Professional Documents
Culture Documents
Client ref.:
Project:
UGS Dambořice Upgrade
Frames Process Systems B.V.
Eikenlaan 237
Vendor:
2404 BP Alphen aan den Rijn
The Netherlands
Frames ref.: PHO-103775
Equipment: Silica Gel Polishing Units OA-27 & OA-28 of the Gas Treatment Unit
TABLE OF CONTENTS
1 General –
Document ..................................................................................................... 3
1.1 Purpose of this document .............................................................................................. 3
1.2 Reference
documents ................................................................................................... 4
1.2.1 Project - Client specifications ......................................................................................... 4
1.2.2 Frames prepared design documents ................................................................................ 4
1.3 Appendices ................................................................................................................. 4
1.4 Abbreviations used in this document ............................................................................... 5
5 Timers ...................................................................................................................... 28
5.1 Timers ...................................................................................................................... 28 5.2
Tracking signals ......................................................................................................... 28
1 GENERAL – DOCUMENT
This document covers the safeguarding functions for the Silica Gel Polishing Unit of the GTU, such to
allow configuration of the safeguarding system. Together with P103775-PC-IOM-001, “Installation,
Operation and Maintenance Manual”, this document
serves as an operating manual.
None.
In addition, while reading the document, reference shall be made to the latest revision of the following
design documents prepared by Frames for this project:
Special note:
For the above listed Control and Switch Setting list (CSS) the following shall be noted; the values given
in this document are based on the last known revision of the CSS at the date of document issue and
are as such for information only. For the actual required settings reference shall be made to the CSS at
all times.
1.3 Appendices
None.
Abbreviation: Explanation:
AMS Asset Management System DCS Distributed Control
System
ESDS Emergency Shutdown System
FE Final Element
GTU Gas Treatment Unit
GTU-DCS Gas Treatment Unit Distributed Control System
HMI Human Machine Interface
LTS Low
Temperature Separation MCC
Motor Control Centre MV
Measured Variable
(Value) n/a
Not Available
OP Output (Value)
PID Piping and Instrumentation Diagram
SP Set Point (Value)
SPU Silica Gel Polishing Unit
SSV Safety Shutdown Valve
UCP Unit Control Panel
2 GENERAL - PROJECT
In 2018, due to changes in the composition and flow of the produced gas, modifications are planned
on the GTU. This includes modifications of the current LTS unit as well as the addition of a Silica Gel
Polishing Unit, SPU, on each train. In each train of the LTS, there are equipment which are added,
replaced, modified or removed.
The Frames scope of supply covers two identical GTU trains, including LTS units OA-23/OA-24 and
Silica Gel Polishing Units OA-27/OA-28, with identical skid mounted items (interconnecting piping
excluded). Each train will be designed to handle 50% of the total flow.
In this document and in P103775-PC-FTD-002 for control and sequencing functions, only the Silica Gel
Polishing Unit is covered. The equipment in this scope are listed below:
The following control systems will be supplied by Frames for operation of the trains as described in sec
2.2:
Equipment TAG Number Train
OA-27 Train OA-28
Silica Gel Polishing BA34 BA35
UCP
The SPU is equipped with the necessary pneumatic actuated ON/OFF shutdown valves, which are used
to shut certain process lines when required by the safety system in order to guarantee the safety and
integrity of the SPU. Actuation of these valves is performed by the ESD safeguarding system. In this
document the following signals are used:
Signals of limit switches will be visualized on the HMI by change of colour on the respective symbol.
The SPU is equipped with the necessary pneumatic actuated ON/OFF blowdown valves, which are used
to release high pressure gas when required by the safety system in order to guarantee the safety and
integrity of the SPU. Actuation of these valves is performed by the ESD safeguarding system. In this
document the following signals are used:
Signals of limit switches will be visualized on the HMI by change of colour on the respective symbol.
Each adsorber column is equipped with 3 inlet and 3 outlet pneumatic actuated ON/OFF switching
valves, which are used to redirect the gas streams and accordingly switch the adsorber column
operational mode when required. In this document the following signals are used:
Signals of limit switches will be visualized on the HMI by change of colour on the respective symbol.
3.4.1 FIT-27053
FIT-27053 is a venturi type flow meter, which is used to measure of the regeneration gas flow to the
SPU adsorbers. Measured value unit is in mbar, and converted to an volumetric flow rate according to
the calculation below. At low flows the accuracy of
the measurement decreases, therefore a low flow
cut off is implemented. Low flow cut off value =
1500 Sm3/hr (10% max flow range).
(��)√ ��×3
2
�� �� 6
0
0
2×∆
𝑄 𝑣 = 𝐶𝑑 × 𝐸 × 𝜀 × ×
Where:
𝑄𝑣 volumetric flow rate in Sm3/h (@ standard conditions 15 °C, 1013,25 mbar)
𝐶𝑑 discharge coefficient which depends on the Reynolds value, this value is set to
0.984
𝑑 throttle orifice of the meter in m: 0.067866 m (67.866 mm)
𝛽 Beta ratio i.e. the ratio of throat diameter to inlet pipe ID. The value for is 0.69847
𝐸 velocity of approach factor 1.146
In this section the safety functions implemented in the safety system are described in detail. While reading
this section, refer to P103775-PC-CED-001, “Cause and Effect Diagram”.
SPU operation is always performed under supervision of ESD safety functions. Upon initiation (cause) of a
trip by one of the initiators, an action (effect) shall be taken to prevent a certain hazardous situation from
occurring. Trips shall be initiated by client ESD system or by causes in the SPU train. Reference is made to
P103775-PC-CED-001, “Cause and Effect Diagram”.
TAHH-27003 High High Temperature from Regeneration Gas Heater P103775-PC-PID-014 4.2.2
TAHH-27006 High High Temperature from Regeneration Gas Pre-Cooler P103775-PC-PID-015 4.2.3
TALL-27006 Low Low Temperature from Regeneration Gas Pre-Cooler P103775-PC-PID-015 4.2.4
LSHH-27002 High High Level Regeneration Gas K.O. Drum P103775-PC-PID-015 4.2.5
LSLL-27003 Low Low Level Regeneration Gas K.O. Drum P103775-PC-PID-015 4.2.6
4.1
Objective
To prevent mechanical damage to the downstream equipment
Setpoint
50 °C
Actions
Stop production gas in LTS (signal XS-27006)
Close switching valves POV-27102/~202/~302
Stop regeneration heater H-27003 (signal XS-27050 to SPU UCP BA34)
Stop fan motors KM-27004A/B (TIM-101 time delayed action) and track-close Pre-cooler A-27004
louvres
TY-27010 (via SPU UCP BA34) (TIM-104 time delayed action)
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
TIM-101 starts when stop command XS-27050 is given to the Regeneration Gas Heater H-27003. A
time delay of 10 seconds prior to stopping fan motors KM-27004A/B is used to cool down the gas as
necessary during the time gas has not yet stopped flowing.
TIM-104 starts when the stop command is given to the Regeneration Gas Cooler fans KM-27004A/B. A
time delay of 30 seconds prior to closing the louvers is used to allow the fans to stop turning prior to
closure of louvers.
Objective
Setp
35°
oint To prevent mechanical damage to the downstream equipment
Acti
2StopCregeneration heater H-27003 (signal XS-27050 to SPU UCP BA34)
ons
Close switching valves POV-27104/~204/~304 (TIM-102 time delayed action)
Stop fan motors KM-27004A/B (TIM-101 time delayed action) and track-close Pre-cooler A-27004
louvres
TY-27010 (via SPU UCP BA34) (TIM-104 time delayed action)
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
TIM-101 starts when stop command XS-27050 is given to the Regeneration Gas Heater H-27003. A
time delay of 10 seconds prior to stopping fan motors KM-27004A/B is used to cool down the gas as
necessary during the time gas has not yet stopped flowing.
TIM-102 starts when stop command XS-27050 is given to the Regeneration Gas Heater H-27003. No
time delay is required prior to closing POV-27104/~204/~304 in the current design, however, the
delay function is supplied with 0 second delay in case it is required in the future.
TIM-104 starts when the stop command is given to the Regeneration Gas Cooler fans KM-27004A/B. A
time delay of 30 seconds prior to closing the louvers is used to allow the fans to stop turning prior to
closure of louvers.
Objective
To prevent mechanical damage to the downstream equipment
Setpoint
80 °C
Actions
Stop regeneration heater H-27003 (signal XS-27050 to SPU UCP BA34)
Close switching valves POV-27104/~204/~304 (TIM-102 time delayed action)
Stop fan motors KM-27004A/B (TIM-101 time delayed action) and track-close Pre-cooler A-27004
louvres
TY-27010 (via SPU UCP BA34) (TIM-104 time delayed action)
De-energize Regeneration Gas Pre-Cooler Air Blower Heaters EH-27004A/B
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
TIM-101 starts when stop command XS-27050 is given to the Regeneration Gas Heater H-27003. A
time delay of 10 seconds prior to stopping fan motors KM-27004A/B is used to cool down the gas as
necessary during the time gas has not yet stopped flowing.
TIM-102 starts when stop command XS-27050 is given to the Regeneration Gas Heater H-27003. No
time delay is required prior to closing POV-27104/~204/~304 in the current design, however, the
delay function is supplied with 0 second delay in case it is required in the future.
TIM-104 starts when the stop command is given to the Regeneration Gas Cooler fans KM-27004A/B. A
time delay of 30 seconds prior to closing the louvers is used to allow the fans to stop turning prior to
closure of louvers.
Objective
To prevent hydrate formation
Setpoint
18 °C
Actions
Stop regeneration heater H-27003 (signal XS-
27050 to SPU UCP BA34)
Close switching valves POV-27104/~204/~304
(TIM-102 time delayed action)
Stop fan motors KM-27004A/B (TIM-101 time delayed action) and track-close Pre-cooler A-27004
louvres
TY-27010 (via SPU UCP BA34) (TIM-104 time delayed action)
Trip indication
An alarm shall be raised and visualized on the operator screen
(HMI) in control room.
Over
Manual Not applicable
Automatic
rides Automatic trip override is initiated when water desorption is not happening
override: (no regeneration flow) or the system is still in the initial heat-up cycle. The
override: SPU PLC is sending the signal “TALL-27006 auto override” signal to ESD
system.
Re
set The trip shall be reset manually via common alarm reset on the
operator screen (HMI) in control room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
TIM-101 starts when stop command XS-27050 is given to the Regeneration Gas Heater H-27003. A
time delay of 10 seconds prior to stopping fan motors KM-27004A/B is used to cool down the gas as
necessary during the time gas has not yet stopped flowing.
TIM-102 starts when stop command XS-27050 is given to the Regeneration Gas Heater H-27003. No
time delay is required prior to closing POV-27104/~204/~304 in the current design, however, the
delay function is supplied with 0 second delay in case it is required in the future.
TIM-104 starts when the stop command is given to the Regeneration Gas Cooler fans KM-27004A/B. A
time delay of 30 seconds prior to closing the louvers is used to allow the fans to stop turning prior to
closure of louvers.
Objective
To prevent liquid carry over to the downstream system.
Setpoint
Set @ 800 mm (discrete signal)
Actions
Stop regeneration heater H-27003 (signal XS-27050 to SPU UCP BA34)
Close switching valves POV-27104/~204/~304 (TIM-102 time delayed action)
Stop fan motors KM-27004A/B (TIM -101 time delayed action) and track-close Pre-cooler A-27004
louvres
Trip indication
An alarm shall be raised and visualized on the
operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
TIM-101 starts when stop command XS-27050 is given to the Regeneration Gas Heater H-27003. A
time delay of 10 seconds prior to stopping fan motors KM-27004A/B is used to cool down the gas as
necessary during the time gas has not yet stopped flowing.
TIM-102 starts when stop command XS-27050 is given to the Regeneration Gas Heater H-27003. No
time delay is required prior to closing POV-27104/~204/~304 in the current design, however, the
delay function is supplied with 0 second delay in case it is required in the future.
TIM-104 starts when the stop command is given to the Regeneration Gas Cooler fans KM-27004A/B. A
time delay of 30 seconds prior to closing the louvers is used to allow the fans to stop turning prior to
closure of louvers.
Objective
To prevent gas blow by to the downstream system.
Setpoint
Set @ 200 mm (discrete signal)
Actions
Close valve SSV-27001
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
No special details applicable.
Objective
To prevent mechanical damage to the equipment
Setpoint
9 barg
Actions
Close valve SSV-27001
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
No special details applicable.
Objective
To prevent condensate contamination by water.
Setpoint
600 mm (56% of measurement)
Actions
Close valve SSV-27001
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
No special details applicable.
Objective
To prevent gas blow by to the downstream system.
Setpoint
200 mm (11% of measurement)
Actions
Close valve SSV-27002
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
No special details applicable.
Objective
Setpoint
600 mm (60% of measurement)
Actions
Stop regeneration heater H-27003 (signal XS-27050 to SPU UCP BA34)
Close valve SSV-27001
Stop off-gas compressor K-25020 (signal XS-27007 to compressor UCP BA36)
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
No special details applicable.
Objective
To prevent gas blow by to the downstream system.
Setpoint
200 mm (20% of measurement)
Actions
Close valve SSV-27003
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Timer details
No special details applicable.
Objective
To prevent overheating and damage in the Regeneration Gas
Heater
Setp 3
21 /
oint
00S h
Acti
Stop regeneration heater H-27003 (signal XS-27050 to SPU UCP
ons m BA34)
Trip
indicati An alarm shall be raised and visualized on the operator screen
Over (HMI) in control room.
on
Manual
rides
Automatic
override: Not applicable
set
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control room.
Instrumentation details
No special details applicable.
Implementation details
No special details applicable.
Objective
To establish safe stop of the Silica Gel Polishing Unit.
Setpoint
0 (software signal)
Actions
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Implementation details
No special details applicable.
Timer details
TIM-104 starts when the stop command is given to the Regeneration Gas Cooler fans KM-27004A/B. A
time delay of 30 seconds prior to closing the louvers is used to allow the fans to stop turning prior to
closure of louvers.
Objective
To establish safe conditions in the Silica Gel Polishing Unit and to prepare the SPU UCP BA34 BA34 for
disconnection of power supply.
Setpoint
0 (software signal)
Actions
Close valve SSV-27001
Close valve SSV-27002
Close valve SSV-27003
Open POV-27012
Open POV-27014
Open switching valves POV-27101/~201/~301
Close switching valves POV-27102/~202/~302
Open switching valves POV-27103/~203/~303
Close switching valves POV-27104/~204/~304
Open switching valves POV-27105/~205/~305
Open switching valves POV-27106/~206/~306
Open blowdown valves BDV-27107/~27207/~27307 (TIM-103 time delayed action)
Stop regeneration heater H-27003 (signal XS-27050 to SPU UCP BA34)
Stop fan motors KM-27004A/B and track-close Pre-cooler A-27004 louvres TY-27010 (via SPU UCP
BA34)
(TIM-104 time delayed action)
De-energize Regeneration Gas Pre-Cooler Air Blower Heaters EH-27004A/B
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control
room.
Implementation details
Valves POV-27012, POV-27014, BDV-27107/~27207/~27307, POV-27101/~201/~301,
POV27103/~203/~303, POV-27105/~205/~305 and POV-27106/~206/~306 are fail open, which
means that in the event of removal or loss of control signal, the valve will be driven to its open
position.
Timer details
TIM-103 starts when XS-27002 command is activated. A time delay of 15 seconds prior to opening the
BDV’s is due to the travel time of the switching valves.
TIM-104 starts when the stop command is given to the Regeneration Gas Cooler fans KM-27004A/B. A
time delay of 30 seconds prior to closing the louvers is used to allow the fans to stop turning prior to
closure of louvers.
Objective
To establish safe conditions in the Silica Gel Polishing Unit and to prepare the SPU UCP BA34 for
disconnection of power supply. The client ESD does not wait for feedback, but immediately turns off
the power distribution cabinets and UPS to the SPU UCP BA34.
Setpoint
0 (software signal)
Actions
Close valve SSV-27001
Close valve SSV-27002
Close valve SSV-27003
Close POV-27012
Close POV-27014
Open switching valves POV-27101/~201/~301
Close switching valves POV-27102/~202/~302
Open switching valves POV-27103/~203/~303
Close switching valves POV-27104/~204/~304
Open switching valves POV-27105/~205/~305
Open switching valves POV-27106/~206/~306
Open blowdown valves BDV-27107/~27207/~27307 (TIM-103 time delayed action)
Stop regeneration heater H-27003 (signal XS-27050 to SPU UCP BA34)
Stop fan motors KM-27004A/B and track-close Pre-cooler A-27004 louvres TY-27010 (via SPU UCP
BA34)
(TIM-104 time delayed action)
De-energize Regeneration Gas Pre-Cooler Air Blower Heaters EH-27004A/B
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) central room.
Overrides
Manual override: Not applicable
Automatic override: Not applicable
Reset
The trip shall be reset manually via common alarm reset on the GTU DCS operator screen (HMI).
Implementation details
Valves POV-27012, POV-27014,
BDV-27107/~27207/~27307,
POV-27101/~201/~301, POV27103/~203/~303, POV-27105/~205/~305 and POV-27106/~206/~306
are fail open, which means that in the event of removal or loss of control signal, the valve will be
driven to its open position.
Timer details
TIM-103 starts when XS-27002 command is activated. A time delay of 15 seconds prior to opening the
BDV’s is due to the travel time of the switching valves.
TIM-104 starts when the stop command is given to the Regeneration Gas Cooler fans KM-27004A/B. A
time delay of 30 seconds prior to closing the louvers is used to allow the fans to stop turning prior to
closure of louvers.
To establish SPU regeneration shutdown and to prevent overheating and damage in the Regeneration
Gas Heater when, due to other trips, the gas flow in the upstream LTS is stopped.
Stop fan motors KM-27004A/B (TIM-101 time delayed action) and track-close Pre-cooler A-27004
louvres
Trip indication
An alarm shall be raised and visualized on the operator screen (HMI) in control room.
Overrides
Reset
The trip shall be reset manually via common alarm reset on the operator screen (HMI) in control room.
Implementation details
Timer details
TIM-101 starts when stop command XS-27050 is given to the Regeneration Gas Heater H-27003. A time
delay of 10 seconds prior to stopping fan motors KM-27004A/B is used to cool down the gas as
necessary during the time gas has not yet stopped
flowing.
TIM-104 starts when the stop command is given to the Regeneration Gas Cooler fans KM-27004A/B. A
time delay of 30 seconds prior to closing the louvers is used to allow the fans to stop turning prior to
closure of louvers.
None.
5 TIME
Below
RS the various timers resulting of above functional write up are
reference. Timer settings as listed in these the tables
textare
grouped and shown in tables for easy
5. Tim
governing over those given in above.
1 Please
ers note that below tag numbers for timers may not be reflected in
this is pending system
the
Tagcontrol
Descri and safeguarding logic, Time
constraints.
TI -1 TI -1 starts when stop -270 given to the 1
no. Gas ption -270 Atime of 10 seconds topi fan (seconds)
M0 K M-270
0 command
A/is used to XS gas
down 50 as
isRegeneration
necessary during0
Heater
has not03.yet delay prior to s p ngmotors
1 M
TI -1 TI 1 starts
04
-1 B coolwhen thestopthe
-270time gas to the
is given 0
H
stopped
Gas flowing.
-270 . No time delay is requiredclosing-
M 0 271 M 0/~204/
command in theXS 50 Regeneration
current design, however, the
Heater H03
supplied prior
with to
0 second thein POV
delay
2 04
TI -1 TI 2~304
-1 starts delay
-270 function
command is is activated. A 1
case it is prior
seconds required in
to opening future.
the BDV’sswitch
is due to
M 0 valvM 0 when XS 02 time delay of 15 5
TI -1 TIthe-1 travel
startstime of the
the stop command is given ing to the3
3 Cooler
es.3 -270A/B. A time delay of 30 seconds
M 0 louvers
M 0 when Regeneration
is used to allow theGasfans to stop turning
0
fans KM04 prior to closing the
4 prior 4 to closure of louvers.
5. Tracking
2 No .
signals
ne