Boiler

ABB Lummus Global B.V.

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120.011

04217

E-15100-TN-5306-0001

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Project

Document Number

SHELL EASTERN PETROLEUM (PTE) LTD. SINGAPORE SHELL ECC PROJECT

STEAM PRODUCTION & DISTRIBUTION DISTRIBUTION CONDENSATE COLLECTION DESALINATED WATER STORAGE DEMINERALISED WATER MAKE-UP SYSTEM

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

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Rev.

Table of Contents

1.

BACKGROUND PROCESS INFORMATION

4

1.1

PROCESS AND PROJECT

4

1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10

STEAM AND POWER GENERATION / DISTRIBUTION SYSTEM Super High Pressure (SHP) Steam High Pressure (HP) Steam Medium Pressure Desuperheated (MPD) Steam Medium Pressure Desuperheated (MPD) Steam Low Pressure (LP) Steam Low Pressure Desuperheated (LPD) Steam Letdown Stations Steam Boilers Power Generation System Blowdown and Flash Drums

6 6 6 6 6 6 6 6 7 7 7

1.3

CONDENSATE TREATMENT AND RECOVERY SYSTEMS

7

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.8

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SHP/HP STEAM DESUPERHEATER, J-15101A/B, PRESSURE CONTROL PICA-063, PICA-014, PY-014, TICA-005, HS-023 Objective Functional Description Operational and Implementation Aspects History

17 17 17 17 18 19

BOILER COMBUSTION AIR CONTROL HLA10AA001, FIC-502, XC504 Objective Functional Description Operational and Implementation Aspects History

24 24 24 24 25 30

GAS/FUEL OIL CONTROL V102 – FC155, V201 – FC172, V302 – PDC165, V502 – PDC182 Objective Functional Description Operational and Implementation Aspects History

31 31 31 31 33 39

BOILER STEAM DRUM LEVEL AND ECONOMIZER INLET TEMPERATURE CONTROL40 LAB10AA022 – FC101 LC101, LAB10AA032 - TIC-103 40

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

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Rev.

1.

BACKGROUND PROCESS INFORMATION

1.1

PROCESS AND PROJECT The ten Cracking Heaters in the LOP, and three Steam Boilers, will generate Super High Pressure (SHP) steam, which is used to drive large turbines. High Pressure (HP) steam is extracted from the Cracked Gas Compressor turbine and used for various heat exchangers, smaller turbines and a number of pumps. Medium Pressure (MP) steam is mainly extracted from the Power Generator and used for process heat exchangers in all the process units. In addition, MP steam is also used as atomizing steam, for boiler soot blowing and to drive smaller turbines, pumps and fans. MP steam is also used in the flare. Medium Pressure Desuperheated (MPD) steam is produced by desuperheating MPS steam. MPD steam is required for several heat exchangers/reboilers in the PPS and LOP. LP steam is produced by various backpressure turbines, and by extraction from the C3-REF Compressor – K-11501. The remainder is produced via letdown of MPS. LP steam is used in all process units and offsite systems in heat exchangers, heating coils, Deaerators and for stripping purposes.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

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NCC is collected in the Condensate Surge Tank T-15101 from the following sources and used as BFW: • Turbine Steam Condenser E-151910 • Ethylene Refrig Compressor, Steam Condensate Cooler E-15613 • Charge Gas Compressor, Steam Condenser E-11212 • MP Condensate Trim Cooler E-15107 • Ethylene Refrig Compressor, Steam Condensate Cooler E-15513 • Treated PCC from Condensate Activated Carbon Filters V-15104A/B MP Condensate is collected in the MP Condensate Flash Drum V-15102 from the following sources and used as BFW: • PHU Users • BEU-1 Users • MP Condensate/Process Water Exchanger E-1132 • ECU Users HP Condensate is collected in the HP Condensate Flash Drum V-15103 from the following sources and is recycled to the MP Flash Drum: • E-13206 in the BEU-1 • Drier Regeneration Gas Heater E-11214 Desalinated water is imported from the Bukom Refinery’s desalination plant and stored in

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

1.2

120.011

04217

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STEAM AND POWER GENERATION / DISTRIBUTION SYSTEM Steam is generated and used at six pressure/temperature levels, namely the SHP, HP, MP, MPD, LP and LPD levels.

1.2.1

Super High Pressure (SHP) Steam The LOP unit’s cracking heaters and the steam boilers generate the SHP steam. The SHP steam is used to drive the following three turbines: • Cracked Gas Compressor (CGC) turbine K-11201 • Propylene Refrigeration Compressor (PRG) turbine K-11501 • Power Generation (PG) turbine GT-15190 All three turbines are designed as a combination of extraction/condensing type turbine to meet the needs of steam and power for the complex.

1.2.2

High Pressure (HP) Steam HP steam is extracted from the CGC turbine and used: • for various equipment in the LOP units. • to drive backpressure turbines and produce LP steam. • for various process heat exchangers in the process units. • to support the MP steam system.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

1.2.8

120.011

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Rev.

Steam Boilers Three steam boilers are provided to generate the required quantity of SHP steam during normal operation with all three boilers in operation. The steam boilers are normally fired with fuel oil, which is produced by the LOP units as Ethylene Cracker Residue (ECR). Natural gas is used as primary back-up fuel for the boilers. Cracked Gas Oil (CGO) is used as secondary back-up fuel and can also be blended with ECR. One motor driven and steam turbine driven forced draft fan for each steam boiler supply the necessary combustion air. Each boiler system comprises a steam drum, a furnace box, a superheater, an economizer, one FD fan, flue gas ducts and exhaust stack. Two Deaerators are provided to produce the necessary boiler feed water (BFW). The BFW is pumped to the boilers by means of both turbine driven and motor driven pumps. The BFW is also treated by injecting various chemicals such as an oxygen scavenger, amine and phosphate.

1.2.9

Power Generation System A power generator driven by an extracting/condensing steam turbine is provided to supply the electricity required. The generator electricity produced will be integrated with the site electrical system. Only one power turbine/generation set is provided. Any problem associated with the steam power generation will require the Cracker Complex to switch its power supply to the outside power source from the Bukom Refinery.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

1.3.2

120.011

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PCC PCC is the LP condensate returned from the heat exchangers, reboilers, heating coils etc. operating at LPS and LPD level. Due to its low pressure, the return condensate is more susceptible to hydrocarbon contamination. The PCC bottoms, from the PCC Flash Drum V-15101 are pumped by the PCC Pumps P-15109A/B through the PCC/Condensate Interchanger E-15102 where heat is exchanged with Polished Condensate from A-15140. The stream is further cooled in the PCC Trim Cooler E-15104 using Cooling Water, before being sent to the PCC Cartridge Filters S-15135A/B. The stream leaves the filters and goes through the Condensate Activated Carbon Filters V-15140A/B before entering the Condensate Surge Tank T-15101. Contaminated PCC can be sent to the PCC Emergency Basin. Flashed-off steam is condensed in the PCC Flash Drum Vent Condenser E-15101, installed on top of the vessel. In this way the flashed steam is recovered and its energy is used to heat-up demin water, which is sent to the Deaerators for BFW make-up. The cooled, flashed steam, then discharges to ASL.

1.3.3

NCC NCC is the LP condensate returned from the surface condensers of the steam turbines, driving the big compressors and the power generator. NCC is normally clean and contains no hydrocarbons. However, it can be contaminated by inorganics in the case of cooling water leakage in the surface condensers. The Condensate Transfer Pumps P-15101A/B/C pump the tank inventory to the Condensate Treatment Package A-15140.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

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Polishing The PCC is sent through the Cation Exchangers and Mixed Bed Polishers where all hardness, alkalinity, other inorganic compounds and humic acids are removed in the Condensate Cation Exchangers V-15151A/B and the Mixed Bed Polishers V-15151A/B. A sodium-analyser is installed downstream the Cation Exchangers in order to monitor whether the cationic resin is still active, or has to be regenerated. In order to monitor any breakthrough of compounds which shall be adsorbed by the Polishers, a silica-analyser, conductivity-analyser and a pH-analyser are installed downstream the Mixed Bed Polishers. The Mixed Bed Polisher exit stream is heated in PCC/Condensate Interchanger E-15102 and the MP Condensate Cooler E-15106. After being heated, the stream is goes to the Deaerators as BFW. Backwash & Regeneration Regeneration of the Cation Exchangers is done by diluted acid, followed by backwashing with demin water. The Mixed Bed Polishers are regenerated by diluted caustic / diluted acid, and are backwashed with demin water. Diluted acid is made on-line by mixing demin water and 98% Sulphuric acid coming from P-16104 A/B.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

1.5

120.011

04217

E-15100-TN-5306-0001

2.00

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DEMINERALISED WATER The Demineralised Water System consists of: • Demineralised Water Package A-15165. • Low pressure demin water storage tank T-15103. • Demin Water Transfer Pumps P-15103A/B/C • Regeneration and Backwash Pumps P-15106A/B. • Waste Water Neutralisation Sump A-15110. • Neutralised Waste Transfer Pump P-15108. Desalinated water is pumped from the Desalinated Water Tank to the Demin Water Package A-15165, by using pumps P-15105A/B. The Demin Water Package A-15165 consists of a large number of ‘stacks’ in parallel. A stack comprises a number of dual-chambered cells, sandwiched between two electrodes. Within each cell there are two different chambers: a dilute (“D”) chamber through which the desalinated water is fed for de-ionisation and a concentrate (“C”) chamber used to collect and remove the extracted ions. Demin water is stored in the Demin Water Storage Tank T-15103. During normal operation, the tank is operated full, at constant liquid level. The tank type is a Low Pressure Cone Roof storage tank. The tank material will be epoxy-coated CS

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

2.

CONTROL DESCRIPTION

2.1

STEAM SYSTEM

120.011

04217

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Document Number

Rev.

The main control objectives for the Steam/BFW/Condensate and Power Generation System can be summarized as follows: • Maintain the pressure/temperature in all six steam headers (SHP, HP, MP, MPD, LP and LPD). • Provide a boiler feed water control system for the steam boilers A-15101/2/3 and Cracking Heaters F-10100-11000 where the supply of water matches the steam production rate such that the level in the steam drums is maintained around midpoint. • Provide a control system to maintain the level and pressure in the Deaerator V15120A/B during boiler load variations. • Provide a burner management system that includes: • Load control on steam pressure (by steam boiler vendor). • Ratio control of fuel and combustion air with lead/lag function (by steam boiler vendor). • Low and high pressure protective control of the fuel supply (by steam boiler vendor). • Adequate removal/re-use of the condensate from the blowdown drums and condensate flash vessels V-15101/2/3/4/5. • Provide an electrical system for the turbine-generator controls. Provide MP Steam Export flow- and temperature control.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

The signal from a pressure controller PICA-070 (or PICA-071) is sent to the burner management system of the relevant boiler, along with the ECR/CGO flow rate, Natural gas flow rate, the air flow rate and the stack Oxygen content. In the event that the capacity of the boiler under pressure control reaches a constraint (for example the boiler is at its minimum turndown or the boiler is at 100% MCR), the load of the second and third boiler is adjusted. A further decrease in the Primary SHP steam header pressure will result in the second pressure controller PICA-068, reducing the steam demand on the Power Generation (PG) turbine. The signal from the pressure controller is therefore sent to the control system of the Steam Turbine/Generator Package. If the pressure, in the SHP steam header becomes high, a third pressure controller PICA-069 will open the SHP/HP steam desuperheater/letdown valve J-15101A or B and SHP steam is letdown to the HP steam header. 2.1.3

HP Steam Header There are five pressure controllers PICA-013 until PICA-017 on the HP Steam Header. The PV for all pressure controllers is derived from a MOO3 configuration with three pressure tappings.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

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Rev.

The pressure in the MP Steam Header is normally controlled by pressure controller PICA-025 which manipulates the steam extraction control valve of the Power Generation Steam Turbine GT-15190. In the event that the pressure in the MP Steam Header decreases, PICA-022 will open the HP/MP Steam Desuperheater/letdown valve J-15102A or B. HP Steam is then letdown from the HP Steam Header to the MP Steam Header, via high signal selector PY-022. Shall the pressure continue to fall in the MP Steam Header, PICA-023 will open HP/MP Steam Desuperheater/letdown valve J-15110A or B. More HP steam is then letdown from the HP Steam Header, to the MP Steam Header. At the other hand in the event the pressure in the MP steam Header increases, pressure controller PICA-024 will open the control valve PICA-031CV (via high signal selector PY-031), installed upstream the MP/LP Steam Desuperheater J-15103. MP steam is then letdown to the LP Steam Header. A continued increase in pressure in the MP Steam Header will result in PICA-021 opening a vent control valve to ASL. The temperature controller TICA-010 is used to control the exit temperature of the HP/MP Steam Desuperheaters J-15102A or B, by manipulating the amount of MBFW added to the HP/MP Steam Desuperheater. TICA-011 is used to control the exit temperature of MP/LP

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

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Upon decreasing pressure in the LPD steam Header, pressure controller PICA-036 will open the control valve upstream the LP/LPD Steam Desuperheater J-15104. LP steam is then letdown to the LPD steam header. Upon increasing pressure in the LP Steam Header, pressure controller PICA-037 will opening a vent control valve to ASL. The temperature controller TICA-017 is used to control the exit temperature of the LP/LPD Steam Desuperheater J-15104, by manipulating the amount of MBFW added to the LP/LPD Steam Desuperheater.

3.

DETAILED CONTROL NARRATIVES

3.4

STEAM BOILERS, A-15101/2/3, STEAM LOAD CONTROL PICA-070, PICA-071, HIC-100, HIC-200, HIC-300, Y-100, Y-200, Y-300, HS-098, HS-401, UC-400, UC-401 UFS E-00000-TN-2366-0026

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

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The signal from HS-401 determines the position of the calculation blocks Y-100, Y-200 and Y-300. The boiler in balancing mode selects the signal from HS-098, the other boilers select the signal from their respective HIC. The output of the three calculation blocks Y-100, Y-200 and Y-300 is sent to the burner management system of respectively boiler A-15101, A-15102 and A-15103. The steam production rate of the two boilers at fixed load will automatically be adjusted in parallel when the MCR of the balancing boiler exceeds a fixed high value, or falls below a fixed low value. The signal from the Primary SHPS Header pressure controller PICA-070 or the Secondary SHPS Header pressure controller PICA-071 is sent to the proportional-only controller UC-401, depending on the position of the hand switch HS-098. When this signal is higher than the fixed low value, and lower than the fixed high value, the controller will not be active. PV Tracking will make the setpoint equal to the measurement. When the measurement exceeds the fixed high value, or falls below the fixed low value, the controller will be made active with the setpoint having the value of the fixed high value or the fixed low value respectively. The output of the direct acting, proportional only controller UC-401 is sent as a bias signal to HIC-100, HIC-200 and HIC-300. Trip signals from the three boilers A-15101, A-15102 and A-15103 are sent to HS-401 through 151UZ-xx1, 151UZ-xx2 and 151UZ-xx3 respectively. In case that the balancing boiler trips, HS-401 will switch the backup balancing boiler to balancing mode. In case that the backup balancing boiler trips, HS-401 will switch the boiler at fixed rate to backup balancing mode.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.4.3.2

120.011

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E-15100-TN-5306-0001

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Dept./Sect.

Project

Document Number

Rev.

Start up N/A.

3.4.3.3

Normal Steady State The manual input stations HIC-100, HIC-200 and HIC-300, and the switch HS-401 will always be in AUTO. The calculation blocks Y-100, Y-200, Y-300 will always be in CAS. Controller UC-401 cannot be switched to MAN.

3.4.3.4

Crippled Mode Operation When PICA-070 or PICA-071 becomes BAD, the controller shall be set to MAN with its last good output value.

3.4.3.5

Shutdown When a trip signal from the boiler in balancing mode is received, the boiler in backup balancing mode will be switched to balancing mode through HS-401. The boiler in fixed production mode shall be switched to backup balancing mode. When a trip signal from the boiler in backup balancing mode is received, the boiler in fixed production mode shall be switched to backup balancing mode through HS-401.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

09-05-2006

3.5

GRI

120.011

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E-15100-TN-5306-0001

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Dept./Sect.

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Rev.

Original Document

SHP/HP STEAM DESUPERHEATER, J-15101A/B, PRESSURE CONTROL PICA-063, PICA-014, PY-014, TICA-005, HS-023

3.5.1

UFS E-15100-TN-2396-0001 E-15100-TN-2396-0003

Deaerator and SHP Steam Production HP Steam Distribution

UEFS E-15100-TN-2395-0006

SHP/HP Steam Desuperheaters

Objective To protect SHP steam header against high pressure and to protect HP steam header against low pressure. Both objectives are achieved by SHP to HP steam letdown through the SHP/HP Steam Desuperheater J-15101. When for low pressure protection this line of defence is not sufficient a separate pressure controller activates a second SHP to HP steam letdown through the SHP/HP Steam Desuperheater J-15109. For detail specification see section 3.11. The objective for TICA-005 is to maintain a steady temperature for the desuperheated

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

TICA-005 2 HS-023

PID

3

HS-023

-

Direct -

-

-

120.011

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Yes -

TICA-005CVA/  PICA-014CVA TICA-005CVB/  PICA-014CVB

NOTE: 1: The pressure controller uses the output (OP) of Moo3 PY-012 as PV. 2: Describes control with manual selection switch in position “J-15101A”. 3: Describes control with manual selection switch in position “J-15101B”. 3.5.3

Operational and Implementation Aspects

3.5.3.1

Operational Modes This control scheme is required to be operational during start up and normal operation.

3.5.3.2

Start up

3.5.3.3

Normal Steady State During normal operation the pressure controllers PICA-069 and PICA-014 and the calculation block PY-014 shall be in AUTO. The temperature controller TICA-005 shall be in

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.5.3.10

120.011

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Special Considerations The setpoint of the protective controllers PICA-069 and PICA-014 cannot be changed by the operator. The mode of these protective controllers shall always be AUTO.

3.5.4

History Date 10-03-2006

Author RVO

Description Original Document

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

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NEM General comments: 1.

Please also provide input for Section 2, ‘Control Description’.

2.

We have checked this document towards your ‘Process Control Diagrams’ (PCD’s). Many calculation blocks/functions are not described in this document. Please give a (brief) description of all calculation blocks/functions.

3.

We assume that selection of the atomizing medium is done in/via the Burner Management System (BMS). NO, in DCS

4.

Add a separate section for the sootblowing sequence control.

5.

Add a separate section for the Cooling Air Fans Automatic take-over

6.

Add a separate section for the control and safeguarding of the FD Fan K15161, including: • Steam Turbine KT-15161 • Lube Oil System • Automatic “clutch” system, i.e. switch-over system from steam turbine to electric motor and vice versa

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.6

120.011

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BOILER OPERATION AND CONTROL INTRODUCTION This document describes the fired steam boiler for the Ethylene Cracker Complex (ECC) to be installed at Shell Eastern Petroleum Plant. It should be read in conjunction with the piping and instrumentation diagrams (P&ID's), which are mentioned as reference documents. The document describes the controls, system protection, settings etc. in general for items within the responsibility and scope of NEM. See also process control diagrams 36005-646-01. All instrument tag numbers will have prefix ‘151’. (The Logic Diagrams and Loop Diagrams shall describe these in detail and are always leading above this document). The boiler forms an integral part of the plant and produces SHP superheated steam for the plant by firing different fuels. This SHP steam is fed to the steam header of the plant at the following normal operating conditions: Flow: 72 - 180 t/h (40 – 100% MCR) Pressure: 120 – 125 bar(g) Temperature: 515 – 525 °C

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

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This logbook will be very helpful also in case of malfunctioning of a part to assure fast and adequate NEM response. Note: 1) In this document reference is made to equipment or parts of the plant not in NEM scope. This document does not change NEM’s scope. Here it has the purpose to explain the functionality of the NEM scope integrated in the total plant. The NEM scope is also defined in the P&ID’s (see reference documents)

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

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Document Number

Rev.

OPERATION AND DESIGN CRITERIA Regulations and Design Codes The system is designed and fabricated according to the applicable rules: 1. ASME I Edition 2004, including addenda 2005 2. ASME VIII Edition 2004, including addenda 2005 3. ASME B31.1 Edition 2004 4. ASME B31.3 Edition 2004 5. NFPA85 Edition 2004 Supervision The system is designed for constant supervision from a CCR in the vicinity of the boiler. Operation The boiler is designed for a life time of 20 years. The operating schedule for each unit is 8760 hr of service per year. The boiler plant consists out of three (3) boilers operating simultaneously. In case one of the boilers is out of service the remaining boilers will operate at 100%MCR. Within the life time of the boiler the number of start-up/shutdowns are based on cold conditions and limited to: Type of cycle

Number

Definition of cycle

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.7

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

BOILER COMBUSTION AIR CONTROL HLA10AA001 (IGV FD Fan), FC-202B (Combustion Air), QC-021 (Oxygen)

3.7.1

P&ID 36005-105-02

Fluegas System

PCD

111

UEFS E-15100-TN-2395-0031

Steam Boiler Package A-15101 – Flue Gas System

Objective The air flow and air/fuel ratio control take care for an optimal and safe combustion of fuel oil (ECR/CGO), Natural gas (NG) or a combination of fuels. Depending on boiler load (firing rate) measured air and fuel flows are used for this control with the O2 content measured at the stack inlet as correction parameter.

3.7.2

Functional Description The desired boiler load is compared with the total measured fuel and air flow load in a minimum

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Please briefly describe all calculation blocks, switches, High or Low Selectors, etc.

Tag name FC-202B QC-021 Y-202A

DCS – Analogue Control Service Action PID Direct PID Direct Automatic start up function

PV-Tracking No No No

Valve Name FICA-202 -

NOTE: DCS - Discrete Control Tag name HS-204

Service Switch to gas or steam atomising. Calculation to Combustion air equivalent is dependant on atomisation.

NOTE:

Limit PDIC216/PC216 or PDIC227/PC227 are on AUTO

Action Operator

Valve/Controller PDIC-216 or PDIC-227

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.7.3.4

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Crippled Mode Operation Instrument Output Controller BAD IPS BAD FC-202B BAD BAD BAD BAD BAD BAD BAD QC-021 BAD -

Tag Name 1) FZA-201 FICA-202 TI-201 PIA-203 TI-202 PIA-202 TIA-203 TIA-204 2) QICA-021 PI-204 1) NOTE: IPS 2) In JVN Scope 3.7.3.5

Action Boiler trip Mode to MAN Mode to MAN -

Output Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze Freeze

Shutdown It is only for a limited time (maximum 60 seconds) allowed keeping the combustion air flow through the boiler when the boiler is not in operation anymore. The air will forcibly cool down the boiler in a rapid time, may be too fast with respect to temperature gradients in the

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

HY-261D

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

 y =  x1 +  x 2 + x3

HY-261A

HY-261B

HY-261D

HY-261A

Total air flow leakage correction for n air doors not closed and n  burners in operation HY-261E

 y =  x1 /  x 2 Air flow leakage correction factor for n air doors not closed and n burners in operation

HY-260A

HY-260B

 y = C 1260 A ∗  x1 + C 2 260 A Excess air depending on boiler load [%MCR] High SEL in case of combined fuel firing

Y-202 Boiler load % MCR value Minimum excess air factor for NG

HY-260C HY-260D

High SEL excess air factor Low SEL excess air factor

HY-260A HY-260C

HY-260E FY-202A

High SEL excess air factor

HY-260D FICA-202

 y =  x1 /  x 2

Minimum excess air factor for CO HY-260B Maximum Excess air factor QY-021C FY-502D

HY-261C

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

FY-212A

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

 y =  x1 − x 2 Combustion air equivalent CO

FY-212B

 y =  x1 − x 2 Combustion air equivalent correction for atomizing gas

FY-212C

 y =  x1 − x 2 Combustion air equivalent NG

FY-212D

 y =  x1 / C CO Calculation stochiometric air flow to CO flow in kg/h

FY-212E

 y =  x1 / C  NG Calculation stochiometric air flow to NG flow in kg/h

FY-212F

 y = ( x1 − x 2)  / 1000 NG flow correction for atomizing gas flow in t/h

FY-206A

 y =  x1 ∗ (C OG or  C OS ) Contribution atomizing medium

QY-021

 y = C 1021 ∗  x1 + C 2 021

FY-211A kg/h

FY-205B kg/h

FY-212A kg/h

FY-205A kg/h

FY-212G kg/h

FY-206B kg/h

FY-212B kg/h

HC-206 CCO

FY-212C kg/h

HC-205 CNG

FY-212E kg/h

FY-206A kg/h

FI-207 kg/h

HC-206C/D COG or COS

Y-202 Boiler load

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

TAG FICA-202 PIA-203 PIA-202 PIA-202 TIA-203 TIA-204 QICA-021 FA-202A FA-202A NOTE:

TAG FZA-201 FZA-201 FZA-202A NOTE:

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Description AA+ A+ AA+ A+ AA+ A-

Alarms Level Indication Indication Indication Indication Indication Indication Indication Indication Indication

Value 108000 90 30 -10 390 To follow 1.1 1.6 1.05

Units kg/h mBar(g) mBar(g) mBar(g) °C °C % -

Description Z-A- HOLD Z--

Trips Level IPS – SIL1 IPS – SIL1 ??????????

Value 90000 108000 1.0

Units kg/h kg/h -

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

C2260A

C1021 C2021 HS-021 C502b CCOG

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Conversion for excess air depending on boiler load [%MCR] Conversion for O2 % depending on boiler load [%MCR] Conversion for O2 % depending on boiler load [%MCR] O2 vol % Influence of firing mode on excess air Conversion factor from PV CO flow to required CO flow (with gas atomization) Please consider to use the output of the flowmeter, which is installed in the gas atomizing line.

NOTE: 3.7.3.8

Interfaces

2.05

-

-0.16

-

12.7

-

1.1 (min.) 7.0 (max) To follow

% (vol)

To follow

-

%

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.8

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

GAS/FUEL OIL CONTROL PC-209A / PC209B / FC-205 (NG), PC-214A / PC214B / FC206 (CO), PDIC-227 / PC-227 (Atomizing Steam), PDIC-216 / PC216 (Atomizing Gas) P&ID 36005-105-17 P&ID Piping burner system 36005-824-04-151-002/003/004 P&ID Common skid 36005-824-04-151-005/006/007 P&ID Local burner fuel system

3.8.1

PCD

112

UEFS E-15100-TN-2395-0039

Steam Boiler Package A-15101 – Fuel Control System

Reference document 36005-824-04-148

Burner system description

Objective The fuel flow control takes care for an optimal and safe combustion of fuel oil (ECR/CGO), Natural gas (NG) or a combination of fuels. Depending on boiler load the measured fuel flow is used for this control.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

Tag name FC-205 PC-209A PC-209B FC-206 PC-214A PC-214B PDIC-216 PDIC-227 PC-216 PC-227 NOTE:

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

DCS - Analogue Control Service Action PID Direct PID Indirect PID Indirect PID Direct PID Indirect PID Indirect PID Indirect PID Indirect PID Indirect PID Indirect

PV-Tracking Yes Yes Yes Yes Yes Yes No No Yes Yes

Valve Name PICA-209 PICA-209 PICA-209 PICA-214 PICA-214 PICA-214 PDIC-216 PDIC-227 PDIC-216 PDIC-227

DCS - Discrete Control Tag name HS-270

Service Switch NG to AUTO or MAN SP

Limit N.A.

Action Operator

HS-269

Switch CO to AUTO or MAN SP

N.A.

Operator

HS-227

Switch

N.A.

Operator

atomising

Valve/Controller PICA-209/  FC-205 PICA-214/  FC206 PDIC-216/ 

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

3.8.3

Operational and Implementation Aspects

3.8.3.1

Operational Modes This control scheme is required to be operational during start up and normal operation and shutdown. General operation aspects:  Operation modes The boiler is able to operate with different fuels in a load range of 40 – 100% with all six burners in operation. Normal operation is based on ECR with natural gas as atomizing medium. For the normal start up with Natural Gas an automatic start up procedure is incorporated, however manual start up with ECR or CGO is possible. Natural gas and/or CGO will be used as back up fuel in case no ECR is available. It is also possible to fire the fuel combinations ECR/CGO, ECR/NG or NG/CGO. Atomizing steam will be available as back up for NG atomization. Operating limits The turndown ratio of the burner system with six burners in operation is: ECR/CGO 5:1 NG 6:1

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Fuels:  When firing fuel oil (ECR, CGO) always atomizing gas or steam is required. Starting a burner on fuel oil must always be done with a clean (purged) oil gun. This means that the oil gun must be purged with steam at the end of the stop/trip sequence of each burner. When firing NG only the fuel oil gun has to be cooled by steam (steam tip cooling). Firing mixed fuels Following mixed fuel firing modes can be distinguished: • Fuel combinations: ECR/CGO in any proportion. Dual fuel: ECR/CGO/NG or ECR/NG or CGO/NG, simultaneous on the same burner • 2) • Dual fuel, simultaneous on different burners

1)

For dual fuel firing on the same burner both fuels (oil and gas) one fuel will can be in AUTO control mode simultaneously or with and one fuel is at in MAN mode at a fixed load. For dual fuel firing mode this mode of operation the operator has to select in the DCS the fuels, operating mode per burner (oil or gas) and control mode (AUTO/MAN). Also the fuel ratio has to be selected which can be adjusted manually in the DCS. 1)

In case of dual fuel firing the air flow and air/fuel ratio will be based on the air/fuel

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

In this case the main fuel flow will be controlled by the boiler steam flow controller set to a fixed value. To start the changeover, the operator can start the second fuel from DCS or local panel. The second fuel must be started at minimum load per burner. During start up of the second fuel is on pressure control. Further, the burners have to be taken into operation one by one with sufficient time delay to let the system accommodate to the new situation. When adding the second fuel the load of the main fuel is automatically decreased by the boiler load controller. When the second fuel flow set point is > minimum, the second fuel will be switched to pressure control for the maximum pressure controller. By changing the fuel ratio (NG/OIL) the second fuel will be increased while the main fuel is automatically decreased. When the main fuel is at minimum load the fuel supply to each burner can be stopped and the changeover is completed.

Note: (HOLD) After a burner is taken into operation with the second fuel at minimum load the excess air amount will temporally decrease. Sub-stochiometric conditions however will not occur due to the limited fuel flow of the added second fuel. After the combustion air control system has been accommodated to the new heat input the air/fuel ratio is corrected to the required value. Atomizing medium changeover: 

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Start up with NG  When starting the boiler the pressure controllers PC-209A and PC-209B are in AUTO. Flow controller FC-205 is in MAN mode output 0%. When starting the first burner the minimum stop at the fuel control valve will ensure sufficient NG to light-off the burner. The NG vent valve UZ-506 is open to create flow to be able to control the NG on pressure. This valve will be closed after the first burner is in operation. The NG control valve is positioned by the start sequence program (or when in manual mode by the operator). The set point of controller PC-209B is set to a low value (by the start program) corresponding with the required burner start load. When three (3) burners are in operation at the required load the set point of PC-209B will be gradually increased to its normal set point (maximum pressure set point). At the same time flow controller FC-205 is put in AUTO and FC-205 controls the flow at the predefined boiler load (given by the start sequence program). During start phase air controller FC-202B will be switched to AUTO when all burners are in operation (HOLD). When the boiler is connected to the steam grid the load controller will be switched to AUTO (pressure or flow) and receive their set points from the overall load control. Start up with fuel oil  Prior to start up with oil the supply temperature and viscosity must be correct. Therefore the oil system will be circulated. The oil to the burners will be branched off from the common

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.8.3.4

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Crippled Mode Operation

PZA-210 PIA-211

Instrument Output Controller BAD FC-205 BAD PC209A/B BAD IPS BAD IPS

PZA-212 FIC-206 TIA-222 PICA-214

BAD BAD BAD BAD

PZA-213

BAD

PICA-227

BAD

Tag Name FIC-205 PICA-209

IPS FC-206 PC214A/B, PDIC-227, PDIC-216 IPS PDIC-227 PC-217

Action Mode to MAN Mode to MAN

Output Freeze Freeze

NG trip Abort Leakage Proofing / NG trip NG trip Mode to MAN Mode to MAN

Freeze Freeze

CO + Atomising trip Mode to MAN

Freeze

Freeze Freeze Freeze Freeze

Freeze

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

PY-209B

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Low SEL Limits the maximum flow for NG High SEL Limits the minimum flow for CO Low SEL Limits the maximum flow for CO High SEL Limits the minimum atomising gas pressure

PY-209A

PC-209B

FC-206

PC-214A

PY-214A

PC-214B

PDIC-216

PC-216

PY-216A

 y =  x1 − x 2

PICA-216

PICA-214

PY-227

High SEL Limits the minimum atomising steam pressure

PDIC-227

PC-227

PY-227A

 y =  x1 − x 2

PICA-227

PICA-214

PY-214A PY-214B PY-216

NOTE: 3.8.3.7

Initialisations Ranges TAG FC-205

Description NG Controller

Range 0 – 100

Units %

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

TAG PI163 PZA-210 PZA-212 PIA-211 PZA-213 PZA-215 PZA-217 PIA-232 NOTE: PZA-213:

Description Z++ Z-Z++ A+ / AZ-Z-Z-A+ / A-

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Trips Level IPS – SIL1 IPS – SIL1 IPS – SIL1 IPS – SILa IPS – SIL HOLD IPS – SILa IPS – SILa IPS – SILa

Value To follow To follow To follow To follow To follow To follow To follow To follow

Units Bar(g) Bar(g) Bar(g) Bar(g) Bar(g) Bar(g) Bar(g) Bar(g)

SIL classification to be defined by JV Settings TAG C402 HC-205A HIC-272 HC-209A

Description NG flow per ignition burner SP NG maximum load SP NG when in MAN mode SP min. NG

Value To follow To follow By operator To follow

Units Kg/s t/h t/h Bar(g)

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.9

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

BOILER STEAM DRUM LEVEL AND ECONOMIZER INLET TEMPERATURE CONTROL LAB10AA022 (TIC-207A) – FICA-203 – LICSA-202 LAB10AA032 (TIC-207B) - TC-207B HAD15AA001 (US-532) – HAD15AA002 (US-531)

1. Note: • •

P&ID 36005-105-03 36005-105-04

Economizer System Evaporator System

PCD

113

UEFS E-15100-TN-2395-0032 E-15100-TN-2395-0033

Steam Boiler Package A-15101 – Economiser System Steam Boiler Package A-15101 – Evaporator System

Can “Heat Input On” – LY101d (Y-202) – be taken as a signal from the BMS? NEM expect the signal from DCS

Does flowmeter LAB10 CF101 (BFW supply) have a local read-out? (DELETED) We have added a “Steam Boiler Start-up & Shutdown Block”. This block is configured in the DCS. Via a selector switch the operator can select the following modes:

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.9.2

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Functional Description

Drum level The drum level controller is designed as a three-element controller using the drum level as the primary control variable. The steam and feedwater flows are used as feed forward. The drum level will be controlled by regulating the feedwater flow to the boiler with feedwater control valve LAB10 AA022 (TIC-207A). For fast response and more stable operation of the control loop, the difference between steam and feedwater flow is used as feed forward signal in the drum level controller. To avoid instability at low flows this feed forward signal is activated at steam/feedwater flows higher than 20% MCR. Feed forward at loads > 20% MCR to be incorporated by JV When starting the boiler the water level and set point of the controller will be set to start level (SL) to allow level swell when boiler starts to produce steam. In this situation no feedwater is supplied to the drum. Drum level swell compensation is incorporated to avoid wrong actions of the feedwater control valve if swell or shrink, caused by pressure changes in the drum, occurs. Hereto the differentiated steam flow is added to the output of the level controller. Swell compensation to be incorporated by JV Once the start-up swell is over the set point of the level controller is brought to normal level (NL) of the drum and stays here as long as the boiler is in operation.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Please briefly describe all calculation blocks, switches, High or Low Selectors, etc.

Tag name LICSA-202 FICA-203 TC-207B LY-101b TY-103a

DCS - Analogue Control Service Action PID Indirect PID Direct PID Indirect FF balance BFW CV correction

PV-Tracking Yes Yes Yes Yes Yes

Valve Name TIC-207A LZA-201 -

NOTE: DCS - Discrete Control Tag name XS-203 FS-213 FS-213 FS-213

Service Switch to activate feedforward control if load > 35 t/h Close eco circulation valves if BFW flow is high enough during start-up Close eco circulation valves if BFW flow is high enough during start-up Open eco circulation valves if BFW

Limit -

Action Switch

HH

-

H

Close

L

Open

Valve/Controller US-531 US-532 US-531

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

- Output temperature controller LAB10 CT003: 0% - Output of control valve LAB10 AA032: 0% When boiler load > 15%, then: - Temperature controller and control valve LAB10 AA032: AUTO-mode When the boiler load > 15%, then the temperature controller TC-207B and control valve TI-207B are put in AUTO mode During start up phase the drum level set point has to be raised gradually from SL to NL. See also section 3.19 3.9.3.3

Normal Steady State During normal operation the temperature controllers LICSA-202, FICA-203 and TC-207B shall be in AUTO.

3.9.3.4

Crippled Mode Operation

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.9.3.6

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Calculations

TAG FY-204

Output (y) Calculation

Input (x1,x2,x3)

 x1

 y = C 204 ∗  x1 ∗  ρ ( x 2, x3) / ρ design

 x 2

 x3

PICA-207

TICA-217

LT-202A mmwc PIA-206 Bar(g) HEAT INPUT ON LY-202B t/h FT-203 t/h

LT-202B mmwc LY-202 mmwc

LT-202C mmwc -

LZA-201A mmwc PT-205

LZA-201B mmwc LZA-201

FI-204 t/h

1)

Pressure and temperature correction for steam flow LY-202

 y =  MeanValue( x1, x 2, x3)

LY-202A

 y =  LevelCorrection( x1, x 2)

2)

LY-202B

 y = Setpo int  Level ( x1)

3)

LY-202C

 y =  x1 + x 2

FY-203

 y =  x1 ∗  ρ ( x 2 ,  p d  ) / ρ (t d  , p d  ) Temperature correction for feedwater 4) flow

LZA-201 LZA-201

 y = 2oo3( x1, x 2, x3)  LevelCorrection( 1 2)

2)

FY-204A t/h TI-205

LZA-201C mmwc

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

TAG FY-203 LZA-201A LZA-201B LZA-201C LT-202A LT-202B LT-202C LT-202A LT-202B LT-202C LZA-201A LZA-201B LZA-201C PIA-206 PIA-206 NOTE:

Description A+ AAAAAAA+ A+ A+ A+ A+ A+ A+ A-

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Alarms Level Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication Indication

Value 190 -150 -150 -150 -150 -150 -150 +150 +150 +150 +150 +150 +150 135 0

Units t/h mm mm mm mm mm mm mm mm mm mm mm mm Bar(g) Bar(g)

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

FY-203A Gain for TIC-207A FY-207D Gain for TIC-207B FY-207E Gain for TIC-207A LY-202B Normal level (from centerline) LY-202B Start level (from centerline) HC-207B SP BFW temp. before ext. eco 1) NOTE: Flow > 15 t/h for at least 60 seconds 2) Flow < 12 t/h for at least 60 seconds

3.9.3.8

HOLD HOLD HOLD -25 -400 150

mm mm °C

Interfaces N/A.

3.9.3.9

Operator Interfaces Operator can access tags on the DCS.

3.9.3.10

Special Considerations During start up and shutdown of the boiler the economizer circulations valves HAD15 AA001/002 have to be opened and closed. Opening of the valves makes the economizer

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.10

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

BOILER START-UP PRESSURE CONTROL LBA10AA051 (PICA-207), PC-207, TC-254

3.10.1

P&ID 36005-105-06

Main Steam Line System

PCD

115

UEFS E-15100-TN-2395-0035

Steam Boiler Package A-15101 – Main Steam Line

Objective Pressure control is required to gradually increase boiler pressure, temperature and flow during start-up independently from the conditions of the common steam grid. This is achieved by controlling the valve position LBA10 AA051 (PICA-207) with pressure controller PC-207. For start-up following situations are distinguished: 1. Cold start-up (boiler at atmospheric conditions) 2. Warm start-up (conditions after a shutdown of more than 2 hours, but t_drum > 100°C) 3. Hot start-up (conditions after a shutdown of 2 hours, t_drum > 300°C)

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Additional to the main function of the pressure control system following functions are incorporated: • Limiting too high pressure/temperature gradients in the drum and superheaters during start up. (HOLD) • Pre-safety function in case of too high steam pressure. • Limiting too low pressure when the boiler is shutdown (prevent vacuum conditions) (HOLD) 3.10.2

Functional Description Depending on the pressure in the boiler the pressure the set point will be put in memory has to be set to at the actual pressure via an automatic switch when the first burner is started with a minimum of 2 bar(g). During Heat Input by the burners the boiler will be heated, produce steam and pressure will rise. After the set point of the controller is reached the startup valve will be opened and pressure is controlled until an opening position for LBA10 AA051 (PICA-207) of 30% is reached. Valve PICA-207 will stay in this position until the steam pressure reaches normal operating set point. When the steam pressure has reached the normal set point pressure controller PC-207 is switched to MAN mode and at the same time the opening limit of PICA-207 is removed. Pressure controller PC-207 is put in AUTO mode after a certain time and then controls the pressure at normal the operating value.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

Tag name HS-201

XY-207 HS-265 HS-098

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

DCS – Discrete Control Service Limit Permission to open main steam L block valve MOV-201 if pressure difference is low enough Automatic set point switch-over See settings for start-up with timer Switch set point during start-up See section sequence initializations Switch input signal to PDS-204 See JVN from PICA-070 or PICA-071 section

Action Permission

Valve/Controller MOV-201

Switch + timer SP change

PC-207 PICA-207

NOTE: IPS - Discrete Control Tag name N.A. NOTE:

3.10.3

Service

Operational and Implementation Aspects

Limit

Action

Valve/Controller

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.10.3.4

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Crippled Mode Operation

Tag Name PIA-206 PICA-207 PICA-070/  PICA-071 NOTE: 3.10.3.5

120.011

Instrument Output Controller BAD TC-254 BAD PC-207 BAD Y-100

Action Mode to MAN Mode to MAN Mode to MAN

Output Freeze Freeze Freeze

Shutdown It is not necessary to close the MOV-201 when taking the boiler out of operation. The check valve will keep the line shut in boiler direction. See also section 3.19

3.10.3.6

Calculations

TAG TY-251A

Output (y) Calculation

 y =

d ( x1)

Input (x1,x2,x3)

 x1 2)

TY-251

 x 2

 x3

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

TAG PICA-207 PICA-207 TYA-254 High TYA-254 Low

Description A+ AA+ Load increase ALoad decrease

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Alarms Level Indication Indication Indication

Indication

Value 130 115 See calculations

Units Bar(g) Bar(g) °C/min

See calculations

°C/min

NOTE:

TAG N.A. NOTE:

Description

Trips Level

Value

Units

Settings TAG f max 

Description Gradient for drum temperature

Value 0.0538

Units -

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.10.3.8

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Interfaces N/A.

3.10.3.9

Operator Interfaces Operator can access tags on the DCS.

3.10.3.10

Special Considerations During start-up following critical process parameters must be kept within allowable limits: • Steamdrum water/steam temperature gradient • Steam temperature gradient (see also section 3.11) • Steam flow through the superheater to cool the superheater tubes (CHECK) • Pressure gradient at boiler outlet to limit the start-up time

3.10.4

History Date 20-07-2007

Author HuR/WiH

Description Original Document

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.11

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

BOILER STEAM DESUPERHEATER TEMPERATURE CONTROL LAE10AA014 (TICA-214), TC-212, TC-214 LAE20AA014 (TICA-215), TC-215, TC-215B TC-202

3.11.1

P&ID 36005-105-05

Superheater System

PCD

116

UEFS E-15100-TN-2395-0034

Steam Boiler Package A-15101 – Superheater System

Objective The steam temperature control has the objective to control the final superheater temperature and to limit the superheater tube wall temperatures. This is to avoid lifetime reduction and/or damage to the steam system. Steam temperature control is achieved by regulating the spray water flow to two (2) inter-stage desuperheaters. This spray water is taken from the feedwater line to the boiler upstream of the feedwater control valve. The boiler is designed to control the steam temperature at the superheater outlet at a constant value within the boiler load range of 40% - 100% MCR. The normal set point is

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

The steam temperature at the outlet of the secondary superheater is controlled by the slave controller but has also a steam temperature gradient controller (TC-202). This controller limits the heat input to the burners during start up, normal operation and shutdown if the steam temperature gradient exceeds allowable limits.

Tag name TC-212 TC-214 TY204a,b TC-215B TC-215 TY206a,b TC-202 NOTE:

DCS - Analogue Control Service Action PID Direct PID Direct FF & SEL PID Direct PID Direct FF & SEL PID Indirect

PV-Tracking Yes Yes Yes Yes Yes Yes Yes

Valve Name TICA-214 TICA-215 -

IPS - Discrete Control Tag name 1) TZA-211

Service Steam Temperature too close to saturation.

Limit LL

Action Close

Valve/Controller UZ-552

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

TICA-215 1) TZA-213 TICA-217 1) TZA-218 1) NOTE: IPS 3.11.3.5

BAD BAD BAD BAD

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

TC-215 TC-215B -

Mode to MAN Mode to MAN -

Freeze Freeze Freeze Freeze

Shutdown See also section 3.19

3.11.3.6

Calculations

TAG TY-202A TY-202B (H) TY-202C (L) TYA-202

Output (y) Calculation

 y =

d ( x1)

2)

Input (x1,x2,x3)

 x1

 x 2

TIA-212

dt 

 y ≤ hmax ∗  x1 + k max 1)

PIA-206

 y ≥ hmin ∗  x1 − k min 1)

PIA-206

 y =  x1 − x 2

TY-202A

TY-202B

 x3

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

 y = T ( x1)

TY-212

PV SHP steam (t/h)

 y = M ST  1 ∗  x1 + T ST  1 ; if  ( x1 ≤ 126 t  / h)  y = M ST  2 ∗  x1 + T ST  2 ; if  ( x1 > 126 t  / h) Load(%) 40 70 100

Temp. 482 478 495

UZ-550

 y = CLOSE  if  ( x1 <  x 2 + ∆T SAT  )

TZA-211

TY-252

UZ-560

 y = CLOSE  if  ( x1 <  x 2 + ∆T SAT  )

TZA-213

TY-252

NOTE:

3.11.3.7

Steam(t/h) 72 126 180

1) 2)

See settings. Sampling time may be up to one minute.

Initialisations Ranges TAG

Description

Range

Units

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

TAG TZA-211 TZA-213 TZA-218 NOTE:

Description Z-Z-Z++

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Trips Level SIL1 SIL1 SIL1

Value 330 330 540

Units °C °C °C

Settings TAG h max  k max  h min 

k min 

∆T SAT 

Description Gradient for superheater temperature increase (start up) Gradient for superheater temperature increase (start up) Gradient for superheater temperature decrease (shutdown) Gradient for superheater temperature decrease (shutdown) Required temperature difference above saturation.

Value 0.4344

Units -

22

°C/min

0.4098

-

55

°C/min

30

°C

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.11.3.8

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Interfaces N/A.

3.11.3.9

Operator Interfaces Operator can access tags on the DCS.

3.11.3.10

Special Considerations The setpoint of the controller TC-215B may be changed, but only to a temperature between 515 and 525 °C, by the operator. The mode of this cont roller shall always be AUTO. Closing the block valves LAE10 AA011 (UZ-552) and LAE20 AA0011 (UZ-562) upstream the desuperheaters is a SIL 1 application.

3.11.4

History Date 20-07-2007

Author HuR/WiH

Description Original Document

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.12

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

BOILER DRAIN AND BLOWDOWN CONTROL HAH10AA404 (FIC-204A), HAH10AA424 (FIC-204B), LBA10AA404 (TICA-217), HAD10AA470 (LICS-202), HAD10AA471 (LICS-202A), GAC10AA011 (TICA-219), HAD10AA460 (QISA-202)

3.12.1

P&ID 36005-105-04 36005-105-07 36005-105-08 36005-105-09

Evaporator System Drain System Blow Down System Sample unit

PCD

117

UEFS E-15100-TN-2395-0036 E-15100-TN-2395-0043

Steam Boiler Package A-15101 – Blowdown & Drain System Steam Boiler Package A-15101 – Sample Unit

Objective Condensate will be formed in the superheaters and connecting piping if the boiler is shutdown and during start-up. The boiler drain control has the objective to discharge this condensate to the intermittent blowdown drum during start up of the boiler.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

accordance with the formula

C valve Pdrum

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

.

In this formula the constant Cvalve is the drum pressure where the control valve is allowed to open fully at controller output of 100% (Cvalve see setting list below). This limitation shall always be present to avoid damage to the blow down tank; also when the blow down control is in MAN mode. The HP intermittent blow down valve LICS-202B is on AUTO after valve LICS-202B is opened (ZS = 100%). The HP intermittent blow down control valve LICS-202A is set to –10% opening (MAN 0% output) as soon as drum level is at NWL for a certain time (tclose see setting list below). The HP intermittent blow down valve LICS-202B is closed after control valve LICS-202A is closed (ZS = 0%) for a certain time (tclose see setting list below). Continuous blowdown At normal operation boiler water from the drum will be discharged via the continuous blowdown valve to an external system. The amount depends on the water quality in the drum. The flow has to be manually adjusted by valve HAD10 AA461. Based on the results of the water quality samples the operator can choose to adjust the valve opening of HAD10

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

QIS-202

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Open CBD valve QISA-202 for t202 minutes if the conductivity in the drum is too high

H

Open

QISA-202

Close CBD valve if conductivity after timer t202 is elapsed. elapsed.

t202

Close

QISA-202

This CBD valve is working “discontinuously”. Please consider to install a “continuously” working CBD valve. If this is not possible or not preferred by NEM, please explain. PENDING (decision by JV see conference notes 2007-04-03) NOTE: IPS - Discrete Control Tag name N.A.

Service

Limit

Action

Valve/Controller

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.12.3.5

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Shutdown See also section 3.19

3.12.3.6

Calculations

TAG TS-403 TS403

Output (y) Calculation

Input (x1,x2,x3)

 x1

 y = 0% if  ( x1 > TSAT ( x 2) + ∆TSAT LBA10 else  y = 100%

CT001

 x 2 LBA10 CP001

DELETED TY-217

 y = Tsat  ( x1) + ∆TSAT )

PICA-207

SP for temperature controller at which valve TICA-217 is closed TY-217A TY-217B

 y =

C 217 A

 x1  y =  MIN ( x1 (digital), x 2 (digital))

PICA-207 TC-217

Low SEL TS-404 TS404

 y = 0% if  ( x1 >  x%)

FY-102

TY-217A

 x3

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Please describe: TY403b  Low Selector? NO, is output limiter TY404b  Low Selector? NO, is output limiter

3.12.3.7

YES, Low SEL YES, Low SEL

Initialisations

Ranges TAG TY-403 TY403 TY-404 TY404 FC-202 TC-217 TC-219 LC-207 NOTE:

Description Switch close/open Switch close/open Steam flow controller drain valves FIC-204A/B Steam tempeprature controller drain valve TICA-217 Industrial water temperature controller IBD level controller

Alarms

Range 0/100 0/100 0 - 100

Units % % %

0 - 100

%

0 - 100

%

0 - 100

%

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

t IBD-valve

∆T SAT  C 217A C 202A

∆ L206 A ∆ L401a C 207 t 202

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Timer for to close valve LICS202B after IBD control valve LICS-202A is closed Required temperature difference above saturation. Constant which limits opening of the valve at higher pressures Constant which limits opening of the valve at higher pressures Level margin to open IBD block valve LICS-202B Level margin to close IBO valve

60

seconds

30

°C

To follow

√(Bar)

To follow

√(Bar)

150

mm

160

mm

Constant which limits opening of the valve at higher pressures Timer for opening CBD valve QISA-202

To follow

√(Bar)

4

hours

PENDING (decision by JV see conference notes 2007-04-03) LC-207

Gain for LC-207 (100%/150mm) HOLD

Initial, to be finalized during operation 0.67 HOLD

-

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.13

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

DUAL DRIVEN FD FAN

P&ID

36005-560-04-151 36005-560-04-151-002 36005-105-13

PCD

3.13.1

UEFS E-15100-TN-2395-0041 E-15100-TN-2395-0044

Steam Boiler Package A-15101 – Dual Driven FD Fan Steam Boiler Package A-15101 – Lube Oil System

Reference documents 36005-560-04-148 36005-560-04-148-001

Operating procedure Control Narratives

Objective The objective for the dual driven FD Fan is to supply combustion air to the boiler in a controlled manner. The fan will be driven by a steam turbine as main driver and in case the steam turbine is not available or tripped the driving function is taken over by an electric

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

TA-258

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Lube oil temperature in tank

L

Switch heater on

NOTE: IPS - Discrete Control Tag name UC-580

Service Steam turbine speed

Limit H

TISA-249

Steam turbine inlet temperature

S

PZA-223

FD Fan bearings Lube oil pressure to bearings Lube oil pressure to bearings

HH LL HH

Action Trip turbine Trip turbine Trip Fan Trip Fan Trip Fan

Valve/Controller UC-581 UC-??? UC-581 UC-???

NOTE: Note:

Trip steam turbine TISA-249 HOLD. High temperature is a SILa classification Decision by JV

3.13.3

Operational and Implementation Aspects

3.13.3.1

Operational Modes

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Manual take-over:  A planned take-over from steam turbine to electric motor or from electric-motor to steam turbine has to be done manually (from DCS or local panel). From steam turbine to electric motor (Preliminary) For take over from steam turbine to electric motor next procedure has to be followed: • Start permissive when electric motor temperatures is within operating range • Start electric motor to full speed 1) • Auxiliary lube oil pump will start automatically if PISA-222 is LOW • Speed set point is ramped to zero (slow rate) • When set point is zero, valve limiter is stepped to zero 1)

Manual start from local panel also possible

From electric motor to steam turbine (preliminary) The take-over from E-motor to steam turbine needs additional local, manual actions (preheating steam lines to and from steam turbine, valves in correct position etc.). The steam turbine will be started according the normal start up procedure and when the steam turbine reaches his normal speed the electric motor can be switched off. During take-over, generally the driver with the highest speed will drive the FD Fan. For take over from electric motor to steam turbine start up procedure (see 3.13.3.2) has to be followed:

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

E-motor permissive  • Verify bearing temperatures are within operating range. • Verify is FD Fan speed is 0 rpm or 1500 rpm Lube oil unit permissive  • Verify emergency cooling water conditions (press/temp) are within operating range • Lube oil reservoir level > LOW Start lube oil unit (DCS or LOCAL) • Lube oil system to be started with the auxiliary lube oil pump (motor driven). • Verify lube oil pressure (PISA-222) within operating range • Verify differential pressure (PDIA-226) lube oil filter < HIGH • Verify water content (QIA-206) < HIGH • Verify bearing and gearbox temperatures are within operating range Start steam turbine operation (DCS or LOCAL) • Put governor in start function • Start steam turbine • Governor will ramp up turbine to nominal speed to minimum operating speed (500 rpm HOLD). • Check differential temperature between steam turbine inlet and outlet (dT < 177°C)

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Controls  Steam turbine/motor/lube oil unit At starting of the steam turbine the turbine speed controller (UC-580) is in start up mode. When the speed reaches normal set point the controller will be switched to AUTO. The pressure controller PIC-225 in the lube oil system will always be on AUTO. FD Fan At starting of the boiler the controllers FC-202B and QC-021 are in MAN mode, output 0%. Both controllers can be put on AUTO when: • All burners are in operation HOLD • FD Fan unit is in stable operation The controllers FC-202B and QC-021 receive their set points from the overall load control. See also section 3.19

3.13.3.3

Normal Steady State During normal operation the steam turbine speed controller (UC-580), oil pressure controller (PIC-225) and controllers FC-202B and QC-021 shall be in AUTO.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

5)

LISA-204 BAD Note Freeze 6/7) TA-258 BAD Note Freeze 8) PDIA-226 BAD Note Freeze 9) QIA-206 BAD Note Freeze 10) PISA-222 BAD Note Freeze 11) PZA-223 BAD Note Freeze PT-225 BAD PIC-225 Mode to MAN Freeze 1) NOTE: When two/three signals are BAD stop turbine manually and start E-motor if possible 2) Steam turbine and E-motor must be stopped 3) Start steam turbine if possible 4) When signal is BAD stop turbine manually and start E-motor if possible 5) Shut off heater and check oil level 6) When HIGH switch heater off 7) When LOW switch heater on 8) Switch-over to other filter 9) Check oil system and replace oil content 10) Automatic start aux. lube oil pump 11) Check/adjust control valve PIC-225 3.13.3.5

Shutdown

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.13.3.6

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Calculations

TAG

Output (y) Calculation

Input (x1,x2,x3)

 x1

 x 2

?????

 y = stop aux. lub e oil  pump if 

UC-580

ST-204

( x1 &  x 2 = 0 rpm  for  t stop sec onds ) NOTE:

3.13.3.7

Initialisations Ranges TAG PIC-225 UC-580 NOTE:

TAG

Description Lube oil pressure controller Speed controller

Description

Alarms Level

Range 0 - 100 0 - 100

Value

Units % %

Units

 x3

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

NOTE:

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

1)

When two/three signals are BAD stop turbine manually and start E-motor if possible 2) Steam turbine and E-motor must be stopped 3) Start steam turbine if possible 4) When signal is BAD stop turbine manually and start E-motor if possible 5) Shut off heater and check oil level 6) When HIGH switch heater off 7) When LOW switch heater on 8) Switch-over to other filter 9) Check oil system and replace oil content 10) Automatic start aux. lube oil pump 11) Check/adjust control valve PIC-225

TAG Description UC-580/  Z+ UZ-571 1) SS-207 Z+ TISA-249 S 2) PZA-223 Z-3) PZA-??? Z1) NOTE: Mechanical trip

Trips Level -

Value 5450

Units rpm

SILa SIL1 -

5500 430 1.5 0.62

rpm °C Bar(g) Bar(g)

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

151XI-xxx 151XI-xxx 151XI-xxx 151XI-xxx 151XI-xxx 151XI-xxx 151XI-xxx 151XI-xxx Signal 151US-xxx Signal 151US-xxx Signal 151US-xxx Signal 151US-xxx 151TIZA-239

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

panel Switch on local panel Switch on local panel Indication in DCS Indication on local panel Indication in DCS Indication on local panel Indication in DCS Indication on local panel Signal

Signal to MCC to start KM-15161

Signal

Signal from MCC to confirm that KM-15161 is running

Indication in DCS

Indication any failure

Indication on local panel Signal

Indication any failure

To start auxiliary lube oil pump To stop auxiliary lube oil pump Indication that KM-15161 is ready to start Indication that KM-15161 is ready to start Indication that KT-15161 is running Indication that KT-15161 is running Indication that KM-15161 is running Indication that KM-15161 is running

Trip FD Fan (stop electric motor KM-15161)

High

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.13.3.10

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Special Considerations During purge, start up and shutdown the air flow through the FD Fan will be limited by means of a mechanical minimum stop. Cooling water for the lube oil system will be supplied from the emergency cooling water system. The number of consecutive starts with the E-motor is limited to: • 3 cold starts • 2 warm starts When a start is not succeeded after 3 cold or 2 warm starts a waiting time of 300 minutes is required to cool-down the motor sufficiently.

3.13.4

History Date 20-07-2007

Author HuR/WiH

Description Original Document

On this P&ID we have shown/made three (3) control/safeguarding blocks:

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.14

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

COOLING AIR FANS K-15162A/B AUTO TAKE-OVER P&ID

36005-105-12

PISA - 205, KM - 15162A, KM - 15162B, US-540 UEFS E-15100-TN-2395-0038

Steam Boiler Package A-15101 - Cooling Air Viewports

See typical control loop PUMP AUTO TAKE-OVER in General Functional Specification, doc. E-00000-TN-5306-0001.  I don’t know if this is still applicable to a FAN. J.V. to advise.

3.14.1

Objective The fans supply cooling air to the boiler view ports and burner igniters. The air will also be used as seal air for the sootblower wall box and to prevent ingress of flue gas into the sootblower lance when the sootblower is not blowing steam.

3.14.2

Functional Description To start the standby fan KM - 15162B or KM - 15162A on detection of a low discharge

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.14.3.5

Shutdown

3.14.3.6

Calculations

3.14.3.7

Initialisations

TAG PISA-205 PISA-205 NOTE:

Description AA--

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Alarms Level Indication Indication

Value HOLD HOLD

Units Barg(g) Barg(g)

Low discharge pressure switch PISA-205 will be automatically reset when the pressure rises above the low switch setting. 3.14.3.8

Interfaces

3.14.3.9

Operator Interfaces

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.15

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

SOOTBLOWER SYSTEM P&ID

36005-105-10 36005-105-11

PISA-208, TISA-220, TISA-221

3.15.1

UEFS E-15100-TN-2395-0037

Steam Boiler Package A-15101 – Sootblower System

Reference document 36005-553-04-118

Sootblower Logic Diagram

Objective The sootblowers will be used to keep the heating surfaces of superheaters and economizers in the boiler free from soot and dust as much as possible. Especially during firing of fuel oil the sootblowers will blow MP steam to the heating surfaces within a certain time interval. Always one sootblower at a time is in operation. Seal air is supplied the sootblower wall box to prevent flue gases escaping from the boiler and to prevent ingress of flue gas into the sootblower lance when the sootblower is not blowing steam.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

3.15.3

Operational and Implementation Aspects

3.15.3.1

Operational Modes The boiler can be claeaned by an automatically fixed sootblowing sequence or by manual/individual sootblowing.

3.15.3.2

Normal Steady State

3.15.3.3

Start up Automatically blowing sequence:  This sequence will start with the boiler sootblowers in lane 1. Subsequently the sootblowers in lane 2 up to 7 will be started. The sequence ends with the sootblowers of the external economizer of lane 8 and 9. • • • • • •

Power on Check all sootblowers in retracted position If not retracted press retract/fault reset button All sootblowers in retracted position Drain valves HCB10 AA010 (KBS-212) and HCB10 AA030 (KBS-213) are opened Steam supply valve HCB10 AA001 (KBS-211) is opened

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

• • • • • • • • • • • • • • • • • • •

3.15.3.4

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

If steam temperature TISA 220 > HIGH (S+), drain valve HCB10 AA010 closes If steam temperature TISA 221 > HIGH (S+), drain valve HCB10 AA030 closes If drain valves closed, check steam pressure PISA 208 > HIGH (S+) INDIVIDUAL sootblowers selected Press start button Sequence started (individual sootblower operation) Sootblower motor energized Sootblower inserted Sootblowing in advance When limit switch position ‘close’ is reached motor is switched to reverse action Sootblower is retracted When limit switch position ‘open’ is reached sootblower motor is switched off Sequence starts next sootblower Sequence continues up to last sootblower Wait for timer is finished Check for all sootblowers retracted Steam supply valve HCB10 AA001 (KBS-211) is closed Drain valves HCB10 AA010 (KBS-212) and HCB10 AA030 ( KBS-213) are opened Power off

Crippled Mode Operation

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

TISA-220 TISA-221 TISA-220 TISA-221 HOLD (Blowing time)

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Close drain valve KBS-212 if steam temperature > HIGH (S+) Close drain valve KBS-213 if steam temperature > HIGH (S+) Sootblowing suspended if steam temperature < LOW (S-) Sootblowing suspended if steam temperature < LOW (S-) Sootblower operating will retract and suspended if MAX blowing time (insert + retract time) is elapsed

NOTE: 3.15.3.8

Interfaces

3.15.3.9

Operator Interfaces Operator can access tags on the DCS. Following functions/signals are present:

280

°C

280

°C

260

°C

260

°C

10

minutes

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.16

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

ATOMIZING STEAM CONTROL LBG30AA011 (PICA-115) LBG30AA016 (TICA-081)

3.16.1

P&ID

36005-105-14

PCD

114

UEFS E-15100-TN-2395-0004

Steam Boiler Package A-15101 – Atomising Steam System

Objective To supply MP steam to the fuel skid with a constant superheated temperature used for atomizing of the fuel oil in the burners.

3.16.2

Functional Description To supply MP steam of the required conditions to the fuel skid MP steam and MP desuperheated steam will be mixed. To mix the two flows with nearly equal pressures a pressure controller PC-115 controls the MPD steam to a fixed pressure downstream of the

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.16.3.2

Start up

3.16.3.3

Normal Steady State

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

During normal operation the controllers PC-115 and TC-081 shall be in AUTO. 3.16.3.4

Crippled Mode Operation

Tag Name PICA-115 TICA-081 NOTE: 3.16.3.5

Shutdown

3.16.3.6

Calculations

TAG N.A.

Instrument Output Controller BAD PC-115 BAD TC-081

Output (y) Calculation

Action Mode to MAN Mode to MAN

Output Freeze Freeze

Input (x1,x2,x3)

 x1

 x 2

 x3

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.16.3.8

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Interfaces N/A.

3.16.3.9

Operator Interfaces Operator can access tags on the DCS.

3.16.3.10

Special Considerations The maximum allowable mixed temperature (324°C) is lower than the design temperature of the MP steam (400°C). If the mixed tem perature exceeds the allowable temperature the opening of the MP steam control valve will be limited.

3.16.4

History Date 20-07-2007

Author HuR/WiH

Description Original Document

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.17

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

BOILER START UP AND SHUTDOWN HLA10AA001, FIC-502, FIC-502, XC504

(HOLD)

P&ID 36005-105-??

(HOLD)

PCD

(HOLD)

Question to JV: Will there be a check on conditions as a release signal for start up? Fuel supply OK Feedwater conditions OK MP and LP steam conditions for steam turbine OK Industrial water conditions OK Cooling water conditions OK Instrument air conditions OK Atomizing steam conditions OK Sootblower steam conditions OK

3.17.1

Objective

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

3.17.3

Operational and Implementation Aspects

3.17.3.1

Operational Modes

3.17.3.2

Start up CHECK UPS PRIOR TO START PROGRAM • Auxiliary systems standby at the required conditions for normal operation, i.e. feedwater, cooling water, industrial water, auxiliary steam systems, oil system FD fan, fuel system, chemical dosing systems, plant/instrument air. Boiler equipment standby. • • All valves in correct position. • Boiler is vented and drum level is brought to start level. • Burner system and fuel lines standby. • The water level in the intermittent blowdown drum is brought to minimum level by supplying industrial water. START UP MODES As far as applicable three different start up modes are distinguished: • Cold start up: defined as t drum < 100°C • Warm start up: defined as t drum ≥ 100 10 0 and a nd < 300 3 00° °C • Hot start up: defined as t drum ≥ 300 °C

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Boiler start-up At starting of the boiler the set point of the pressure controller PC-207 is, via an automatic switch, put in memory to the remaining pressure in the boiler with a minimum of 2 bar(g) The boiler start-up is initiated by setting the desired boiler load from the DCS with a maximum of 40% MCR. This will initiate a starting sequence of the burners (for NG). During the start program is running other actions will be initiated such as open and closing of drains, level increase of the drum level from SL to NWL, NWL, activate of control functions. Details can be found in the Functional Control Diagrams (HOLD). Burner start The burner start is described in the Burner System Description. Each burner start is performed from the DCS or burner local panel. Burner starting sequence The burner starting sequence as described in this paragraph needs to be followed to start-up the boiler in the correct manner. Once more it is noted that the boiler has six (6) burners located at the front side of the furnace divided into 2 rows with each 3 burners. The bottom row burners will be started first, and later on the top row burners, in order to heat up the boiler as gradually as possible. Furthermore, two holding points are included to startup the boiler correctly.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Burner 1 (A)

Burner 2 (B)

Burner 3 (C)

Burner 4 (D)

Burner 5 (E)

Burner 6 (F)

Figure 1. Burner front (seen from burner platform)

Load to 12.5% boiler load (final value to be defined during commissioning) The load of the boiler is set to 12.5% MCR. The first three (3) burners are started in the sequence as given in table 2. At that point a hold point (1) is applied to heat up the boiler gradually. Furthermore, the condensate in the superheater tubes needs to be removed. The hold point (1) needs to be maintained until the following conditions are met: • Drum level HAD10 CL004/5/6 (LT-202A/B/C) is constant for at least 120 seconds. • Drum pressure HAD10 CP001 (PIA-206) is > 2 bar(g) and stable for at least 120

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

The steam pressure will reach the set point of the start up blow off valve LBA10 AA051 (PICA-207) and the valve will control the steam pressure at 120 bar(g). Feedwater control valves during start up To close and open control valve LAB10 AA032 (TIC-207B) see section 3.9.3.2. During start up of the boiler control valve LAB10 AA032 will be forced to close. When the boiler load < 15%, then: • Output temperature controller LAB10 CT003: 0% • Output of control valve LAB10 AA032: 0% When boiler load > 15%, then: • Temperature controller and control valve LAB10 AA032: AUTO-mode Warming up steam lines As soon as the steam production starts the superheater and main steam line will be warmed up by the steam/condensate discharged via the start up drain valves HAH10 AA402/424 and LBA10 AA404. The start up drain valves will be closed during the start up procedure. ECO circulation valve during start-up The ECO circulation valves HAD15 AA001 (US-532) and HAD15 AA002 (US-531) can be closed as soon as the following conditions are met: (HOLD) • FW flow LAB10 CF101 is > 15 t/h for at least 60 seconds.

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Close start up valve LBA10 AA051 (PICA-207) The valve will automatically close as soon as there is a steam demand from the common steam system respectively steam turbines. Controller PC-207 will be switched to MAN, 0% output when: • Valve PICA-207 is closed and • Valve MOV-201 is open If valve LBA10 AA051 is closed the set point of the valve will be increased with a upset of 2 bar to 122 bar(g). (HOLD) Boiler control Control can be performed in two different manners. 1. Pressure control by master pressure control system. 2. Boiler steam flow control. Master pressure control or flow control can be activated if: • Valve PICA-207 is closed and • Valve MOV-201 is open

Transfer from 40% load to 100% load The boiler load can be transferred from 40% to normal operation as soon as the following

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

3.17.3.5

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

Shutdown In order to shut down the boiler, the following actions need to be taken: • Open manual steam blow off valve LBA10 AA050 • Adjust set point for pressure controller PC-207 to an appropriate value just above of the actual pressure in main steam line (to avoid steam blow off) • Put pressure controller/start up valve PICA-207 on AUTO • Reduce boiler load slowly to approximately 20% MCR (with constant steam header pressure) • The HP steam line MOV LBA10 AA003 (MOV-201) can be closed (manually from CCR) as soon as the boiler load is < 40%. Potential stored heat can be released by the start up valve LBA10 AA051 operating as pre-safety valve. • As soon as the boiler load is < 20% MCR the top burners and finally the bottom burners are stopped consecutively • As soon as all burners are out of operation FD Fan HLB10 AN001 (K-15161) will automatically stopped by activating the stop program of the steam turbine or electric motor • The economizer circulation valves HAD15 AA001/002 are opened automatically as soon the FW flow LAB10 CF101) < 12 t/h for at least 60 seconds • The drum level will be brought from normal level to start level • Close continuous blowdown valve HAD10 AA460 (QISA-202) • Put pressure controller/start up valve PICA-207 on MAN, 0% output • The start up valve set point will follow the actual steam pressure (with a margin of 2 bar)

ABB Lummus Global B.V.

Client

SHELL EASTERN PETROLEUM (PTE) LTD.

Subject

PROCESS CONTROL FUNCTIONAL SPECIFICATION

120.011

04217

E-15100-TN-5306-0001

2.00

Dept./Sect.

Project

Document Number

Rev.

REFERENCES 3.18

DRAWINGS PID’s 36005-104-01 36005-104-02 36005-105-01 36005-105-02 36005-105-03 36005-105-04 36005-105-05 36005-105-06 36005-105-07 36005-105-08 36005-105-09 36005-105-10 36005-105-11 36005-105-12 36005-105-13 36005-105-14 36005-105-15 36005-105-16

Legend and symbols for P&ID's Legend and symbols for P&ID's PFD and material balance P&ID Flue gas system P&ID Economiser system P&ID Evaporator system P&ID Superheater system P&ID Main steam line P&ID Drain system P&ID Blow down system P&ID Sample unit P&ID Sootblower system boiler P&ID Sootblower system economizer P&ID Cooling air view ports P&ID Steam lines turbine P&ID Atomizing steam desuperheater station P&ID Cooling water P&ID Instrument air