Control Narratives GDC-121-8

INDUSTRIAL DIVISION GDC-121-8
CALCULATION AND DESIGN GUIDE Revision: 0

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CONTROL NARRATIVE
TÉCNICAS REUNIDAS, S.A.
TABLE OF CONTENTS
1. PURPOSE, RESPONSIBILITY, REFERENCES ......................................................3

1.1. PURPOSE.........................................................................................................3
1.2. RESPONSIBILITY.............................................................................................3
1.3. REFERENCES..................................................................................................3
2. INTRODUCTION ......................................................................................................4
3. FUNCTIONAL DESCRIPTION RELEVANTO TO COMPLEX CONTROL LOOPS...5
3.1. REFERENCE P&IDS ........................................................................................5
3.2. FUNCTIONAL DESCRIPTION ..........................................................................5
3.3. CONTROLLED VARIABLES .............................................................................5
3.4. MANIPULATED VARIABLES ............................................................................5
3.5. SCHEME...........................................................................................................5
3.6. BLOCKS DESCRIPTION ..................................................................................5
4. COMPLEX CONTROL LOOPS ................................................................................7
4.1. HEAT EXCHANGER SPLIT RANGE CONTROL ..............................................7
4.2. HEAT EXCHANGER OPPOSITE RANGE CONTROL......................................8
4.3. BLANKETING SPLIT RANGE CONTROL ........................................................9
4.4. CHARGE HEATER LOAD BALANCING CONTROL.......................................11
4.5. COMBUSTION CONTROL .............................................................................12
4.6. ALTERNATIVE COMPRESSOR CONTROL ..................................................13
4.7. DUTY CONTROL ............................................................................................16
4.8. THREE ELEMENT CONTROL........................................................................17
5. EXAMPLE CONTROL NARRATIVE .......................................................................18
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CONTROL NARRATIVE
1. PURPOSE, RESPONSIBILITY, REFERENCES

1.1. PURPOSE
The purpose of this guide is to establish the information that a Control Narrative has to contain
as well as the format that it must have in order to be used by the instrumentation department.
Several examples of complex control loops have been chosen to be shown in an Example
Control Narrative because of the frequency they are found in Units.
This guide will be used by the Process Departments of the Técnicas Reunidas Group
The information set forth in this guide is provided to users for their consideration. This is of
particular importance where GDC’s may not cover every requirement or diversity of condition at
each location. The system of GDC’s is expected to be sufficiently flexible to allow individual
operating companies to adapt the information set forth in GDC’s to their own environment and
requirements.
1.2. RESPONSIBILITY
The Standards and Specifications Coordinator, and, in his absence, the Process Manager on
behalf of the SSC, has the necessary responsibility and authority to enforce the application of
this guide to ensure that the technical norms and computer programs used in the development
of the powers of the process department are appropriate and are up-dated and available.
If any particular regulation exists in which some of the requirements may be different from those
in this GDC the Client shall determine which of the requirements take preference and which
combinations of requirements will be acceptable. In all cases, the Client shall inform the TR
Group company of any deviation from the requirements of this GDC, that is considered to be
necessary in order to comply with a particular regulation.
1.3. REFERENCES
This document can be found at the intranet addresses:
o INITEC: Documentum / Docbases / DOCBASE_INI / BIBLIOTECA / Normativa Interna /

Initec / Procesos / Procedimientos.
o TR: Y:\Información Departamento \ Guías de diseño y cálculo.
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CONTROL NARRATIVE
2. INTRODUCTION
Control Narrative is a document that provides a functional description of complex control loops
of a Unit. Therefore simple regulatory control loops, the functionality of which can be inferred
from PI&Ds and control loops within packages are not described in Control Narratives. It
contains important information for the Project that will be used by other disciplines. It should
therefore be kept updated.
Control Narratives have three parts. The first and the second part consist in an introduction and
some general statements. Those statements shall be identical for every Control Narrative (See
2.1 and 2.2 of the Example Control Narrative). The third part is the functional description
relevant to complex control loops.
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CONTROL NARRATIVE
3. FUNCTIONAL DESCRIPTION RELEVANT TO COMPLEX CONTROL LOOPS

For each complex control loop the following items must be described:
3.1. REFERENCE P&IDS

For all equipment, stream and instrumentation relevant to the control loop the corresponding
P&ID has to be listed.
3.2. FUNCTIONAL DESCRIPTION

Functional Description is the control loop objective including a brief explanation of the control
strategy. The name and Tag number of every equipment item, controller, valve and transmitter
have to be mentioned at this point.
3.3. CONTROLLED VARIABLES

Controlled Variables must be listed. This list must include the measurable property (level,
temperature, pressure, flow rate, flow ratio, etc) as well as the name and Tag number of any
relevant equipment item, instrument or stream.
3.4. MANIPULATED VARIABLES

Manipulated Variables must be listed. The list must include the measurable property (level,
temperature, pressure, flow rate, flow ratio, etc) as well as the name and Tag number of any
relevant equipment item, instrument or stream.
3.5. SCHEME
Every block of the control loop as transmitters, controllers, arithmetic blocks as well as final
control element must be shown in a scheme. In addition the scheme should identify inputs,
outputs and the action of each controller.
3.6. BLOCKS DESCRIPTION

Each control block must be described as it is shown in the example control narrative by two
items: Type (PID controller, Arithmetic control block, Low/High Signal Selector, Hand Controller,
etc.) and Function (Inputs, Outputs and Equation)
Type should also stand if it is a Direct or Reverse Action Controller for PID controllers. For other
control blocks actions as scaling, supporting cascades, initialization and back calculation should
be specified. In addition if the control block makes a calculation with the Process Variable this
item should explain the calculation. Finally any other consideration or note about the controller
action must be specified.
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CONTROL NARRATIVE
The Function item is the explanation of the scheme by listing inputs and outputs of the block. It
has to specify the preceding block Tag number of each input signal and the destination block
Tag number of each output signal. It has to be pointed out here if it is a percentage or
engineering units signal.
Spring action of the valve (failure open or failure close) does not determine the control action of
the PID controller (direct or reverse). Spring action (and subsequently the instrument air failure
position of the valve) shall be determined with a safety analysis independently from the control
action. For each particular case, the spring action will be determined taking into account the
whole process in which the valve is involved.
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CONTROL NARRATIVE
4. COMPLEX CONTROL LOOPS

The following complex control loop examples have been chosen because of the frequency they
are found in Units. Those are typical configurations to be used as bases for punctual cases.
There are many possible variations for control schemes depending on the particular system. In
this guide, representative schemes will be examined over which modifications can be effected
to suit particular systems. Complete blocks schemes and the corresponding narratives are
shown in the Example Control Narrative (section 5 of this guide) below the following process
diagrams. The examples will follow the recommended structure explained in section 3 of this
guide.
Control Narratives shall be updated in Detailed Engineering based in the received information
from the Basic Engineering.
4.1. HEAT EXCHANGER SPLIT RANGE CONTROL

This example refers to a temperature control loop for a VGO cooler exchanger. The narrative for
this control loop is shown at the item 3.1 of the Example Control Narrative.
Figure 4.1. Heat exchanger in split range control

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CONTROL NARRATIVE
4.2. HEAT EXCHANGER OPPOSITE RANGE CONTROL

This example refers to a temperature control loop for a VGO cooler exchanger. The narrative for
this control loop is shown at the item 3.2 of the Example Control Narrative.
Figure 4.2. Heat Exchanger in opposite range control

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CONTROL NARRATIVE
4.3. BLANKETING SPLIT RANGE CONTROL

This example refers to a pressure control loop of the feed surge drum of an HDT unit. The
narrative for this control loop is shown at the item 3.3 of the Example Control Narrative.
FG to
FG
Flare
PV PY PY PV
001A 001A 001B 001B
PC
001
PT
001
D001
Figure 4.3. Blanketing split range control

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CONTROL NARRATIVE
The objective of this control loop could also be achieved by a two controllers configuration as
the following scheme shows. The narrative for this control loop is shown at the item 3.4 of the
Example Control Narrative.
FG to
FG
Flare
PV PC PC PV
001A 001A 001B 001B
PT
001
D001
Figure 4.4. Two controllers control pressure loop

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CONTROL NARRATIVE
4.4. CHARGE HEATER LOAD BALANCING CONTROL

This example refers to a twelve pass heater which feeds atmospheric residue to a vacuum
distillation column. The narrative for this control loop in shown at the item 3.5 of the Example
Control Narrative.
Figure 4.5. Charge heater load balancing control

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CONTROL NARRATIVE
4.5. COMBUSTION CONTROL

This example refers to a forced draft heater which can operates either with Fuel Gas or Fuel Oil.
The narrative for this control loop is shown at the item 3.6 of the Example Control Narrative.
Figure 4.6. Combustión control

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CONTROL NARRATIVE
4.6. ALTERNATIVE COMPRESSOR CONTROL

This examples refers to the control pressure loop at the reaction section in an HDT unit. The
narrative for this control loop is shown at the item 3.7 of the Example Control Narrative.
FC
>
001
>
PV 001
PC PC
003A 003B
FT
001 FV 001
PC PC
001 002A
PT PT PT
001 002 003
D 001 D 003
D 002 T001
PC
002B
K001
E 001
PV 002
Figure 4.7. Alternative compressor pressure control

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CONTROL NARRATIVE
The objective of this control loop it could also be achieved by a split range control strategy as
the following scheme shows. The narrative for this control loop is shown at the item 3.8 of the
Example Control Narrative.
Figure 4.8. Alternative compressor pressure control in split range

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CONTROL NARRATIVE
If both compressor stages of Figure 4.8 are equipped with capacity controllers, the output signal
of high selectors must be split between the spill back control valves and the capacity controllers.
The narrative for this control loop is shown at the item 3.9 of the Example Control Narrative.
Figure 4.9. Alternative compressor capacity control

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CONTROL NARRATIVE
4.7. DUTY CONTROL

This example refers to a HVGO pump around of a vacuum tower. The narrative for this control
loop is shown at the item 3.10 of the Example Control Narrative.
TT TDI TT
001 002
001
E 001
JY
XXX
JV-001B
AO/AFC
FC FT
001
001
AC/AFO
FV-001
JY JC
001B 001
JY
001B
E 002
JV-001A
AC/AFO
Figure 4.10. Duty control in a pump around

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CONTROL NARRATIVE
4.8. THREE ELEMENT CONTROL

This example refers to a steam generator. The narrative for this control loop in shown at the
item 3.11 of the Example Control Narrative.
Figure 4.11. Three element control loop

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CONTROL NARRATIVE
5. EXAMPLE CONTROL NARRATIVE

XXXXXXXXX UNIT XXXXXXXXXXXXX
CONTROL PAGE 1 OF 71
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Client’s Name:
Project Title:
Project Location:
CONTROL NARRATIVE
REVISION STATUS
Revision Comment
REVISION
DATE
ORIG. BY
CKD. BY
APP. BY
XXXXXXXX UNIT XXXXXXXXXXXX
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INDEX
1. INTRODUCTION .................................................................................................... 3
2. GENERAL ............................................................................................................... 4
2.1. GENERAL NOTES.......................................................................................... 4
2.2. ABBREVIATIONS .......................................................................................... 5
3. FUNCTIONAL DESCRIPTION RELEVANT TO COMPLEX CONTROL
LOOPS. ............................................................................................................................ 6
3.1. TEMPERATURE CONTROL LOOP FOR VGO ........................................... 6
3.2. VGO SUPPLY TO THE HIDROTREATER TEMPERATURE CONTROL. 9
3.3. FIRST TRAIN PRESSURE CONTROL LOOP AT THE FEED SURGE
DRUM ........................................................................................................................ 12
3.4. TWO CONTROLLERS PRESSURE CONTROL LOOP ............................. 16
3.5. CHARGE HEATER LOAD BALANCING CONTROL .............................. 19
3.6. COMBUSTION CONTROL.......................................................................... 26
3.7. REACTION SECTION PRESSURE CONTROL LOOP .............................. 40
3.8. REACTION SECTION PRESSURE SPLIT RANGE CONTROL LOOP.... 46
3.9. ALTERNATIVE COMPRESSOR PRESSURE CONTROL LOOP WITH
CAPACITY CONTROLLER (HYDROCOM).......................................................... 53
3.10. DUTY IN HVGO PUMPAROUND CIRCUIT CONTROL ..................... 63
3.11. LEVEL IN STEAM DRUM CONTROL................................................... 68
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1. INTRODUCTION
This document provides a functional description of the complex control loops of the
XXXXXXXX Unit.
Simple regulatory control loops, the functionality of which can be easily inferred from
P&IDs and control loops within vendor packages are not described in this document.
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2. GENERAL
2.1. GENERAL NOTES

1. It is advised that the following items are not accessible to operators, e.g., by
engineering key-lock:
• Tuning parameters, such as gain, reset time and derivative time of controllers.
• Any other “tuneable” input parameters.
• Operating modes of protective (override) controllers.
2. Bumpless transfer must be ensured in the following cases:
From a manual mode to an automatic mode.
From an automatic mode to a cascade mode.
3. Prevent reset windup when the controller has a secondary data point that may or may
not be responding to the output of this data point.
4. Control actions of PID controllers have been defined such, that increasing controller
output will cause the control valve that is manipulated to open and a decreasing output
will cause the control valve to close. Therefore the control action is not affected by
whether the spring action of the valve is failure open or failure close. In case it is fail
open, the controller output valve has to be reversed prior to being processed as a field
out signal.
5. Control valves should be able to be operated manually from DCS, either switching
controllers to manual or by installing “auto/man” stations if necessary. Attention shall
particularly be paid to split range control strategies, in which it shall be possible to
manually override the output of each final control element independently.
6. For the split range control strategies, the split points and therefore the
characterization for each final control element shall be established during the
Implementation Phase. Preliminary values are indicated in this document. Achieving a
constant process gain over the whole range of the split range control, shall be
considered when assigning split points.
7. Whenever a block is included in a control path, it must support cascading, scaling,
initialization and back calculation to ensure bumpless transfers.
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2.2. ABBREVIATIONS
P&ID Piping and Instrument Diagram

OP Output of a controller/calculator/transmitter
PV Process value, or measured value
SP Set point of a controller
AI Analog Input
AO Analog Output
DI Digital Input
PID Proportional Integral Derivative Controller
AC/AFO Air to close/ Valve opens on air failure
AO/AFC Air to open/ Valve closes on air failure
AO/AFS Air to open / Air failure safe
ARTH Arithmetic Block
ARTHC Arithmetic Control Block.
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3. FUNCTIONAL DESCRIPTION RELEVANT TO COMPLEX CONTROL

LOOPS.
3.1. TEMPERATURE CONTROL LOOP FOR VGO
3.1.1. Reference P&IDs

Refer to the following P&IDs:
XXXX-XXXX-XX-XXXX-XXXX
3.1.2. Functional Description
The objective of this split range loop is to control the temperature of the VGO at the
outlet of the VGO Cooler E-001.
Temperature at E-001 is measured by TT-001 and the signal is sent to the temperature
controller TC-001. The temperature output signal from this controller is sent to the
following valves:
• TV-001A: E-001 by-pass valve.
• TV-001B: outlet of E-001 valve.
3.1.3. Controlled Variable

Temperature at the VGO outlet of the VGO Cooler.
3.1.4. Manipulated variables

The manipulated variables are:
• Flow rate of VGO through E-001.
• Flow rate of VGO through the heat exchanger by-pass.
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3.1.5. Scheme
0 - 50%
50 – 100%
3.1.6. Blocks Description
TC-001
Type:
PID controller.
Direct Action.
Function:
Input:
PV: Output of TT-001, temperature of VGO to E-002 stream, (temperature
engineering units, ºC).
SP: By operator (temperature engineering units, ºC).
Output:
OP: percentage value, 0-100%.
The output signal range is divided. The following table shows the split range
functional description:
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Valve Position (%)

Controller Output (%)
TV-001 A TV-001 B
0 100 0
50 100 100
100 0 100
TY-001 A
Type:
Arithmetic control block.
This block shall be a control block, supporting cascades, scaling, initialization and back
calculation.
TY-001 A changes the scale of the input signal and reverses it to an output between
100-0%.
Function:
Input:
IN: Output of TC-001 (percentage value, 0-50%).
Output:
OP: Input of TV-001 A (percentage value, 100-0%).
TY-001 B
Type:
calculation.
TY-001 B changes the scale of the input signal to an output between 0-100%.
Function:
Input:
IN: Output of TC-001 (percentage value, 50-100%).
Output:
OP: Input of TV-001 B (percentage value, 0-100%).
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3.2. VGO SUPPLY TO THE HIDROTREATER TEMPERATURE CONTROL

Refer to the following P&ID:
XXXX-XXXX-XX-XXXX-XXXXXX

The objective of this opposite range loop is to control the Temperature of the
VGO supply to the hydrotreater, by acting on the downstream of VGO Product
Cooler E-002 and in the cooler bypass line flow.
The Temperature of VGO supply to the hydrotreater is measured by TT-002 and

the signal is sent to the temperature controller TC-002. The output signal from
this controller is sent to the following valves in an opposite range strategy:
• TV-002A that is located downstream of VGO Product Cooler E002

• TV-002B that is located in the E002 by-pass line
3.2.3. Controlled Variables

VGO supply temperature to the hydrotreater.
3.2.4. Manipulated Variables

Manipulated variables are:
• VGO flow downstream of E-002. TV-002A
• VGO flow downstream of E-0002 (E-0014 by-pass line). TV-002B
3.2.5. Scheme
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0 - 100%
0 - 100%

TC-002.
Type:
PID controller.
Direct Action.
Function:
Input:
PV: Output of TT-002, VGO to hydrotreater line temperature (temperature
SP: By operator (temperature engineering units, ºC).
Output:
The following table shows the opposite range functional description:
Valve Position (%)
Controller Output (%) TV-002A TV-002B
0 0 100
50 50 50
100 100 0
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TY-002 A.
Type:
Auto/Man control block.
calculation. It is included with the purpose of enabling the operator to manually
manipulate TV-002A.
Function:
Inputs:
IN: Output of TC-002 (percentage value, 0%-100%)
Output:
OP: Input of TV-002A (percentage value, 0%-100%)
Equation:
OP = IN + BIAS
TY-002B.
Type:
calculation.
TY 002B reverses the signal to an output between 100-0%.
Function:
Inputs:
IN:Output of TC-002 (percentage value, 0%-100%)
Output:
OP:Input of TV-002B (percentage value, 100%-0%)
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3.3. FIRST TRAIN PRESSURE CONTROL LOOP AT THE FEED SURGE

DRUM


The objective of this split range loop is to control the pressure at the Feed Surge Drum,
D-001, by pressurizing or depressurizing the drum as needed.
The pressure at D-001 is measured by the pressure transmitter PT-001, and the signal is
sent to the pressure controller PC-001. The pressure output signal from this controller is
sent to the following valves:
PV-001A: Fuel Gas valve to D-001.
PV-001B: Fuel Gas Valve to Flare.

First Train Feed Surge Drum D-001 pressure.

• Fuel gas flow from fuel gas header to D-001.
• Fuel gas from D-001 to flare.
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3.3.5. Scheme
PC-001.
Type:
PID controller.
Direct Action.
Function:
Input:
PV: Output of PT-001 (pressure engineering units, kg/cm2g).
SP: By operator (pressure engineering units, kg/cm2g).
Output:
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Valve Position (%)

PV-001A PV-001B
0 100 0
45 0 0
50 0 0
55 0 0
100 0 100
PY-001 A.
Type:
calculation.
PY-001A changes the scale of the input signal and reverses it to an output between 100-
0%.
Function:
Input:
IN: Output of PC-001 (percentage value, 0-50%).
Output:
OP: Input of PV-001 A (percentage value, 100-0%).
PY-001 B.
Type:
calculation.
PY-001 B changes the scale of the input signal to an output between 0-100%.
Function:
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Input:
Output:
OP: Input of PV-001 B (percentage value, 0-100%).
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3.4. TWO CONTROLLERS PRESSURE CONTROL LOOP


The objective of this loop is to control the pressure at the Feed Surge Drum, D-001, by
pressurizing or depressurizing the drum as needed.
The pressure at D-001 is measured by the pressure transmitter PT-001, and the signal is
sent to two controllers PC-001A and PC-001B. The pressure output signal from these
controllers is sent to the following valves:
PV-001A: Fuel Gas valve to D-001.
PV-001B: Fuel Gas Valve to Flare.

First Train Feed Surge Drum D-001 pressure.

• Fuel gas flow from fuel gas header to D-001.
• Fuel gas from D-001 to flare.
3.4.5. Scheme
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3.4.6. Blocks description

PC-001A.
Type:
PID controller.
Reverse Action.
Function:
Input:
Output:
OP: Input to PV-001A (percentage value, %).
PC-001B
Type:
PID controller.
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Direct Action.
Function:
Input:
PC 001B set point shall be slightly higher than PC 001A set point.
Output:
OP: Input to PV-001B (percentage value, %).
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3.5. CHARGE HEATER LOAD BALANCING CONTROL


The objectives of this loop are:
1. Achieve an overall fired heater flow set point
2. Achieve equal outlet temperatures from each pass.
3. Control the ratio of the steam flow to Atmospheric Residue Flow per pass.
As a minimum, the fired heater load balancing controller shall achieve the
functionality outlined below. A typical implementation is provided to clarify the
functionality – this implementation is not intended to be prescriptive.
In the next diagram, instrument loops F-001÷012, F-101÷112 and T-001÷012 are
associated with one fired heater pass whereas F-XXX and T-XXX are common to
all passes. With the exception of tag numbers, the controls associated with each pass
are identical.
The feed flowrate is multiplied by a predetermined ratio in FY-001÷012 to calculate
the setpoint of the steam flow controller FC-101÷112. The controls associated with
other passes are identical to this pass, and the ratio used in FY-001÷012 is common
to all passes.
The actual overall feed flowrate is calculated by summation block FY-XXX. This
then becomes the measured variable for FC-XXX.
The average heater outlet temperature is calculated by TY-XXX. This then becomes
the setpoint for TC-001÷012.
The outputs of FC-XXX and TC-001÷0012 are passed to TY-001÷012. TY-
001÷012 calculates the sum of the FC-XXX output and the TC-001÷012 output. The
output of TY-001÷012 then becomes the setpoint of FC-001÷012.
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The controlled variables are:
• Temperature differentials between the average heater outlet temperature and the
outlet temperature of each pass.
• Overall inlet flow to the FR-001.
• Steam flow to Atmospheric Residue Flow ratio per pass

The manipulated variable is the flow for each pass.
• Steam Flow per pass. FC-101÷112.
• Atmospheric Residue Flow per pass. FC-001÷0012.
3.5.5. Scheme
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ARTH
ARTH
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TY-XXX
Type:
Arithmetic block.
It calculates the average temperature of 12 passes.
Function:
Inputs:
PV of TC-001÷012 (temperature engineering units, ºC).
Output:
SP of TC-001÷012 (temperature engineering units, ºC)
Equation
Average temperature is calculated as follows.
T001 + T002 + T003 + T004 + T005 + T006 + T007 + T008 + T009 + T010 + T011 + T012
Taverage =
12
T001 ÷ 012: output of TT-001÷012 (temperature engineering units, ºC).
Taverage: SP of TC-001÷012 (temperature engineering units, ºC).
FY-XXX
Type:
Arithmetic Block.
It calculates the total flow to the fractionator heater, FR-001.
Function:
Inputs:
Q001÷012: PV of FC-001÷012 (liquid flow engineering units, m3/h).
Output:
Input of FC-XXX, total flow calculated adding the twelve flow measurements
(liquid flow engineering units, m3/h).
Equation
QT = Q001 + Q002 + Q003 + Q004 + Q005 + Q006 + Q007 + Q008 + Q009 + Q010 + Q011 + Q012
QT: PV of FC-XXX, total flow (liquid flow engineering units, m3/h).

Q001÷012: Output of FC-001÷012 (liquid flow engineering units, m3/h).
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FC-XXX
Type:
PID controller.
Reverse Action.
Function:
It controls the total flow to the heater FR-001.
Inputs:
SP: By operator, (liquid flow engineering units, m3/h).
PV: Output of FY-XXX, FR-001 total flow (liquid flow engineering units, m3/h).
Output:
Input (IN1) of TY-001 (percentage value, %).
TY-001÷012
Type:
It calculates the sum of the OP of FC-XXX and the OP of TC-001÷012 (temperature of
12 passes).
Function:
Inputs:
IN1: Output of FC-XXX (percentage value, %).
IN2: Output of TC-001÷012 (percentage value, %). IN2 is a percentage value that
shall be limited between -5% and 5%.
Output:
SP of FC-001÷012 (liquid flow engineering units, m3/h)
Equation
OP = IN1+IN2
TC-001÷012
Type:
PID controller.
Direct Action.
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Function:
Input:
PV: Output of TT-001÷012, outlet FR-001 temperature transmitters (temperature
SP: OP of TY-XXX (temperature engineering units, ºC).
Output:
OP: Input (IN2) of TY-001÷012. It shall be limited between -5% and 5%.
FC-001÷012
Type:
PID controller.
Reverse Action
Function:
Input:
SP: Output of TY-001÷012 (liquid flow engineering units, m3/h).
PV: Output of FT-001÷012 (liquid flow engineering units, m3/h).
Output:
OP: Input of FV-001÷012 (percentage value, %).
FC-101÷112
Type:
PID controller.
Reverse Action
Function:
Input:
SP: Output of FY-001÷012 (liquid flow engineering units, m3/h).
PV: Output of FT-101÷112 (liquid flow engineering units, m3/h).
Output:
OP: Input of FV-101÷112 (percentage value, %).
FY-001÷012.
Ratio Controller.
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calculation.
FY-001÷012 multiplies the PV of FC-001÷012 by a factor f set by the operator.
Function:
Inputs:
IN: PV of FC-001÷012, atmospheric residue flow in each pass (liquid flow
engineering units, m3/h)
f: by operator, f = (steam flow, kg/h) / (atmospheric residue flow, m3/h)
Ouput:
OP: SP of FC-101÷112, (liquid flow engineering units, m3/h).
Equation:
OP = f*IN
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3.6. COMBUSTION CONTROL


The main objective of this loop is to optimize excess-air for fuel efficiency. The
control scheme is designed such that, when an increase in duty is required, the air
flow rate is increased before the fuel flow rate is increased. Conversely, when a
decrease in heater duty is required the fuel is conduced prior to the air flow rate
being reduced. This is an example for a forced draught heater which uses both Fuel
Oil and Fuel Gas.
Firing demand is set by the heater process outlet temperature (TIC 002) and it is
used for regulating the fuel and air flow rates by sending it to a pair of signal
selectors. A high signal selector compares the firing rate demand against the
operating total fuel flow signal. Previous to the high signal selector a small negative
bias is needed to permit a faster response to load changes.
Combustion air is flow controlled by FIC 001 and it is temperature compensated.

The set point of the air flow rate is from the high signal selector TY 002 B. The air
flow is adjusted by dividing it by the air/fuel ratio. The air fuel ratio is the output of
the AIC 001 oxygen controller. As a safety precaution the output of this controller
has to be filtered by high and low limiters (0.8 to 1.2, typical).
A low signal selector compares the firing rate demand signal against the adjusted air
flow rate signal. A small positive bias is applied to the air flow signal to permit a
faster response to load changes. The output of the low signal selector is the set point
for the total fuel flow controller (FIC 004).
REV
NARRATIVE
Fuel Gas flow rate is controlled by FIC 003. The flow measurement point shall be
compensated for density (FY 003) in order to obtain a mass flow rate. The set point
for the fuel gas flow controller is the output of the total fuel controller FIC004. The
output signal from the fuel gas flow controller is sent to a high signal selector which
allows the operator to fix the set point to the pressure controller PIC 001. This
pressure controller sends its output to the control valve FV001.
Fuel Oil is flow controlled by FIC 002. The fuel flow measurement is calculated
from the difference between the supply and return flows. This mass flow goes to the
oil flow controller FIC 002 as its process variable. The output signal from the fuel
oil flow controller is sent to a high signal selector which allows the operator to fix
the set point to the pressure controller PIC 002. This pressure controller sends its
output to the control valve FV002.
The fuel oil flow rate signal, computed as the difference between supply and return
flows, along with the density corrected FG flow rate are the inputs to the summer
that computes the total fuel flow. FO signal needs to be converted to a FG
equivalent by using the corresponding heating value. The output of the summer is
the measured variable of the total fuel controller FIC-004.
The atomizing steam flow to the furnace is controlled by PDIC-014 which fixes the
differential pressure between the fuel oil and the steam. The controller sends the
output to the control valve PDV-014, located in the steam line.

The controlled variables are:
• Oxigen content in flue gas.
• Process Outlet Temperature

• Combustion Air Flow rate
• Fuel Oil Flow Rate
REV
NARRATIVE
• Fuel Gas Flow Rate
3.6.5. Scheme
REV XX
NARRATIVE
REV XX
NARRATIVE

FY-001
Type:
Arithmetic block
Temperature compensation of the air flow indicator signal
Function:
Input:
IN1: output of FT001, air flow rate (mass flow rate engineering units, kg/h).
IN2: output of TT001, air flow temperature (temperature engineering units, ºC).
Output:
OP: Input to FC001 as its set point and FY005A (mass flow rate engineering units,
kg/h).
Equation
OP = IN1*(TR/T)0.5
TR: Reference temperature in ºK
T: Actual temperature in ºK = IN2 + 273.15
AC-001
Type:
PID controller.
Reverse Action.
Controller output has to be filtered by high and low limiters.
Function:
Inputs:
PV: Oxygen content in flue gas (concentration engineering units)
SP: By Operator, oxygen content in flue gas (concentration engineering units)
Output:
OP: Input to FY005A and FY005B, air/fuel ratio correction factor. It should be
limited (0.8 to 1.2 typical). A 50% controller output signal should give a 1.0 air/fuel
correction factor.
REV
NARRATIVE
FY-005 A
Type:
This block shall be a control block, supporting cascades, scaling initialization and back
calculation.
It operates with three inputs and adds a positive bias to the output signal.
Function:
Input:
IN1: output of FY001, actual air flow rate (mass flow rate engineering units, kg/h).
IN2: output of AC001, air/fuel ratio correction factor.
IN3: output of HIC003 (operator input), air/fuel ratio (ratio of mass flow rate
engineering units, kg/h air/ kg/h FG).
Output:
OP: Input to TY002 A, actual air flow rate (mass flow rate engineering units, kg/h
FG).
Equation
IN1
OP = + BIAS
IN 2 * IN 3
Note: HIC003 is included with the purpose of enabling the operator to manually
manipulate the air fuel ratio.
FY-003
Type:
Arithmetic block.
It adjusts Fuel gas mass flow by density.
Input:
IN1: output of FT003, fuel gas flow rate (mass flow rate engineering units, kg/h
FG).
IN2: fuel gas density (density engineering units, Kg/m3).
Output:
OP: Input to FC003 and FY004, fuel gas flow rate (mass flow rate engineering
units, kg/h FG).
REV
NARRATIVE
Equation
OP = IN1*(IN2/RDEN)0.5
RDEN: reference density, kg/m3
FY-002
Type:
Arithmetic block.
It Computes the difference between supply and return flows.
Input:
IN1: output of FT002A, fuel oil flow rate (mass flow rate engineering units, kg/h
FO).
IN2: output of FT002B, fuel oil flow rate (liquid mass flow rate engineering units,
kg/h FO).
Output:
OP: Input to FY004 and FC002, Fuel oil flow rate (mass flow rate engineering
units, kg/h FO).
Equation
OP=IN1-IN2
TC-002
Type:
PID controller.
Reverse Action.
Function:
Inputs:
PV: output of TT002, process outlet temperature (temperature engineering units,
ºC).
SP: By Operator (temperature engineering units, ºC).
Output:
OP: Input to TY002A/B, firing demand (mass flow rate engineering units, kg/h
FG). Use total fuel controller FC004 range to convert the percentage signal to
engineering units.
REV
NARRATIVE
Note: Total fuel controller FC004 must have the same range as the Fuel Gas
controller FC003.
FY-004
Type:
calculation.
It converts the FO signal into a FG equivalent by using the corresponding heating value
It calculates the total fuel mass flow rate and adds a negative bias to the output signal.
Function:
Inputs:
IN1: output of FY002, fuel oil flow rate (mass flow rate engineering units, kg/h
FO).
IN2: output of FY003, fuel gas flow rate (mass flow rate engineering units, kg/h
FG).
Output:
OP: Input to TY002B and FC004, total fuel flow rate (mass flow rate engineering
units, kg/h FG).
Equation:
OP = IN1*f + IN2 - BIAS
f: ratio between fuel oil and fuel gas heating values.
LHV of FO: XXXXX
LHV of FG: XXXXX
LHV: low heating value
TY-002A
Type:
Low Signal selector.
It selects the lower of the two input signals.
Function:
Inputs:
REV
NARRATIVE
IN1: output of FY005A, actual air flow rate (mass flow rate engineering units, kg/h
FG).
IN2: output of TC002, firing demand (mass flow rate engineering units, kg/h FG).
Output:
OP: Input to FC004 total fuel controller as its set point (mass flow rate engineering
units, kg/h FG).
TY-002B
Type:
High Signal selector.
It selects the higher of the two input signals.
Function:
Inputs:
IN1: output of TC002, firing demand (mass flow rate engineering units, kg/h FG).
IN2: output of FY004, total fuel flow rate (mass flow rate engineering units, kg/h
FG).
Output:
OP: Input to FY005B, firing demand (mass flow rate engineering units, kg/h FG)
FY-005B
Type:
calculation.
Multiplies the two input signals.
Function:
Inputs:
IN1: output of TY002 B, firing demand (mass flow rate engineering units, kg/h
FG).
IN2: output of AC 001, air/fuel ratio correction factor.
IN3: output of HIC003 (operator input), air/fuel ratio (ratio of mass flow rate
engineering units, kg/h air/ kg/h FG).
REV
NARRATIVE
Output:
OP: Input to FC001 as its set point, air flow rate (mass flow rate engineering units,
kg/h Air).
Equation
OP=IN1*IN2*IN3
Note: HIC003 is included with the purpose of enabling the operator to manually
manipulate the air fuel ratio.
FC-001
Type:
PID controller.
Reverse Action.
Function:
Inputs:
PV: output of FY001, actual air flow rate (mass flow rate engineering units, kg/h
Air).
SP: output of FY 005B, air flow rate (mass flow rate engineering units, kg/h Air).
Output:
OP: Input to FV001 (percentage units, %).
FC-004
Type:
PID controller.
Reverse Action.
It is the total fuel controller.
Function:
Inputs:
PV: output of FY004, total fuel flow rate (mass flow rate engineering units, kg/h
FG).
SP: output of TY 002A, firing demand (mass flow rate engineering units, kg/h FG).
Output:
REV
NARRATIVE
OP: Input to FC003 as its set point and input to FY006 (mass flow rate engineering
units, kg/h FG)
Note: Total fuel controller FC004 must have the same range as the Fuel Gas
controller FC003.
FC-003
Type:
PID controller.
Reverse Action.
Function:
Inputs:
PV: output of FY003, fuel gas flow rate (mass flow rate engineering units, kg/h
FG).
SP: output of FC004 total fuel controller, fuel gas flow rate (mass flow rate
engineering units, kg/h FG).
Output:
OP: Input to PY002 (pressure engineering units, kg/cm2).
Note: Ranges of FC003 and FC002 should be configured so that FC003 maximum
range value multiplied by the low heating value of FG is equal to the FC002
maximum range multiplied by the low heating value of FO.
FY-006
Type:
calculation.
It converts the equivalent FG flow rate signal into FO flow rate by using the
corresponding heating value
Function:
Inputs:
IN: output of total fuel controller FC004 (mass flow rate engineering units, kg/h
Output:
REV
NARRATIVE
OP: Input to FC002 as its set point, fuel oil flow rate (mass flow rate engineering
units, kg/h)
Equation:
OP = IN1/f
f: ratio between fuel oil and fuel gas heating values.
LHV of FO: XXXXX
LHV of FG: XXXXX
LHV: low heating value
FC-002
Type:
PID controller.
Reverse Action.
Function:
Inputs:
PV: output of FY002, fuel oil flow rate (mass flow rate engineering units, kg/h FO).
SP: output of FY006, fuel oil flow rate (mass flow rate engineering units, kg/h FO).
Output:
OP: Input to PY001, flow pressure (pressure engineering units, kg/cm2g).
Note: Ranges of FC003 and FC002 should be configured so that FC003 maximum
range value multiplied by the low heating value of FG is equal to the FC002
maximum range multiplied by the low heating value of FO.
PY-002
Type:
High signal selector
It is included with the purpose of enabling the operator to manually manipulate PC001.
Function:
Inputs:
IN1: output of FC003, fuel gas pressure (Pressure engineering units, Kg/cm2g).
IN2: Set by operator, fuel gas pressure (Pressure engineering units, Kg/cm2g).
REV
NARRATIVE
Output:
OP: Input to PC 002 as its set point (Pressure engineering units, Kg/cm2g).
PY-001
Type:
High signal selector
It is included with the purpose of enabling the operator to manually manipulate PC001.
Function:
Inputs:
IN1: output of FC002, fuel oil pressure (Pressure engineering units, Kg/cm2g).
IN2: Set by operator, fuel oil pressure (Pressure engineering units, Kg/cm2g).
Output:
OP: Input to PC 001 as its set point (Pressure engineering units, Kg/cm2g).
PC-001
Type:
PID controller.
Reverse Action.
Function:
Inputs:
PV: output of PT001, fuel oil pressure (Pressure engineering units, Kg/cm2g).
Sp: output of PY001, fuel oil pressure (Pressure engineering units, Kg/cm2g).
Output:
OP: Input to FV002 (Percentage units, %).
PC-002
Type:
PID controller.
Reverse Action.
Function:
REV
NARRATIVE
Inputs:
PV: output of PT002, fuel gas pressure (Pressure engineering units, Kg/cm2g).
Sp: output of PY002, fuel gas pressure (Pressure engineering units, Kg/cm2g).
Output:
OP: Input to FV003 (Percentage units, %).
PDIC-014
Type:
PID controller.
Reverse Action.
Function:
Inputs:
PV: output of PDT-014, fuel oil – steam differential pressure (Pressure engineering
units, Kg/cm2).
Sp: by operator, fuel oil – steam differential pressure (Pressure engineering units,
Kg/cm2).
Output:
OP: Input to PDV-014 (Percentage units, %).
REV
NARRATIVE
3.7. REACTION SECTION PRESSURE CONTROL LOOP

XXXX-XXXX-XX-XXXX-XXX

The objective of this loop is to control the pressure in the VGO-HDT reaction section,
by manipulating the hydrogen make-up flow. The compressor suction and inter stage
pressure must be prevented from reaching low values that might eventually trip the
compressor.
The pressure transmitter PT-003 (Reaction pressure) sends a signal to PC-003A which
controls the pressure of the make-up compressor spill back and to PC-003B which
controls the purge to the fuel gas system from the overhead line of T001. Compressor
suction and inter stage pressures are also controlled.

Reaction section pressure.
First stage suction drum pressure.
Second stage suction drum pressure.

• HP Amine Absorber (T-001) purge flow to fuel gas system.
• Make-up compressor (K-001) spill back by-pass flow.
3.7.5. Scheme
REV XX
NARRATIVE
REVERSE
ACTION
>
PV PC OP IN1
PT PV PY
001 IN2
001 001
OP
PV-001 OP
AC/AFO
PV PV DIRECT
PT PC
ACTION
002
PV 002A
PC REVERSE
ACTION
002B
OP
DIRECT
ACTION IN1
>
PV PC OP IN2 PY
S-63
OP
003A 002
PT PV
003 REVERSE PV-002
DIRECT AC/AFO
ACTION ACTION
PV PC OP SP FC OP
003B 001
FT PV PV
001
FV-001
AC/AFO
REV XX
NARRATIVE

PC-001
Type:
PID controller.
Reverse action.
Function:
Inputs:
PV: Output of PT-001, first stage suction pressure (pressure engineering units,
kg/cm2g).
Output:
OP: Input of PY-001 (percentage value, %).
PY-001
Type:
High signal selector.
It selects the highest signal between the two inlets and it sends it to the control valve
PV-001.
Function:
Inputs:
IN1: Output of PC-001, first stage suction pressure (percentage value, %).
IN2: Output of PC-002 A, second stage suction pressure (percentage value, %).
Output:
OP: Input of PV-001 (percentage value, %).
PC-002 A
Type:
PID controller.
Direct Action.
Function:
Input:
REV
NARRATIVE
PV: Output of PT-002, second stage suction pressure (pressure engineering units,
kg/cm2g).
SP: By operator (pressure engineering units, kg/cm2g). Set Point of PC002A shall
be slightly higher than PC002B set point.
Output:
PC-002 B
Type:
PID controller.
Reverse Action.
Function:
Input:
PV: Output of PT-002, second stage suction pressur (pressure engineering units,
kg/cm2g).
SP: By operator (pressure engineering units, kg/cm2g). Set Point of PC002B shall
be slightly lower than PC002A set point.
Output:
OP: Input of high signal selector PY-002 (percentage value, %).
PC-003A
Type:
PID controller.
Direct Action.
Function:
Input:
PV: PT-003 output, reaction pressure (pressure engineering units, kg/cm2g).
SP: By operator (pressure engineering units, kg/cm2g). Set point of PC 003A shall
be slightly lower than PC 003B set point.
Output:
OP: Input of PY-002 (percentage value, %)
REV
NARRATIVE
PC003B
Type:
PID controller.
Direct Action.
Function:
Input:
SP: By operator (pressure engineering units, kg/cm2g). Set point of PC 003B shall
be slightly higher than PC 003A set point.
Output:
OP: Input of FC-001 as its set point (mass flow engineering units, kg/h)
PY-002
Type:
PV-002.
Function:
Inputs:
IN1: Output of PC-002B, second stage suction pressure (percentage value, %).
IN2: Output of PC-003A, reaction pressure (percentage value, %).
Output:
FC001
Type:
PID controller.
Reverse Action.
Function:
Input:
PV: Output of FT-001 (mass flow engineering units, kg/h).
SP: Output of PC-003B (mass flow engineering units, kg/h)
REV
NARRATIVE
Output:
OP: Input of FV-001 (percentage value, %)
REV
NARRATIVE
3.8. REACTION SECTION PRESSURE SPLIT RANGE CONTROL LOOP.


The objective of this split range loop is to control the pressure in the VGO-HDT
reaction section, by manipulating the hydrogen make-up flow. The compressor suction
and inter stage pressure must be prevented from reaching low values that might
eventually trip the compressor.
The pressure transmitter PT-003 (Reaction Pressure) sends a signal to the pressure
controller PC-003 which controls the pressure in a split range, between the make-up
compressor spill back and the purge to the fuel gas system from the overhead line of
T001. Compressor suction and inter stage pressures are also controlled.

HP Amine Absorber KO Drum pressure.
First stage suction drum pressure.
Second stage suction drum pressure.

3.8.5. Scheme
REV XX
NARRATIVE
REV XX
NARRATIVE

PC-001
Type:
PID controller.
Reverse action.
Function:
Inputs:
PV: Output of PT-001, first stage suction pressure (pressure engineering units,
kg/cm2g).
Output:
PY-001
Type:
PV-001.
Function:
Inputs:
IN2: Output of PY-002 A, second stage suction pressure (percentage value, %).
Output:
PC-002
Type:
PID controller.
Direct Action.
Function:
Input:
REV
NARRATIVE
PV: Output of PT-002, second section suction pressure (pressure engineering units,
kg/cm2g).
SP: By operator (pressure engineering units, kg/cm2g)
Output:
OP: Input of PY-002A and PY-002B (percentage value, %).
Valve Position (%)

PV-001 PV-002
0 0 100
50 0 0
100 100 0
PY-002 A
Type:
calculation.
PY-002 A changes the scale of the input signal to an output between 0-100%.
Function:
Input:
IN: Output of PC-002 (percentage value, %).
Output:
PY-002 B
Type:
calculation.
Function:
TÉCNICAS REUNIDAS, S.A. 49

MADRID
REV
NARRATIVE
Input:
Output:
PC 003
Type:
PID controller.
Direct Action.
Function:
Input:
Output:
Valve Position (%)

FV-001 PV-002
0 0 0
50 0 100
100 100 100
PY-003 A
Type:
calculation.
Function:
Input:

MADRID
REV
NARRATIVE
Output:
OP: Input of high signal selector PY-002 (percentage value, 0-100%).
PY-003 B
Type:
calculation.
Function:
Input:
Output:
OP: Input of FC-001 as its set point (percentage value, 0-100%).
PY-002
Type:
PV-002.
Function:
Inputs:
IN1: Output of PY-002 B, second stage suction drum (percentage value, %).
IN2: Output of PY-003 A, reaction pressure (percentage value, %).
Output:
FC001
Type:
PID controller.
Direct Action.
Function:

MADRID
REV
NARRATIVE
Input:
SP: Output of PY-003B (percentage value, %)
Output:
OP: Input of FV-001 (percentage value, %)

MADRID
REV
NARRATIVE
3.9. ALTERNATIVE COMPRESSOR PRESSURE CONTROL LOOP WITH

CAPACITY CONTROLLER (HYDROCOM)


The objective of this split range loop is to control the pressure in the VGO-HDT
reaction section, by manipulating the hydrogen make-up flow. The compressor suction
and inter stage pressure must be prevented from reaching low values that might
eventually trip the compressor.
The pressure transmitter PT-003 (Reaction Pressure) sends a signal to the pressure
controller PC-003 which controls the pressure in a split range between the purge to the
fuel gas system and a high signal selector. This high signal selector gives a split range
signal between the capacity controller of the second stage compressor and to its spill
back control valve. Thus, these extra blocks, allow a reduction of the amount of
compressed hydrogen, reducing the compressor capacity before opening the spill back
control valve when the reaction pressure increases. Compressor suction and inter stage
pressures are also controlled.
Note: For this explanation it has been considered that a decreasing signal to the
alternative compressor capacity controller, makes a capacity reduction of compressor
Capacity.

• Reaction pressure.
• First stage suction pressure.
• Second stage suction pressure.

MADRID
REV
NARRATIVE

• Make-up compressor (K001) capacity.
3.9.5. Scheme

MADRID
REV XX
NARRATIVE
REV XX
NARRATIVE
Blocks Description
PC-001
Type:
PID controller.
Reverse action.
Function:
Inputs:
PV: Output of PT-001, first stage presure (pressure engineering units, kg/cm2g).
Output:
PY-001
Type:
It selects the highest signal between the two inlets and it splits it between the first stage
spill back control valve and the first stage compressor capacity controller.
Function:
Inputs:
IN2: Output of PY-002A, second stage suction pressure (percentage value, %).
Output:
Input to PY-005A/B (percentage value, %).
PV001
PY001 Output Signal Position (%) Signal to 1st Stage
(%) Compressor (%)
100 100 0
75 50 0
50 0 0
25 0 50
0 0 100
REV
NARRATIVE
PC-002
Type:
PID controller.
Direct Action.
Function:
Input:
PV: Output of PT-002, second stage suction pressure (pressure engineering units,
kg/cm2g).
SP: By operator (pressure engineering units, kg/cm2g)
Output:
OP: Input of PY-002A and PY-002B (percentage value, %).
Signal to 1st Signal to 2st

PC002 PV001 Stage PV002 Stage
Output (%) Position % Compressor Position % Compressor
(%) (%)
0 0 100 100 0
25 0 100 0 0
50 0 100 0 100
75 0 0 0 100
100 100 0 0 100
PY-002 A
Type:
calculation.
Function:
Input:
Output:

MADRID
REV
NARRATIVE
OP: Input to PY-001 high signal selector (percentage value, %).
PY-002 B
Type:
calculation.
PY-002B changes the scale of the input signal to an output between 100-0%.
Function:
Input:
Output:
PY-005 A
Type:
calculation.
PY-005 A changes the scale of the input signal and inverts it. Thus, the output of the
block is a signal between 100-0%.
Function:
Input:
IN: Output of PY-001 (percentage value, %).
Output:
OP: Input to the first stage compressor capacity controller (percentage value, %).
PY-005 B
Type:
calculation.

MADRID
REV
NARRATIVE
Function:
Input:
Output:
OP: Input signal to PV001 (percentage value, %)
PC 003
Type:
PID controller.
Direct Action.
Function:
Input:
PV: PT-003 reaction pressure (pressure engineering units, kg/cm2g).
Output:
Signal to 2st
FV-001 PV002 Stage
Controller Output (%) Position (%) Position (%) Compressor
(%)
0 0 0 100
25 0 0 0
50 0 100 0
75 50 100 0
100 100 100 0
PY-003 A
Type:
calculation.

MADRID
REV
NARRATIVE
Function:
Input:
Output:
OP: Input to PY-002 high signal selector (percentage value, 0-100%).
PY-003 B
Type:
calculation.
Function:
Input:
Output:
OP: Input to FC-001 as its set point (mass flow engineering units, kg/h).
PY-002
Type:
It selects the highest signal between the two inlets and split it between the second stage
spill back control valve and the second stage compressor capacity controller.
Function:
Inputs:
IN1: Output of PY-002 B, second stage suction pressure (percentage value, %).
IN2: Output of PY-003A, reaction pressure (percentage value, %).
Output:
OP: Input of PY-005A/B (percentage value, %).

MADRID
REV
NARRATIVE
PV002 Signal to 2nd

Position (%) Stage
PY002 Output (%)
Compressor
(%)
0 0 100
25 0 50
50 0 0
75 50 0
100 100 0
PY-004 A
Type:
calculation.
PY-004A changes the scale of the input signal and inverts it. Thus, the output of the
block is a signal between 100-0%.
Function:
Input:
Output:
OP: Input to the second stage compressor capacity controller (percentage value, %).
PY-004 B
Type:
calculation.
PY-004B changes the scale of the input signal to an output between 0-100%.
Function:
Input:
Output:

MADRID
REV
NARRATIVE
OP: Input signal to PV002 (percentage value, %)
FC 001
Type:
PID controller.
Reverse Action.
Function:
Input:
SP: Output of PY-003B (percentage units, %).
Output:
OP: Input signal to FV-001 (percentage value, %)

MADRID
REV
NARRATIVE
3.10. DUTY IN HVGO PUMPAROUND CIRCUIT CONTROL


The objective of this loop is to control the duty (Flow x Specific Heat Capacity x
Temperature Difference) in the HVGO pumparound (PA) circuit. The duty is
controlled by JC-001 which adjusts the flow through HVGO Steam Generator E-
001. The flow in the circuit is controlled by FC-001, and the differential
temperature between the inlet to E-001 and the outlet of E-002 is measured in
TDI-001. The arithmetic block JY-XXX calculates the interchanged heat and
sends the duty to the controller JC-001. The opposite range duty controller JC-
001 regulates the HVGO pumparound temperature by adjusting JV-001A
downstream of HVGO Steam Generator E-001 and JV-001B in the steam
generator bypass line.

Controlled variables are:
• Duty in the HVGO pumparound circuit
• HVGO flow in the PA return line

Manipulated variables are:
• HVGO flow from the Steam Generator E-001
• HVGO flow in the Steam Generator By-pass line
• HVGO flow in the PA return line
3.10.5. Scheme

MADRID
REV XX
NARRATIVE
TT TI PV IN1
001 ARTH
001
TDI
OP
001
TI PV
TT
002
002 IN2
AUTO/MAN
IN JY OP
0%-100%
DIRECT
IN2 0001B 0%-100%
ACTION
ARTH
JY OP PV JC OP
XXXX 0001
0%-100%
ARTHC
JV-0001B
IN1 IN AO/AFC
JY OP
0001A 100%-0%
JV-0001A
PV AC/AFO
FC OP
FT
001 PV PV 001
REVERSE
ACTION FV-001
AC/AFO
REV XX
NARRATIVE

TDI-001
Type:
Arithmetic block.
It calculates the differential temperature between the inlet to E-001 and the outlet of E-
002 lines.
Function:
Inputs:
IN1: PV of TI-001, temperature of HVGO in the inlet line to E-001 (temperature
IN2: PV of TI-002, temperature of HVGO in the outlet line of E-002 (temperature
Output:
OP: Input of JY-XXX. Difference between TI-001 and TI-002 (temperature
Equation:
OP = IN1-IN2
FC-001
Type:
PID controller.
Reverse action.
Function:
Inputs:
PV: Output of FT-001, Outlet of E002 flow rate (liquid flow engineering units,
m3/h)
SP: By operator (liquid flow engineering units, m3/h)
Output:
OP: Input of FV-001 (percentage value, 0-100%)
JY-XXX
REV
NARRATIVE
Type:
Arithmetic block.
It calculates the duty in the HVGO pumparound circuit. JY-XXX multiplies the
temperature difference by the flow in the outlet line of E-002 and by a constant f.
Function:
Input:
IN1: PV of FC-001, (liquid flow engineering units, m3/h).
IN2: Output of TDI-001, (temperature engineering units, ºC).
Output:
OP: PV of JC-001 (heat rate engineering units, MM kcal/h)
Equation:
OP = IN1 * IN2 * f
f = specificheatcapacity (kcal / kg º C ) ⋅ density (kg / m 3 ) ⋅ 10 −6
JC-001
Type:
PID controller.
Direct Action.
Function:
Input:
PV: Output of JY-XXX, (heat rate engineering units, MM kcal/h).
SP: By operator (heat rate engineering units, MM kcal/h).
Output:
The following table shows the opposite range functional description:
Valve Position (%)

Controller Output (%) JY-001B JY-001 A
0 0 100
50 50 50
100 100 0

MADRID
REV
NARRATIVE
JY-001 B.
Type:
Auto/Man control block.
calculation.
It is included with the purpose of enabling the operator to manually manipulate JV-
001B
Function:
Inputs:
IN: Output of JC-001 (percentage value, 0%-100%)
Output:
OP: Input of JV-001B (percentage value, 0%-100%)
Equation:
OP = IN + BIAS
JY-001 A.
Type:
calculation.
JY-001A reverses the input signal to an output between 100%-0%.
Function:
Inputs:
IN: Output of JC-001 (percentage value, 0%-100%)
Output:
OP: Input of JV-001 A (percentage value, 100%-0%)

MADRID
REV
NARRATIVE
3.11. LEVEL IN STEAM DRUM CONTROL


The objective of this loop is to control the Steam Drum (D-0001) level. The level in
this vessel is regulated by the controller LC-0007. The level depends on the
saturated steam and the boiling feed water flow. In this case, a steam flow density
compensation and a drum level density compensation are necessary.
The mass flow of steam from Steam Drum R280-D-0001 is measured by FI-0008.
This is then compensated for density variation by FY-0008A. Both signals coming
from FY-0008A and LC-0007 are added via FY-0008B adjusting the flow rate of
supplied BFW via the control valve FV-0019.

The controlled variable is the Steam Drum (D-0001) level

The manipulated variable is the Boiling Feed Water to D-0001 flow.
This control is made via feed forward control.
3.10.5. Scheme

MADRID
REV
NARRATIVE

FY-0008 A
Type:
Arithmetic block.
It compensates the steam mass flow for the density variation using the operating
pressure from PI-0009, which uniquely characterizes the density for saturated steam.
Function:
Inputs:
IN1: PV of FI-0008, (mass flow engineering units, kg/h).
IN2: PV of PI-0009, (pressure engineering units, kg/cm2 g).
Output:
OP: Input of FY-0008B (liquid flow engineering units, m3/h).
Equation:
ρ ( IN 2)
OP =IN1 ⋅
ρ ( Pref )
where “ref” refers to the conditions assumed in calibrating of FI-0008 and

ρ(pressure) is a density correlation factor for saturated steam.

MADRID
REV
NARRATIVE
LY-0007
Type:
Arithmetic block.
It compensates the steam drum level for the density variation using the operating
pressure from PI-0009, which uniquely characterizes the density for saturated water.
Function:
Inputs:
IN1: PV of PI-0009, (pressure engineering units, kg/cm2 g).
IN2: PV of LT-0007, (level engineering units, %).
Output:
OP: PV of LC-0007 (level engineering units, %).
Equation:
ρ ( Pref )
OP =IN 2 ⋅
ρ ( IN1)
where “ref” refers to the conditions assumed in calibrating of LI-0007 and
ρ(pressure) is a density correlation factor for saturated water.
LC-0007
Type:
PID controller.
Reverse Action.
Function:
LC-0007 adds the steam outlet flow feed forward signal, FY-0008A, and D-0001
level controller output, LY-0007, to get the set point that is sent to FC-0019.
Inputs:
PV: Output of LY-0007 (level engineering units, %).
Output:
OP: Input of FC-0019 as its set point (liquid flow engineering units, m3/h).
FC-0019

MADRID
REV
NARRATIVE
Type:
PID controller with a feed forward control signal
Reverse Action.
Function:
Inputs:
Feed Forward signal: Output of FY-0008A (liquid flow engineering units, m3/h).
This feed forward signal shall be scaled at the controller inlet to a value between
-100% and 100%, to get a BIAS=0 when the feed forward signal is 50%. The feed
forward gain is 1,0.
PV: Output of FT-0019 (liquid flow engineering units, m3/h).

SP: Output of LC-0007 (liquid flow engineering units, m3/h).
Output:
OP: Input of FV-0019 (percentage value, 0-100%).

MADRID

Control Narratives GDC-121-8

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INDUSTRIAL DIVISION GDC-121-8

CALCULATION AND DESIGN GUIDE Revision: 0

1. PURPOSE, RESPONSIBILITY, REFERENCES ......................................................3

1. PURPOSE, RESPONSIBILITY, REFERENCES

o INITEC: Documentum / Docbases / DOCBASE_INI / BIBLIOTECA / Normativa Interna /

3. FUNCTIONAL DESCRIPTION RELEVANT TO COMPLEX CONTROL LOOPS

3.1. REFERENCE P&IDS

3.2. FUNCTIONAL DESCRIPTION

3.3. CONTROLLED VARIABLES

3.4. MANIPULATED VARIABLES

3.6. BLOCKS DESCRIPTION

4. COMPLEX CONTROL LOOPS

4.1. HEAT EXCHANGER SPLIT RANGE CONTROL

Figure 4.1. Heat exchanger in split range control

4.2. HEAT EXCHANGER OPPOSITE RANGE CONTROL

Figure 4.2. Heat Exchanger in opposite range control

4.3. BLANKETING SPLIT RANGE CONTROL

Figure 4.3. Blanketing split range control

Figure 4.4. Two controllers control pressure loop

4.4. CHARGE HEATER LOAD BALANCING CONTROL

Figure 4.5. Charge heater load balancing control

4.5. COMBUSTION CONTROL

Figure 4.6. Combustión control

4.6. ALTERNATIVE COMPRESSOR CONTROL

Figure 4.7. Alternative compressor pressure control

Figure 4.8. Alternative compressor pressure control in split range

Figure 4.9. Alternative compressor capacity control

4.7. DUTY CONTROL

Figure 4.10. Duty control in a pump around

4.8. THREE ELEMENT CONTROL

Figure 4.11. Three element control loop

5. EXAMPLE CONTROL NARRATIVE

2.1. GENERAL NOTES

P&ID Piping and Instrument Diagram

3. FUNCTIONAL DESCRIPTION RELEVANT TO COMPLEX CONTROL

3.1. TEMPERATURE CONTROL LOOP FOR VGO

3.1.1. Reference P&IDs

3.1.3. Controlled Variable

3.1.4. Manipulated variables

3.1.6. Blocks Description

Valve Position (%)

3.2. VGO SUPPLY TO THE HIDROTREATER TEMPERATURE CONTROL

3.2.1. Reference P&IDs

3.2.2. Functional Description

The Temperature of VGO supply to the hydrotreater is measured by TT-002 and

• TV-002A that is located downstream of VGO Product Cooler E002

3.2.3. Controlled Variables

3.2.4. Manipulated Variables

3.2.6. Blocks Description

3.3. FIRST TRAIN PRESSURE CONTROL LOOP AT THE FEED SURGE

3.3.1. Reference P&IDs

3.3.2. Functional Description

3.3.3. Controlled Variable

3.3.4. Manipulated Variables

3.3.6. Blocks Description

OP: percentage value, 0-100%.

Valve Position (%)

3.4. TWO CONTROLLERS PRESSURE CONTROL LOOP

3.4.1. Reference P&IDs

3.4.2. Functional Description

3.4.3. Controlled Variable

3.4.4. Manipulated Variables

3.4.6. Blocks description

3.5. CHARGE HEATER LOAD BALANCING CONTROL