculate the cycle and dwell time (open time) of the control solenoid, that will allow a known volume of
unodourized natural gas to pass into the odourant tank, thereby forcing a known volume of natural gas
and ordourant vapour mixture into the pipeline. The cycle and dwell time will be based on the current
volume of natural gas flow, temperature of the ordourant, and operating pressure of the pipeline.
Alarm for the odourization is deriving from the flow switch. If it does not receive confirmation (after
three solenoid opening), then the controller will alarm for odourant no flow (no odourization). If it does
receive confirmation, then there will be no alarms. If the PLC is seeing confirmation from the flow
switch continuously (longer than 10 seconds), then it will alarm for over odourization.
The system is also equipped with the AccuTrak electronic level system that will communicate mercaptan
level to the PLC for low odourant alarm.
The bypass regulator included with the system is used to reduce the line pressure to 35 psi above the
downstream pipeline pressure.
In the event of over odourization, or no odourization alarms occur, the system can be placed into the
manual bypass mode, thereby keeping the gas odorized.
The control solenoid valve is a normally closed solenoid, so it is very uncommon to ever see an over
odourization problem.
The bypass is mechanical (manual bypass) and it is only used when Odourizer is shut down.
172

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SURMONT

Rev Originator Reviewed By Approved Date Description

Number Date Date Entered Page(s) Entered By

1.1: Introduction to Safety

1.2: Safety Briefing

1.3: Introduction and Expectation

1.4: Operating Philosophy and Core Values

1.5: Safety and You

1.6: Our Safety Motto

1.7.1: Refusal of Unsafe Work.

1.7.2: Emergency Procedures

1.7.3: Personal Protective Equipment

1.7.4: Hearing Protection

1.7.5: Gas Detection – Personal Monitors

1.7.6: Eye Wash Stations

1.7.7: Fire Extinguishers

1.7.8: First Aid

1.7.9: SCBA - Air Packs

1.7.10: Spill Prevention Kits

1.7.12: Muster Points

Chapter 2: Once Through Steam Generators (OTSG)

2.2: Our Design Specifications (TIW)

2.3: Purpose of Operation/Start-Up procedure

2.4: BMS (Burner Management System)

2.5: Start-Up Permissive

2.6: Steam Sample Collectors

Chapter 3: Auxiliary Equipment

3.0: Low Pressure Feedwater pumps

3.0.1 LP BFW specifications

3.0.2 LP BFW Theory of Operation

3.1: High Pressure Feedwater pumps

3.1.1: HP BFW specifications

3.1.2: HP BFW Theory of Operation

3.1.3: Lube oil skid

3.1.4: GE Bentley Nevada

3.2: Associated Heat Exchangers

3.2.1: E-541 (Description/Specs)

3.2.2: E-221/211 (Description/Specs)

3.2.3: E-271 (Description/Specs)

3.2.4: E-551 (Description/Specs)

3.2.5: E-552 (Description/Specs)

3.3: Steam Separators (V-502)

3.4: Medium Pressure Steam Separator (V-501)

3.5: FD Fan, Motor, Wind Box and Burner

4.0: Filming Amine

Chapter 5: Boiler Feedwater

5.0: Boiler Feedwater Tank Purpose

5.0.1: BFW Tank Specifications

Chapter 6: Air Make-Up Units

6.0: Air Make-Up Unit description/purpose

Chapter 7: CEMS (Continuous Emissions Monitoring System)

7.0: CEMS Purpose/History

Chapter 8: Utility Steam System

8.0: Process Diagram

Chapter 9: Blowdown system

9.1: Process Diagram

9.3: Disposal System (wells & pumps)

Chapter 10: Glycol System and Heater

Chapter 11: Instrument Air

Chapter 12: Fuel Gas Sigma Thermal Bath Heater

• Ambient temperature - The temperature at a point or area expressed as an average of the

• cgs - centimeter-gram-second system.

• CPF - Central Processing Facility.

• Density - Mass per unit of volume. Density is typically reported in g/cm3.