SUBJECT SUMMARY REPORT ON ISML AUTOMATION PROJECT PHASE-I (BOILER HOUSE AND TALO REFINERY)
CONTRACTOR AUTOMATORS PVT. LTD KARACHI
S/NO. AREA BREAKUP BEFORE AUTOMATION
DIFFERENT INDICATORS AVAILABLE,
DRUM LEVEL CONTROL AVAILABLE,
MANUAL FEEDING IN PRACTICE,
VFDS AVAILABLE FOR ID FAN AND BAGASSE
1 BOILER-1
FEEDERS, BUT MANUAL OPERATION IN USE.
NO O2 CONTROL, DRAFT PRESSURES
INDICATIONS UNAVAILABLE.
NO SPEED CONTROL FOR FD, SA FANS.
DIFFERENT INDICATORS AVAILABLE,
DRUM LEVEL CONTROL AVAILABLE,
MANUAL FEEDING IN PRACTICE,
VFD AVAILABLE FOR ID FAN ONLY BUT
2 BOILER-2
OPERATED MANUALLY.
NO O2 CONTROL, DRAFT PRESSURES
INDICATIONS UNAVAILABLE.
NO SPEED CONTROL FOR FD, SA FANS.
DIFFERENT INDICATORS AVAILABLE,
DRUM LEVEL CONTROL AVAILABLE,
MANUAL FEEDING IN PRACTICE,
VFDS AVAILABLE FOR FD,ID,SA FANS & BAG.
3 BOILER-3 FEEDERS, BUT MANUAL OPERATION IN USE.
NO O2 CONTROL, DRAFT PRESSURES
INDICATIONS UNAVAILABLE.
DIFFERENT INDICATORS AVAILABLE,
DRUM LEVEL CONTROL AVAILABLE,
MANUAL FEEDING IN PRACTICE,
VFDS AVAILABLE FOR FD,ID,SA FANS & BAG.
FEEDERS, BUT MANUAL OPERATION IN USE.
4 BOILER-4
NO O2 CONTROL, DRAFT PRESSURES
INDICATIONS UNAVAILABLE.
ABB PLC AVAILABLE WITH ONLY DRUM LEVEL
CONTROL IN AUTO LOOP REST OPERATED
IN MANUAL MODE IN PREVIOUS PRACTICE.
MANUAL DOSING OF CHEMICALS. NO PH
CONTROL INCORPORATED.
TALO
5
REFINERY
I- MILL HOUSE AUTOMATION IS RECOMMENDED TO MAINTAIN A REGULAR FEEDING OF LESS MOISTURE BAGASSE AND A CONSTANT
SITE COMMENTS/ & LESS VARIABLE STEAM LOAD ON BOILERS.
RECOMMENDATIONS II- KEY ACHIEVEMENTS INCLUDE ENERGY SAVINGS IN BOILER AIR FANS, FUEL SAVINGS, BETTER LOOPS CONTROLS, BETTER BAGASSE
FEEDING, LESS SAFETY VALVE BLOWING AND IMPROVED BOILER EFFICIENCY.
DATE: 16-12-2020
CURRENT SCENARIO AFTER DCS
INCORPORATION
STEAM PRESSURE, DRUM LEVEL & FURNACE
DRAFT CONTROL LOOPS INCORPORATED.
VFDS ADDED FOR FD & SA FANS.
O2 CONTROL ADDED IN STEAM PRESS. LOOP
FOR AIR OPTIMIZATION.
OPERATING STATION AVAILABLE.
STEAM PRESSURE, DRUM LEVEL & FURNACE
DRAFT CONTROLS INCORPORATED.
VFDS ADDED FOR FD,SA FANS & FEEDERS.
O2 CONTROL ADDED IN STEAM PRESS. LOOP
FOR AIR OPTIMIZATION.
FEEDING CONTROLLED VIA CONTROLLER
WITH VFDS.
OPERATING STATION AVAILABLE.
STEAM PRESSURE, DRUM LEVEL & FURNACE
DRAFT CONTROLS INCORPORATED.
O2 CONTROL ADDED IN STEAM PRESS. LOOP
FOR AIR OPTIMIZATION.
FEEDING CONTROLLED VIA CONTROLLER
WITH VFDS.
OPERATING STATION AVAILABLE.
FEEDWATER PRESSURE CONTROL LOOP
ADDED. (COMMON FOR ALL BOILERS)
STEAM PRESSURE, DRUM LEVEL & FURNACE
DRAFT CONTROLS INCORPORATED.
O2 CONTROL ADDED IN STEAM PRESS. LOOP
FOR AIR OPTIMIZATION.
FEEDING CONTROLLED VIA CONTROLLER
WITH VFDS.
OPERATING STATION AVAILABLE.
LIQUOR FLOW,TEMP, TANK LEVEL CONTROL
INCORPORATED.
AUTO DOSING OF CHEMICALS AS PER FLOW.
BETTER PH CONTROL INCORPORATED,
Defecation pH control, Liqor brix control, liqor
temp control also incorporated
OBSERVATIONS/STATUS
BOILER COMMISSIONING COMPLETE.
CONTROL LOOPS LIKE FURNACE
PRESSURE, DRUM LEVEL AND STEAM
PRESSURE ARE WORKING PROPERLY.
OPERATIONS TEAM AT BOILER IS
SATISFIED WITH AUTOMATION.
BLOILERS LOAD MANAGEMENT IS
INCORPORATED.
BOILER COMMISSIONING COMPLETE.
CONTROL LOOPS LIKE FURNACE
PRESSURE, DRUM LEVEL AND STEAM
PRESSURE ARE WORKING PROPERLY.
OPERATIONS TEAM AT BOILER IS
SATISFIED WITH AUTOMATION.
BLOILERS LOAD MANAGEMENT IS
INCORPORATED.
BOILER COMMISSIONING COMPLETE.
CONTROL LOOPS LIKE FURNACE
PRESSURE, DRUM LEVEL AND STEAM
PRESSURE ARE WORKING PROPERLY.
OPERATIONS TEAM AT BOILER IS
SATISFIED WITH AUTOMATION.
BLOILERS LOAD MANAGEMENT IS
INCORPORATED.
BOILER COMMISSIONING COMPLETE.
CONTROL LOOPS LIKE FURNACE
PRESSURE, DRUM LEVEL AND STEAM
PRESSURE ARE WORKING PROPERLY.
OPERATIONS TEAM AT BOILER IS
SATISFIED WITH AUTOMATION AND
OPERATING BOILERS ON AUTO MODE.
TALO REFINERY COMMISSIONED IN
FEB END. SUCCESSFULLY TUNED
AND OBSERVED WORKING PROPERLY
KEY INDICATORS
I-ENERGY SAVINGS AT AIR FANS.
II- FUEL SAVINGS.
III- SMOOTH STEAM PRESSURE
CONTROL.
IV- LESS SAFETY VALVE BLOWING.
V- SMOOTH FEEDING.
VI- BETTER AIR REGULATION.
VII- IMPROVED BOILER EFFICIENCY