Project: LR2 Refinery project

Document Title: FLOW CHART FOR START-UP AND SHUTDOWN

Company Doc. No: 256-F0052-8953
Revision No: X2
Document Class: 1

Revision History

Rev No Rev Date Section Revised Revision Description

B1 25/DEC/14 As marked Separated from Control Narratives

00 23/JAN/15 As marked Revised per comments

X 11/DEC/15 N/A As Built

X1 28/DEC/15 As marked As Built

Reverted back to Rev.X due to wrong

X2 06/JAN/16 Sheet 4 and 8
information
FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 1 of 11

INDEX

ITEM DESCRIPTION SHEET NO.

1 Legend 2

2 Start up for Heater F1601 3

3 Shutdown for Heater F1601 11

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 2 of 11

LEGEND
Abbreviation
Start and Finish of Logic
BMS Burner Management System
CCR Central Control Room
Operator Action MCC Motor Control Center
DCS Distributed Control System
SIS(BMS) Safety Instrumented System
Indication ITR Instrument Technical Room
EWS Engineering Work Station
SER Sequence Event Recorder
Status LP Local Panel
LCS Local Control Station for Motor

Time Delay FDF Forced Draft Fan

Timer
xxx sec VSD Variable Speed Drive
PB Push Button Switch
SW Switch

xxx Press. LL ,HH FG Fuel Gas

Interlock component signal PG Pilot Gas
ESDV Shut Down Valve
SUO Start up override
xxxxx Start
Start command of push button
Local Panel PB On

xxxxx Stop
Local Panel PB On Stop command of push button

Trip Command Trip command signal

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2
 FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 3 of 11

START UP FOR HEATER F1601 Heater Stopping

RESET CONDITION 2
PG Header Press. Not L PIAL00054 RESET CONDITIONS 1
PG to Pilot Press Not LL PZLL16068 (Note 1) PG Block Valves Closed ESDV16066/68
FG Header Press Not LL PIAL00071 Pilot Gas Vent valve Opened ESDV16067
FG to Burner Press Not LL PZLL16069 (Note 1) FG Block Valve Closed ESDV16069/71
FG Vent Valve Opened ESDV16070

RESET CONDITION 3
Unit 16/17 not ESD UZ00003 Stack Damper Open (DCS)
Unit 16 Not depress UZ16001 PV16F48
Not loss of recycle gas UZ16002
Not loss of Kerosene Feed UZ16003
Level Not HH in 82-V1601 UZ16004 Damper Limit Switch
Level Not HH in 82-V1603 UZ16005 Answerback Normal PZSO16F48
Level Not HH in 82-V1609 UZ16085
Feed Flow Not LL FIC16010
Combustion Air flow not LL FZLL16037 (Note 1)
No HC in Heater AAH16068

BMS Reset

Note 1 :SUO shall be applied with combustion

air flow LL (FZLL) and burner flame off (BZL)
FDF Motor Field Control Station to
Remote

FDF Start

FDF Run

Combustion Air Flow Not LL

Ready To Purge

Stack Damper Purge Start

Open LP PB On

From 1 From
Sheet 4 Sheet 4

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 4 of 11

To Sheet 3 1 To Sheet 3

Purging Purge Failure

No
Air Flow Not LL FZLL16037

Yes

Purge Time Note : Purging time shall be

Time delay 10 min. minimum 5 times of heater
radiant volume

Purge Complete

FDF Suction Air Controller to

Auto (Cascade Off) FIC16037

Combustion Air Flow Controller FIC16037 SV to

set 20% of fan rated flow (HS16037)

Stack Damper Controller PIC16048 to be manually

adjusted to negative
draft of radiant top (30-50%open)

PG Leak Test

No PG Leak Test
Successful Y/N

Yes Please refer to Control narrative

Doc No. 256-F0052-8903 Attcmennt for detail
of leak test procedure
FG Leak Test

No FG Leak Test
Successful Y/N

Yes
Burner Firing failure
(From Sheet 9 & 10)
2 X2 Reverted back to Rev. X for this sheet
Pilot ignition failure
(From Sheet 6 & 7)

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 5 of 11

Pilot Start
LP PB On

PG Header Vent valve PG Header Vent valve ESDV16067 Close

ESDV16067 Open PG Header Block valves ESDV16066/68 Open
PG Header Block valves
ESDV16066/68 Close
Time delay
10 sec

ESDV ESDV Limit Switch

Abnormal Answerback Normal
No
Answer back require within 10 sec Yes
Check & Ready for Ignition
repaire

Ignition Power Enable

Normar Procedure

(If trouble occurred)

Pilot Stop
LP PB On

PG Header Block Valves ESDV16066/68 Close

PG Header Vent Valve ESDV16067 Open

Check & Time delay

repaire 10 sec

ESDV ESDV Limit Switch

Abnormal Answerback Normal
No

Yes

Ignition Power Off

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 6 of 11

Pilot Ignition failure 3

Purging required
(To sheet 4)

Re-start from pre-purge

when over 2 times trial
Re-start permitted within
2 times

Pilot 1 Manual Valves Close Pilot 1 Ignition SW On

Stop Ignition Spark

Start Ignition Spark (Pilot 1)
(Pilot 1)

Time delay
10 sec

Pilot 1 Manual Valves Open

Pilot 1 Flame
BL16F05A On

Pilot 1 Ignition Failure Time delay No

BZ16F05A 5 sec
Yes

Stop Ignition Spark (Pilot 1)

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 7 of 11

Pilot Ignition failure 4 Procedure is typical.

Purging required Before proceed the next step, all pilot
(To sheet 4) shall be lighted up

Re-start from pre-purge

when over 2 times trial
Re-start permitted within
2 times

Pilot 6 Manual Valves Close Pilot 6 Ignition SW On

Stop Ignition Spark

(Pilot 6) Start Ignition Spark (Pilot 6)

Time delay
10 sec

Pilot 6 Manual Valves Open

Pilot 6 Flame
BL16F05F On

Pilot 6 Ignition Failure Time delay No

BZ16F05F 5 sec
Yes

Stop Ignition Spark

(Pilot 6)

All Pilot Flame ON

Ready to FG start

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 8 of 11

FG Press Controller PIC16066 SV set to

minimum burner firing rate (20%) (HS16066)

Firing Start
LP PB On

FG Header Vent Valve ESDV16070 Close

FG Header Vent Valve FG Header Block Valves ESDV16069/71Open
ESDV16070 Open
FG Header Block Valves
ESDV16069/71 Close Time delay
10 sec

ESDV Limit Switch

Answerback Normal

No Yes (Normal operation)

ESDV
Answer back require within 10 sec
Abnormal
Firing Stop
LP PB On
Check &
repaire

FG Header Block Valves ESDV16069/71 Close

FG Header Vent Valve ESDV16070 Open

Check & Time delay

repaire 10 sec

ESDV Limit Switch

Answerback Normal

ESDV No
Abnormal
Yes

Ready for Firing

X2 Reverted back to Rev. X for this sheet

6

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 9 of 11

Burner Firing Failure

6
Purging required
(To sheet 4)

Burner 1 Firing
Start LP PB On

Pilot 1 Flame
BI16F01A ON Pilot flame is burner firing condition.
Both signals require to step.

Burner 1 Block Valve ESDV16072A Open

Time delay
10 sec
Burner 1 Block Valve
ESDV16072A Close
ESDV Limit Switch
Answerback Normal

No
Yes
ESDV Answer back require within 10 sec
Abnormal
Time delay Burner ESDV open after pilot ignited,
5 sec burner firing shall be made.
Check &
repaire
No Burner 1 Flame
BL16F01A On

Burner 1 Flame Yes

Failure BZ16F01A

If no flame is exist 5 sec after ESDV

opened, flame failure alarm is required
caused by no flame detcted.
Simulaneously Burner ESDV shall be
closed.

Burner 1 Block Valve

ESDV16072A Close

Time delay
10 sec
Check &
repaire
ESDV Limit Switch
Answerback Normal

ESDV No
Abnormal Yes

Burner 1 Stop

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 10 of 11

Burner Firing Failure

7
Purging required Cross firing shall be carried out as
(To sheet 4) Burner 1→4→2→5→3→6

Procedure is typical.
Burner 6 Firing Before proceed the next step,
Start LP PB On all burner shall be lighted up

Pilot 6 Flame
BI16F01F ON

Burner 6 Block Valve ESDV16072F Open

Time Delay
10 sec
Burner 1 Block Valve
ESDV16072F Close
ESDV Limit Switch
Answerback Normal
No
ESDV Answer back require within 10 sec Yes
Abnormal

Time delay
5 sec
Check &
repaire
No Burner 6 Flame
BL16F01F On

Burner 6 Flame Yes

Failure BZ16F01F

Burner 6 Block Valve

ESDV16072F Close

Check & Time delay

repaire 10 sec

ESDV Limit Switch

ESDV Answerback Normal
Abnormal No
Yes
Burner 6 Stop

Furnace Started

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2
 FLOW CHART FOR START UP AND SHUTDOWN FOR F1601
Sheet 11 of 11

SHUTDOWN FOR HEATER F1601

Heater Started

Unit 16/17 ESD UZ00003

FDF 82-K1606A/B Trip
Combustible Gas In Heater HH (2oo2) UZ16100

Heater ESD SW at CCR HS16066A UZ16081

Heater ESD SW at ITR HS16066B UZ16081
Heater ESD SW at Field HS16066C UZ16081

PG to Pilot Press LL PZLL16068BCD UZ16081(2oo3)

Combustion Air Flow LL FZLL16037BCD UZ16081(2oo3)
FDF K1604A Stop HSL16008A UZ16081
FDF K1604B Stop HSL16008B UZ16081
PG ESDV Discrepancy

Unit 16 Depressurization HS16001ABC UZ16001

Loss of Recycle Gas FZLL16012 UZ16002
Loss of Kerosene Feed FZLL16010 UZ16003
HH Level in 82-V1601 LZHH16011 UZ16004
HH Level in 82-V1603 LZHH16074 UZ16005
HH Level in 82-V1609 LZHH16007 UZ16085
ESDV Discrepancy uz16080

FG to Burner Press LL PZLL16069 UZ16080(2oo3)

FG to Burner Press HH PZHH16069 UZ16080(2oo3)
Heater Draft HH PZHH16067 UZ16080(2oo3)

Pilot 1 Flame Failure BA(XA)16F05A

Pilot 2 Flame Failure BA(XA)16F05B
Pilot 3 Flame Failure BA(XA)16F05C
Pilot 4 Flame Failure BA(XA)16F05D
Pilot 5 Flame Failure BA(XA)16F05E
Pilot 6 Flame Failure BA(XA)16F05F
UZ16081 Power Off for O2 Analyzer AI16066
(6oo6) PG Header Block Valves ESDV16066/68 Close
Note 1 PG Header Vent Valve ESDV16067 Open
FG Header Block Valves ESDV16069/71 Close
FG Header Vent Valve ESDV16070 Open

Burner 1 Flame Failure BA(XA)16F01A

Burner2 Flame Failure BA(XA)16F01B
Burner 3 Flame Failure BA(XA)16F01C
Burner 4 Flame Failure BA(XA)16F01D
Burner 5 Flame Failure BA(XA)16F01E
Burner 6 Flame Failure BA(XA(¥)16F01F
UZ16080 Burner 1 Block Valves ESDV16072A Close
(2oo6) Burner 2 Block Valves ESDV16072B Close
Note 2 Burner 3 Block Valves ESDV16072CClose
Burner 4 Block Valves ESDV16072D Close
Burner 5 Block Valves ESDV16072E Close
Burner 6 Block Valves ESDV16072F Close

(XA) : Tags for local panel alarm

Stack Damper Open PV16F48 open
Snuffing Stm to F1601 HS16027ABC
MS to F1602 ESDV16065 Open

Heater Shutdown

Note 1 6oo6 pilot burner flame failure shall close PG block valve, open vent valve and initiate to
heater shutdown as UZ16082.
Note 2 Each burner flame failure shall close related burner block valve
2oo6 main burner flame failure shall close FG block valves, open vent valve, close individual
FG to burner block valves. Pilot shall remain operation.

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV

YOKOHAMA, JAPAN. DOC. NO. 851-DSP-953 6, Jan. '16 X2