Boiler

ABB Lummus Global B.V.
120.011 04217 E-15100-TN-5306-0001
Dept./Sect. Project Document Number

THIS DOCUMENT/DRAWING IS THE PROPERTY OF ABB LUMMUS GLOBAL B.V. INCLUDING ALL PATENTED AND PATENTABLE FEATURES AND/OR CONFIDENTIAL INFORMATION AND ITS USE IS CONDITIONED UPON THE USER’ S AGREEMENT NOT TO REPRODUCE
SHELL EASTERN PETROLEUM (PTE) LTD.

THE DOCUMENT/DRAWING, IN WHOLE OR IN PART, NOR THE MATERIAL DESCRIBED THEREON, NOR TO USE THE DOCUMENT/DRAWING FOR ANY PURPOSE OTHER THAN AS SPECIFICALLY PERMITTED IN WRITING BY ABB LUMMUS GLOBAL B.V.
SINGAPORE
SHELL ECC PROJECT
STEAM PRODUCTION & DISTRIBUTION

CONDENSATE COLLECTION
DESALINATED WATER STORAGE
DEMINERALISED WATER MAKE-UP SYSTEM
PROCESS CONTROL FUNCTIONAL SPECIFICATION
UNIT 15100
2.00 2006-10-31 Revised Approved for Design RVO GRI GDS

1.00 2006-05-31 Approved for Design RVO GRI GDS
0.00 2006-03-10 ORIGINAL DOCUMENT RVO GRI GDS
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

REPORT TEMPLATE.DOT PCFS NEM_R2.doc Page 1 of 92
Client SHELL EASTERN PETROLEUM (PTE) LTD. 120.011 04217 E-15100-TN-5306-0001 2.00
Subject PROCESS CONTROL FUNCTIONAL SPECIFICATION Dept./Sect. Project Document Number Rev.
Table of Contents
1. BACKGROUND PROCESS INFORMATION 4
1.1 PROCESS AND PROJECT 4
1.2 STEAM AND POWER GENERATION / DISTRIBUTION SYSTEM 6

1.2.1 Super High Pressure (SHP) Steam 6
1.2.2 High Pressure (HP) Steam 6
1.2.3 Medium Pressure Desuperheated (MPD) Steam 6
1.2.4 Medium Pressure Desuperheated (MPD) Steam 6
1.2.5 Low Pressure (LP) Steam 6
1.2.6 Low Pressure Desuperheated (LPD) Steam 6
1.2.7 Letdown Stations 6
1.2.8 Steam Boilers 7
1.2.9 Power Generation System 7
1.2.10 Blowdown and Flash Drums 7
1.3 CONDENSATE TREATMENT AND RECOVERY SYSTEMS 7

1.3.1 Deaerators 7
1.3.2 PCC 8
1.3.3 NCC 8
1.3.4 MP Condensate 8
1.3.5 HP Condensate 8
1.3.6 Condensate Treatment 8
1.4 DESALINATED WATER 9
1.5 DEMINERALISED WATER 10
2. CONTROL DESCRIPTION 11
2.1 STEAM SYSTEM 11

2.1.1 General 11
2.1.2 SHP Steam Header 11
2.1.3 HP Steam Header 12
2.1.4 MP Steam Header 12
2.1.5 MPD Steam Header 13
2.1.6 LP Steam Header 13
2.1.7 LPD Steam Header 13
3. DETAILED CONTROL NARRATIVES 14
3.4 STEAM BOILERS, A-15101/2/3, STEAM LOAD CONTROL 14

PICA-070, PICA-071, HIC-100, HIC-200, HIC-300, Y-100, Y-200, Y-300, HS-098, 14
HS-401, UC-400, UC-401 14
3.4.1 Objective 14
3.4.2 Functional Description 14
3.4.3 Operational and Implementation Aspects 15
3.4.4 History 16

3.5 SHP/HP STEAM DESUPERHEATER, J-15101A/B, PRESSURE CONTROL 17

PICA-063, PICA-014, PY-014, TICA-005, HS-023 17
3.5.1 Objective 17
3.5.4 History 19
3.6 BOILER COMBUSTION AIR CONTROL 24

HLA10AA001, FIC-502, XC504 24
3.6.1 Objective 24
3.6.4 History 30
3.7 GAS/FUEL OIL CONTROL 31

V102 – FC155, V201 – FC172, V302 – PDC165, V502 – PDC182 31
3.7.1 Objective 31
3.7.4 History 39
3.8 BOILER STEAM DRUM LEVEL AND ECONOMIZER INLET TEMPERATURE CONTROL40
LAB10AA022 – FC101 LC101, LAB10AA032 - TIC-103 40
3.8.1 Objective 40
3.8.4 History 46
3.9 BOILER START-UP PRESSURE CONTROL 47

LBA10AA051 - PIC302, TIC301 47
3.9.1 Objective 47
3.9.4 History 52
3.10 BOILER STEAM DESUPERHEATER TEMPERATURE CONTROL 53

LAE10AA014 – TC203, TC204, LAE10AA014 – TC205, TC206 53
3.10.1 Objective 53
3.10.4 History 58
3.11 BOILER DRAIN AND BLOWDOWN CONTROL 59

HAH10AA404, HAH10AA424, LBA10AA404, HAD10AA470, HAD10AA471 - LIC-401,
GAC10AA011 - TC401, HAD10AA460 59
3.11.1 Objective 59
3.11.4 History 64
3.12 DRAWINGS 91
3.13 DOCUMENTS 91

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.
Low Pressure Desuperheated (LPD) steam is produced by desuperheating of LPS steam,

and by the Quench Oil/LP Steam Exchangers E-11133 A/B, in the LOP. LPD steam is
required for several heat exchangers/reboilers in the LOP.
Pressure letdown stations are provided from higher pressure to (the next) lower levels.
During normal operation, pressure letdown is done as much as possible via the turbines and
the amount of steam which is letdown via the letdown/desuperheater stations is minimized.
The condensate treatment systems collects all the returned condensate streams and can be
divided into four categories:
• HP return condensate which is normally clean and not likely to be contaminated is
recycled to the Deaerators via a HP condensate flash drum and via the MP condensate
system without any further treatment.
• MP return condensate which is normally clean and not likely to be contaminated is
recycled to the Deaerators via a MP condensate flash drum without any further
treatment.
• Potentially Contaminated Condensate (PCC) from condensed LP/MPD steam.
• Normally Clean Condensate (NCC) from surface condensers
PCC is collected in the PCC Flash Drum from the following sources, polished and used as
BFW:
• ECU
• U & GF (except LPS users)
• ECC Jets/Tracing
• C4SHU LPD Steam Users
• PHU
• BEU-1 LPS Users

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
the Desalinated Water Storage Tank. The Desalinated Water is used to:
• Supply Desalinated Water to the Demineralised Water Package
• Supply Desalinated Water to Industrial Water Distribution (Not normal flow)
• Supply Desalinated Water to the maintain Fire Water ring main pressure (Not normal
flow)
• Supply Desalinated Water to the Fire Water Pumps (Not normal flow)
The feed to the Demineralised Water System consists of Desalinated Water. The
Demineralised Water System sends Demineralised Water to the Demineralised Water
Storage Tank. It can also be sent to the Waste Water Equalisation Tank, if required, or it is
sent to NCW.
The Demineralised Water is pumped from the tank to:

• Continuous BD Drum Interchanger
• Condensate Treatment Package
• Waste Water Neutralisation Sump
The regenerant waste streams from the PCC/NCC treatment are sent to the waste water
neutralisation sump before being pumped to the Plant Outfall.

1.2 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.
1.2.3 Medium Pressure Desuperheated (MPD) Steam
MP steam is extracted from the PG turbine and used:

• for various equipment (e.g. heat exchangers, turbine drives) in all the process units.
• to drive an air compressor turbine.
• for export to the Bukom Refinery.
• to support the LP steam system.
• as dilution steam for the LOP cracking heaters.
1.2.4 Medium Pressure Desuperheated (MPD) Steam
MPD steam is extracted from the MP steam system and used:

• for the MP condensate collection system.
• to provide heating for the process water stripping in the LOP units.
1.2.5 Low Pressure (LP) Steam
Low Pressure (LP) steam is produced by various backpressure turbines and used to provide
heating for all process units and offsite systems, e.g. heat exchangers, reboilers, Deaerator,
equipment heating and storage tank heating.
1.2.6 Low Pressure Desuperheated (LPD) Steam
LPD steam is extracted from the LP steam system and also generated in the gasoline
fractionator area. It is used to provide heating for various equipment, e.g. reboilers, in all the
process units.
1.2.7 Letdown Stations
Pressure letdown stations are provided from each pressure level to the next lower level.
From each pressure level steam can also be vented to the atmosphere, except for SHP.

1.2.8 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.
1.2.10 Blowdown and Flash Drums
A continuous blowdown drum V-15105 is provided to collect and flash the continuous
blowdown from the three steam boilers and the twelve LOP cracking heaters. The collected
water is cooled and re-used as wash water and dilution water, or in case of surplus, sent to
the intermittent blowdown drum V-15104. This common intermittent blowdown drum, collects
the intermittent blowdown from the LOP cracking heaters. The flashed steam is vented, to
atmosphere, while the liquid is discharged to the LLOD, via the AOC system.
Several flash drums operating at different pressure levels are provided to receive the
condensate streams from the various steam users. The flashed steam is re-used at a lower
pressure level and the condensate is cooled and treated, before it is either re-used, or
disposed.
1.3 CONDENSATE TREATMENT AND RECOVERY SYSTEMS
1.3.1 Deaerators
Two Deaerators V-15120 A/B will be provided to produce all required BFW for the Cracking
Heaters, Steam Boilers, Desuperheaters and other steam generators.
During normal operation, two Deaerators are available and are operating at about 77% of
their design capacity each. In the event that one Deaerator is shutdown for maintenance
and/or statutory inspection, the BFW capacity is decreased by exporting less steam to
Bukom Refinery and stopping the production of electric power. The remaining Deaerator is
then operated at 100% of its design capacity.

1.3.2 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.
In order to minimize ingress of O2 and CO2 in the PCC/NCC, T-15101 is provided with
nitrogen blanketing. Consequently, the tank type is a Low Pressure Cone Roof storage tank.
The tank material will be epoxy-coated CS.
1.3.4 MP Condensate
MP Condensate is collected in the MP Condensate Flash Drum V-15102. The flashed steam
is sent to the LP Steam header and the condensate is sent to the Process Water Stripper
C-11105 and to the Condensate Surge Tank T-15101. Before reaching the Surge Tank, the
condensate is cooled down via the MP Condensate Cooler E-15106 and the MP
Condensate Trim Cooler E-15107. The cooled down condensate without polishing, is the
feed for the Deaerators V-15120 A/B. Contaminated Condensate is sent to the Emergency
Basin.
1.3.5 HP Condensate
HP Condensate is collected in the HP Condensate Flash Drum V-15103 from the following
sources:
• E-13206 in the BEU-1
• Drier Regeneration Gas Heater, E-11214
HP Condensate is collected in the HP Condensate Flash Drum V-15103. The flashed steam
is sent to the MP Steam header and the condensate is sent to the MP Flash Drum.
Contaminated Condensate is sent to the Emergency Basin via HP Condensate Emergency
Cooler E-15108 where it exchanges heat with the MP Flash Drum bottoms exiting E-15106.
1.3.6 Condensate Treatment
Pre-treatment
All rust, debris and hydrocarbons are removed from PCC in the pre-treatment section.
The PCC is sent to the PCC Cartridge Filter S-15135 A/B and the Activated Carbon Filters
V-15140 A/B. In order to detect any hydrocarbon breakthrough, a TOC-analyser is installed
downstream the Activated Carbon Filter.

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.
Diluted caustic is made on-line by mixing demin water and 50% caustic coming from
P-16103 A/B.
The regeneration waste is discharged and neutralised in the Waste Neutralisation Sump
A-15110, before being sent to the Plant Outfall. At the end of the regeneration cycle water is
pumped out of the sump. If the pH at the pump discharge is not between 6.5 and 9, the
sump pump discharge valve remains closed and the water is recirculated back into the
sump. The pH is then adjusted and when it is between 6.5 and 9, it is pumped to the plant
outfall.
1.4 DESALINATED WATER
This tank contains hold-up for Demineralised Water production as well as firewater storage.
Two Desalinated Water Distribution Pumps P-15105 A/B are used to transfer desalinated
water to the Demineralised Water Package. One pump is the operating duty pump and the
other pump is the operator selected standby pump. The Desalinated Water Distribution
Pumps also keep the firewater ring main under pressure.
In the event that the downstream Desalinated Water Package is not operating, the pressure
is maintained by circulating the water over the tank using the pump’s minimum flow. In the
event of a low pressure in the fire water system, an auto-start signal will start the standby
pump.
In order to minimise ingress of O2 and CO2 to the Desalinated Water Tank T-15105 is
provided with nitrogen blanketing. Consequently, the tank type is a Low Pressure Cone Roof
Storage Tank and the tank material is epoxy-coated CS.
The Desalinated Water System also serves as a backup water source for the industrial water
distribution system.

1.5 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
Demin Water from the Storage Tank is pumped by the Demin Water Transfer Pumps
P-15103A/B/C to the Continuous Blowdown Drum Interchanger E-15103. Two of the three
pumps are running and one is spare. In the event of an NCC and/or PCC/NCC failure, the
third demin water pump must/can be switched on to maintain sufficient make-up to the
Deaerators
The Demin Water is also pumped, by the Regeneration and Backwash Pumps P-15106A/B
as Backwash Water, to the Condensate Treatment Package A-15140. Two streams are
taken from the pumps discharge line, one is mixed with 98% Sulphuric Acid and the other is
mixed with 50% Caustic. The dilute Acid stream and the dilute Caustic stream are sent to
both the Condensate Treatment Package and the Waste Water Neutralisation Sump.
The regenerant waste streams from the PCC/NCC treatment are sent to the waste water
neutralisation sump A-15110, where it is neutralised by mixing with a dilute Acid and Dilute
Caustic, before being pumped to the plant outfall by the Neutralised Waste Transfer Pump
P-15108.

2. CONTROL DESCRIPTION
2.1 STEAM SYSTEM
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.
• Provide sufficient storage capacity for Newater, Demin Water and returned Condensate.
• Neutralization control of regeneration waste from Demin and Polisher Unit prior to
discharging to sea.
2.1.1 General
The pressure in each of the five steam headers (SHP, HP, MP, LP and LPD) is controlled in
each header by means of a set of pressure controllers. This makes it possible to split the
operating window for each header into various pressure ranges and for each range to take
specific control actions. The general setup for the control actions is as follows:
• Under normal operating conditions, the SHP Steam header pressure is controlled by
adjusting the load of the steam boilers, the pressure in the HP Steam, MP Steam and LP
Steam headers are controlled by adjusting the steam extraction flows from the steam
turbines and the pressure in the MPD Steam and LPD Steam is controlled by steam
letdown via the desuperheaters.
• On the lower side, when the steam pressure in the header is decreasing, additional
steam can be taken in via a letdown station from the higher pressure level.
• On the higher side, when the steam pressure in the header is increasing, the surplus of
steam can be letdown to a lower pressure level also via a letdown station.
• On the higher side, when the steam pressure is increasing too much, steam is vented to
the atmosphere, except for SHP.
For each steam header this approach will be described in more detail in the next
paragraphs.
The MPD steam header is only temperature controlled.
2.1.2 SHP Steam Header
The pressure in the Primary SHP steam header is maintained under normal operating
conditions by adjusting the load of one of the steam boilers A-15101/2/3. All three boilers will
be in operation, whereby two of them run on a fixed load approximately 75%, while the third
boiler reacts on the pressure variations as set by the pressure controller.

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.
The pressure in the HP Steam Header is normally controlled by pressure controller

PICA-017, which manipulates the steam extraction control valve of the Cracked Gas
Compressor (CGC) Steam Turbine KT-11201.
In the event that the pressure in the HP Steam Header decreases, PICA-014 will open the
SHP/HP Steam Desuperheater/letdown valve J-15101A or B. SHP Steam is then letdown
from the SHP Steam Header to the HP Steam Header via high signal selector PY-014.
Shall the pressure continue to fall in the HP Steam Header, PICA-015 will open via high
signal selector PY-015 SHP/HP Steam Desuperheater/letdown valve J-15109A or B and
more SHP steam is then letdown from the SHP Steam Header to the HP Steam Header.
At the other hand in the event that the pressure in the HP Steam Header increases,
PICA-016 will send a singal to high signal selector 151PY-022 in order to open HP/MP
Steam Desuperheater/letdown valve J-15102A or B and HP steam is then letdown to the MP
steam header, via high signal selector PY-022.
A continued increase in pressure in the HP Steam Header will result in PICA-013 opening a
vent control valve to ASL.
The temperature controller TICA-005 is used to control the exit temperature of the SHP/HP
Steam Desuperheaters J-15101A or B, by manipulating the amount of BFW added to the
SHP/HP Steam Desuperheater. TICA-006 is used to control the exit temperature of SHP/HP
Steam Desuperheater J-15109A or B.
2.1.4 MP Steam Header
There are five pressure controllers PICA-021 until PICA-025 on the MP Steam Header. The
PV for all pressure controllers is derived from a MOO3 configuration with three pressure
tappings.

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
Steam Desuperheater J-15110A or B.
2.1.5 MPD Steam Header
The temperature controller TICA-014 is used to control the exit temperature of the MP/MPD
Steam Desuperheater J-15105, by manipulating the amount of MBFW added to the
MP/MPD Steam Desuperheater.
2.1.6 LP Steam Header
There are three pressure controllers PICA-030, PICA-031 and PICA-032 on the LP Steam
Header. The PV for each pressure controller is derived from a MOO3 configuration with
three pressure tappings.
The pressure in the MP Steam Header is normally controlled by PICA-030 which

manipulates the steam extraction control valve of the Propylene Refrigeration Compressor
Steam Turbine KT-11501.
In the event that the pressure in the LP Steam Header decreases PICA-031 will open the
control valve upstream of the MP/LP Steam Desuperheater J-15103 via high signal selector
PY-031. MP Steam is then letdown from the MP Steam Header to the LP Steam Header.
A high increase in pressure in the LP Steam Header will result in PICA-032 opening a vent
control valve to ASL.
The temperature controller TICA-015 is used to control the exit temperature of the MP/LP
Steam Desuperheater J-15103, by manipulating the amount of MBFW added to the MP/LP
Steam Desuperheater.
2.1.7 LPD Steam Header
There are two pressure controllers PICA-036 and PICA-037 on the LP Steam Header. The
PV for each pressure controller is derived from a MOO3 configuration with three pressure
tappings.

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
E-15100-TN-2396-0001 Deaerator and SHP Steam Production
UEFS
E-00000-TN-2395-0075 BFW and SHPS Distribution – Sheet 10
E-15100-TN-2395-0004 SHP Steam Boilers
3.4.1 Objective
The objective is to balance the steam production with the steam demand, by controlling the
SHP Steam Header pressure with the firing rate and by distributing the load over the three
boilers. This control scheme determines the set point for the boiler firing control scheme.
The load of the boilers is maintained between 72 ton/h and 180 ton/h steam per steam
boiler. Below 72 ton/h (40 % MCR) is not allowed as this is the minimum stable turndown of
the steam boiler. Above 180 ton/h is not allowed as this is above 100 % MCR of the steam
boiler. Additional provisions guarantee steam production during upsets.
3.4.2 Functional Description
Two of the three boilers operate at an operator set fixed steam production rate, as a
percentage of MCR, set by HIC-100 (boiler A-15101), HIC-200 (boiler A-15102), and
rd
HIC-300 (boiler A-15103). The 3 boiler, selected by the operator through HS-401, is in
balancing mode. One of the two boilers at fixed rate will be set as backup balancing boiler by
the operator through HS-401. The signals from HIC-100, HIC-200 and HIC-300 are sent to
the boiler load calculation blocks Y-100, Y-200 and Y-300 respectively.
The SHP steam pressure controller switch HS-098 receives a measurement from either
PICA-070 (normally active) or PICA-071. The operator selects the active pressure controller.
PICA-071 is only used when the primary SHP Steam Header controller PICA-070 is out of
service due to maintenance and/or inspection.
The output of switch HS-098 is sent to the calculation blocks Y-100 (boiler A-15101), Y-200
(boiler A-15102), Y-300 (boiler A-15103) and to the Steam Generation Load Control
151UC-400 ????????

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.
Control Valve
Tag Name Alg Action PV-Tracking Name
PICA-070 PID Reverse Yes -
PICA-071 PID Reverse Yes -
HS-098 MAN-SEL - - -
HS-401 MAN-SEL - - -
HIC-100 - - - -
HIC-200 - - - -
HIC-300 - - - -
Y-100 - - - -
Y-200 - - - -
Y-300 - - - -
UC-401 PID Direct Yes -
UC-400 ??? ??? ??? -
NEM comment: Controller UC-400 to add??????
3.4.3 Operational and Implementation Aspects
3.4.3.1 Operational Modes
Each of the three boilers can be in either balancing mode, backup balancing mode, or fixed
production mode. Selection is made by the operator through switch HS-401. The boiler in
backup balancing mode operates as it is in fixed production mode, but switches to balancing
mode when the boiler in balancing mode trips. The boiler in fixed production mode switches
in this case automatically to backup balancing mode through HS-401. In case that the boiler
in backup balancing mode trips, the boiler at fixed production will be set to backup balancing
mode automatically, through HS-401.

3.4.3.2 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.
3.4.3.6 Calculations
N/A.
3.4.3.7 Initialisations
When the switch Y-100, Y-200, or Y-300 switches from UC-401 to the corresponding manual
input station (HIC-100, HIC-200 or HIC-300 respectively), the HIC shall absorb any
difference to ensure bumpless transfer.
3.4.3.8 Interfaces
Trip signal 151UZ-HOLD from boiler A-15101, trip signal 151UZ-HOLD from boiler A-15102
and trip signal 151UZ-HOLD from boiler A-15103 shall be connected to switch HS-401.
When a boiler trip signal is received, the output of the respective manual input station
(HIC-100, HIC-200 or HIC-300 for boilers A-15101, A-15102, A-15103 respectively) shall be
set to 0%. The respective switch (Y-100, Y-200 or Y-300) shall be switched to select the
input from the manual input station. See for further functional requirements paragraph
3.4.3.1, Operational modes.
3.4.3.9 Operator Interfaces
The operator can access UC-401, HIC-100, HIC-200 and HIC-300 only through the normal
DCS interface.
3.4.3.10 Special Considerations
The manual input stations HIC-100, HIC-200 and HIC-300, and controller UC-401 shall have
high and low output limits at 180 ton/h steam and 72 ton/h steam respectively.
Controller UC-401 shall have a proportional only PID algorithm.
3.4.4 History
Date Author Description

09-05-2006 GRI Original Document
3.5 SHP/HP STEAM DESUPERHEATER, J-15101A/B, PRESSURE CONTROL
PICA-063, PICA-014, PY-014, TICA-005, HS-023
UFS
E-15100-TN-2396-0001 Deaerator and SHP Steam Production
E-15100-TN-2396-0003 HP Steam Distribution
UEFS
E-15100-TN-2395-0006 SHP/HP Steam Desuperheaters
3.5.1 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
steam, regardless of the Desuperheater load.
The protective pressure controller PICA-069 protects the SHP steam header against high
pressure. Pressure controller PICA-069 operates one of the control valves PICA-014CVA/B,
which manipulates the SHP/HP steam letdown flow through the SHP/HP Steam
Desuperheater J-15101A/B.
The protective pressure controller PICA-014 protects the HP steam header against low
pressure. Pressure controller PICA-014 also operates one of the control valves
PICA-014CVA/B.
Both the controllers PICA-069 and PICA-014 send the output signal to the high signal
selector PY-014, which in turn selects one controller to operate one of the control valves
PICA-014CVA/B.
The temperature controller TICA-005 operates one of the control valves TICA-005CVA/B,
which manipulates the HBFW flow to the SHP/HP Steam Desuperheater J-15101A/B.
With manual selector swith HS-023 the operator is able to select the right control valves,
corrresponding to the SHP/HP Steam Desuperheater J-15101A or J-15101B in operation. In
case manual selection HS-032 switch is in position “J-15101A”, the high signal selector
PY-014 sends a signal to control valve PICA-014CVA and temperature controller TICA-005
sends a signal to control valve TICA-005CVA.
Otherwise when manual selection switch HS-023 is in position “J-15101B”, the high signal
selector PY-014 sends a signal to control valve PICA-014CVB and temperature controller
TICA-005 sends a signal to control valve TICA-005CVB.
Control Valve
Tag Name Alg Action PV-Tracking Name
PICA-069 PID Direct No -
1
PICA-014 PID Reverse No -
PY-014 H-SEL - - -

TICA-005 PID Direct Yes -

2
HS-023 - - - TICA-005CVA/
PICA-014CVA
3
HS-023 - - - 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”.
This control scheme is required to be operational during start up and normal operation.
3.5.3.2 Start up
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
AUTO.
If the SHP steam header pressure measurement PI-069 is BAD, the mode of the pressure
controller PICA-069 shall be set to MAN and its output shall be frozen.
If all HP steam header pressure measurements PI-012A/B/C are BAD, the mode of the
pressure controller PICA-014 shall be set to MAN and its output shall be frozen.
If the HP steam header temperature measurement TI-005 is BAD the mode of the
temperature controller TICA-005 shall be set to MAN and its output shall be frozen.
3.5.3.5 Shutdown
N/A.
To prevent the protective pressure controllers PICA-069 and PICA-014 from winding-up,
apply external reset feedback from the output of low signal selector PY-014, when not
selected.
3.5.3.8 Interfaces
N/A.
Operator can access tags on the DCS.

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

10-03-2006 RVO Original Document

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
7. The configuration of the DCS (by Yokogawa) will be done via the NEM logics and the “Shellified”
P&ID’s made by J.V. We will send you our “Shellified” P&ID’s so that you know how we understand
and interpret your intended control and safeguarding.

3.6 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
The boiler operates at single pressure with natural circulation and is fed by FW pumps.
The operation of the boiler and its associated equipment is carried out by the following
systems:
System DCS Local panel

Boiler control/start/stop emergency stop
Fuels/Burners/atomizing control/start/stop start/stop
FD fan (incl. ST) control/start/stop start/stop
Motor drive FD fan start/stop start/stop
Seal and cooling air fan start/stop
Sootblower start/stop
The boiler is designed for operation from the plant CCR. At the boiler and FD Fan local
panel only start-stop of the burners and FD fan unit is possible. Control and monitoring of the
boiler is performed by the DCS. The safeguarding with interlocks is integrated in the plant
ESDS (including BMS). All relevant signals in the ESDS are also monitored in the DCS.
The detailed procedure on the start-up and shutdown, and operation of the burners can be
found in the following documents:
Burner System Description: 36005-824-04-148
Logic Diagrams: 36005-824-04-304-001
Cause and Effect Diagram: 36005-824-04-307
Logbook
The boiler is operated through a DCS. This DCS is capable to supply interactive
communication between the operators and the installation. It also supplies trends of process
values and stores a database of previous operating conditions and boiler status. The owner of
the boiler is obliged to register all relevant data of the boiler in a logbook.
As a minimum the different operating situations are noted: HP steam header conditions, boiler
start/stop, boiler load, boiler steam conditions, fuel and air flow conditions, malfunctioning of
systems/equipment and other process conditions.

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)

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

Cold start-up and shut down 2000 boiler at ambient conditions
Performance
The boiler is designed to meet the performance as noted in NEM’s Performance Table
documents 36005-103-01/36005-103-38. For these documents it is referred especially to the
cases ECR (100% MCR, guarantee) and ECR (70% MCR, normal).
At MCR the steam production of each boiler is 180 t/hr. The boiler turn down range is 40 –
100% MCR load. The steam temperature is controlled for 40 – 100% MCR load.
Dynamic Characteristics
The boiler is designed to follow boiler load fluctuations during normal operation. However, the
boiler pressure and temperature gradients may never exceed the allowable values.
Degree of Automation
The degree of automation is described in more detail in the chapters below.
Protection Concept
Dangerous situations shall be avoided by safety relief valves and by the safety oriented
protection system.
Control System Requirements

The control of the boiler shall be realized with a control system, which is commonly used in
power plants. The control system shall be capable of handling the dynamics of the system
without limiting the performance.
Environmental Conditions
The boiler is located outdoors.
Reference documents
DEP 32.24.20.38-Gen
Standard drawing S24.030-C

3.7 BOILER COMBUSTION AIR CONTROL
HLA10AA001 (IGV FD Fan), FC-202B (Combustion Air), QC-021 (Oxygen)
P&ID
36005-105-02 Fluegas System
PCD 111
UEFS
E-15100-TN-2395-0031 Steam Boiler Package A-15101 – Flue Gas System
3.7.1 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.
The desired boiler load is compared with the total measured fuel and air flow load in a minimum
respectively maximum value selector. The operator has to select the control mode for the fuels
(one fuel in fixed load mode, one fuel in control mode or both fuels in control mode and
atomization medium (if applicable).
The min/max selection takes care for having under all load conditions, and during load increase
and decrease that the air/fuel ratio is held on a predefined value to assure proper and complete
burning. This is achieved during load increase by determination of the desired fuel flow via the
measured air flow and during load decrease by determination of the desired air flow via the
measured fuel flow. The air flow is controlled by the IGV of the FD Fan using the air flow
measured in the FD Fan suction duct.
When firing fuel oil the total fuel load is composed from the measured ECR/CGO flow and
atomizing gas flow. During dual fuel firing the measured total fuel load is composed from the
measured ECR/CGO flow and added with the measured NG flow and atomizing gas flow.
When firing oil and gas together the required air/fuel ratio for oil will be used to determine the
required air flow.
To control the air/fuel ratio under all operating situations in a correct manner the following
corrections are incorporated:
• Boiler load
• Number of burners in operation
• Number of air doors not closed opened
• Fuel temperature (HOLD)
• Igniter in operation (HOLD)
• Variations in heating value (HOLD)
• Natural Gas density (HOLD)

Please briefly describe all calculation blocks, switches, High or Low Selectors, etc.
DCS – Analogue Control Valve

Tag name Service Action PV-Tracking Name
FC-202B PID Direct No FICA-202
QC-021 PID Direct No
Y-202A Automatic start - No -
up function
NOTE:
DCS - Discrete Control

Tag name Service Limit Action Valve/Controller
HS-204 Switch to gas or steam PDIC- Operator PDIC-216 or
atomising. 216/PC- PDIC-227
216 or
Calculation to Combustion air PDIC-
equivalent is dependant on 227/PC-
atomisation. 227 are on
AUTO
NOTE:
IPS - Discrete Control

FZA-201 Combustion Air flow LL Boiler trip Natural gas
Fuel Oil
Atomising valves
1)
NOTE: IPS (SIL1)
This control scheme is required to be operational during start up and normal operation and
shutdown.
3.7.3.2 Start up
At starting of the boiler the controllers FC-202B and QC-021 are in MAN mode, output 0%.
When all the burners are started and on AUTO, the controllers FC-202B and QC-021 will be
switched to AUTO and receive their set points from the overall load control.
See also section 3.19
During normal operation controllers FC-202B and QC-021 shall be in AUTO.

Instrument
Tag Name Output Controller Action Output
1)
FZA-201 BAD IPS Boiler trip Freeze
FICA-202 BAD FC-202B Mode to MAN Freeze
TI-201 BAD - - Freeze
PIA-203 BAD - - Freeze
PIA-202 BAD - - Freeze
TIA-203 BAD - - Freeze
2)
QICA-021 BAD QC-021 Mode to MAN Freeze
PI-204 BAD - - Freeze
1)
NOTE: IPS
2)
In JVN Scope
3.7.3.5 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
steamdrum and superheater headers.
Output (y) Input (x1,x2,x3)

TAG Calculation x1 x2 x3
Y-202 y = CY −202 ∗ x1 or x 2 Y-100 TC-202
Boiler load Steam
Low SEL and SP Calculation
% MCR value temp.
stochiometric air equivalent gradient
[kg/h]
FZA-201 y = C 201 ∗ x1 HLA10CF001
1)
N/m2
Conversion to kg/h
FICA-202 y = C 202 ∗ x1 HLA10CF002
1)
N/m2
Conversion to kg/h
HY-261A 6 NG burner in CO burner
n = ∑1 (x1 + x 2) operation in operation
n burners in operation
HY-261B y = ( x1 − x 2) ∗ C 261B Number of air Air doors Correction
doors not closed value
Air flow leakage correction for n
C261B
air doors closed
HY-261C y = ( x1 − x 2) ∗ C 261C Number of Air doors Correction
NG/CO not closed value
Air flow leakage correction for n
burners in C261C
air doors not closed and n
operation
burners in operation

HY-261D y = x1 + x 2 + x3 HY-261A HY-261B HY-261C

Total air flow leakage correction
for n air doors not closed and n
burners in operation
HY-261E y = x1 / x 2 HY-261D HY-261A
Air flow leakage correction
factor for n air doors not closed
and n burners in operation
HY-260A y = C1260 A ∗ x1 + C 2 260 A Y-202
Boiler load
Excess air depending on boiler % MCR value
load [%MCR]
HY-260B High SEL in case of combined Minimum Minimum
fuel firing excess air excess air
factor for NG factor for
CO
HY-260C High SEL excess air factor HY-260A HY-260B
HY-260D Low SEL excess air factor HY-260C Maximum
Excess air
factor
HY-260E High SEL excess air factor HY-260D QY-021C
FY-202A y = x1 / x 2 FICA-202 FY-502D
Calculation Air/Fuel Ratio
HY-202B y = x1 * x 2 HY-260 HY-261E
Calculation total excess air
factor
FY-202B y = x1 / x 2 FICA-202 HY-202B
Calculation stochiometric air kg/h
requirement
FY-202C y = x1 * x 2 HY-202B FY-211B
SP calculation air requirement kg/h
FY-211A Low SEL or SP and PV Y-202 FY-202B
combustion air equivalent kg/h kg/h
FY-211B High SEL or SP and PV of total Y-202 FY-205D
combustion air equivalent kg/h kg/h
FY-205A y = x1 * C NG * (C COG , C COS FI-207 HC-205B HC-
kg/h CNG 206C/D/E
or C NO ) CCOG, CCOS
Combustion air equivalent or CNO
atomizing gas, steam or no
atomising
FY-205B y = C NG ∗ x1 ∗ 1000 FIC-205 HC-205B
t/h CNG
Combustion air equivalent NG
FY-205D If firing mode is COMBINED: FY-205B FY-206B
y = x1 + x 2 kg/h kg/h
if firing mode is NOT
COMBINED:
y = High SEL( x1, x 2). #
burners
FY-206B y = C CO ∗ x1 FIC-206 HC-206B
kg/h CCO
Combustion air equivalent CO

FY-212A y = x1 − x 2 FY-211A FY-205B

Combustion air equivalent CO kg/h kg/h
FY-212B y = x1 − x 2 FY-212A FY-205A
Combustion air equivalent kg/h kg/h
correction for atomizing gas
FY-212C y = x1 − x 2 FY-212G FY-206B
Combustion air equivalent NG kg/h kg/h
FY-212D y = x1 / C CO FY-212B HC-206
kg/h CCO
Calculation stochiometric air
flow to CO flow in kg/h
FY-212E y = x1 / C NG FY-212C HC-205
kg/h CNG
Calculation stochiometric air
flow to NG flow in kg/h
FY-212F y = ( x1 − x 2) / 1000 FY-212E FY-206A
NG flow correction for atomizing kg/h kg/h
gas flow in t/h
FY-206A y = x1 ∗ (C OG or C OS ) FI-207 HC-206C/D
kg/h COG or COS
Contribution atomizing medium
QY-021 y = C1021 ∗ x1 + C 2 021 Y-202
Boiler load
O2 vol % depending on boiler
% MCR value
load [%MCR]
QY-021B Low SEL excess air factor QC-021 Maximum
excess air
QY-021C High SEL excess air factor QC-021B HY-260B
HY182n y = C CON . f CON ( x1) 1) HC182
HY182g y = C COG . f COG ( x1) 1) HC182
Please consider to use the
output of flowmeter installed in
gas atomizing line
1)
NOTE: Square root operation in DCS
Ranges
TAG Description Range Units
FC-202B Combustion air Controller 30 - 100 %
QC-021 Oxygen outlet boiler controller 0-2 Excess Air
Y-202 Calculation block combustion air 0 – 216000 Equivalent
comb. Air
[kg/h]
NOTE:

Alarms
TAG Description Level Value Units
FICA-202 A- Indication 108000 kg/h
PIA-203 A+ Indication 90 mBar(g)
PIA-202 A+ Indication 30 mBar(g)
PIA-202 A- Indication -10 mBar(g)
TIA-203 A+ Indication 390 °C
TIA-204 A+ Indication To follow °C
QICA-021 A- Indication 1.1 %
FA-202A A+ Indication 1.6 -
FA-202A A- Indication 1.05 -
NOTE:
Trips
FZA-201 Z-- IPS – SIL1 90000 kg/h
FZA-201 A- HOLD IPS – SIL1 108000 kg/h
FZA-202A Z-- ?????????? 1.0 -
NOTE:
Settings
TAG Description Value Units
HC182 Lower Heating Value common By JVN MJ/kg
Oil
CY-202 Conversion from MCR value to 2016 kg/h
CA equivalent flow
C201 Conversion from ∆p To follow Kg/s/√(bar)
measurement to flow in kg/h HOLD
C202 Conversion from ∆p To follow Kg/s/√(bar)
measurement to flow in kg/h HOLD
HC-205B CNG Stochiometric air flow factor 16.4 -
CNG
HC-206B CCO Stochiometric air flow factor 13.0 -
CCO
HC-206C CCOG Calculation factor for gas 1 -
CCOG atomization
HC-206D CCOS Calculation factor for 0 -
CCOS steam atomization
HC-206E CNO Calculation factor for no 0 -
CNO atomization
C261B Air flow factor for cooling when 0.1 -
air door is closed (leakage)
C261C Air flow correction factor for air 1.1 -
door is not closed but burner out
of operation (flame front
resistance)
C1260A Conversion for excess air -0.0137 -
depending on boiler load
[%MCR]

C2260A Conversion for excess air 2.05 -

depending on boiler load
[%MCR]
C1021 Conversion for O2 % depending -0.16 -
on boiler load [%MCR]
C2021 Conversion for O2 % depending 12.7 -
on boiler load [%MCR]
HS-021 O2 vol % 1.1 (min.) % (vol)
7.0 (max)
C502b Influence of firing mode on To follow %
excess air
CCOG Conversion factor from PV CO To follow -
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
With SHP steam load controller Y100
During purge, start up and shutdown the air flow through the FD Fan will be limited by
means of a mechanical minimum stop.
The control system and air/fuel ratio computation counts for the number of burners in
operation and number of air doors NOT closed. In case one or more burners are out of
operation the oxygen controller (QC-021) is put to MAN, 0% output. Counting for the burners
will be based on “oil flame on” or “gas flame on” or both signals healthy for individual burner
(see also DEP 32.24.20.38).
If oxygen controller QC-021 is forced to MAN it shall retain its last output setting unless
manually changed by the operator.
3.7.4 History

20-07-2007 HuR/WiH Original Document

3.8 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
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
3.8.1 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.
The measured fuel flow will be compared with the required fuel flow as determined by the
combustion air control system and the output signal will be used to control the fuel by the control
valves PICA-209 and/or PICA-214. In case the fuel pressure becomes too low the master
control will be override by the slave controller and the fuel is controlled at a minimum pressure.
Similarly, when the fuel pressure becomes too high the fuel is controlled at maximum pressure.
The control system will count for the number of burners in operation and the number of air doors
open.
In the DCS the operator has to select the control mode for the dual fuel firing (one fuel in fixed
load mode, one fuel in control mode or both fuels in control mode). Always one fuel shall be in
the AUTO control mode. Depending on the fuel(s) to be fired the operator has also to select from
DCS the atomizing medium (no atomizing, steam or NG atomizing) and fuel ratio.
Selection to start/stop each burner, selection for fuel and atomizing medium can also be made at
the local burner panel.
Atomizing gas or steam will be supplied at a pressure just above the fuel oil pressure. The
atomizing medium amount is controlled by a pressure difference controller. The controller
compares the fuel and atomizing medium pressure and the output signal will adjust the position
of control valves PDIC-216 or PDIC-227. The amount of atomizing steam or atomizing gas
depends on the nozzle characteristic and medium pressure above the fuel oil pressure. The
atomizing gas flow will be used for monitoring and will be used in the fuel/air control of the total
flow of the different fuels.
Before starting on fuel oil the atomizing medium differential pressure control should be on
AUTO. The atomizing medium pressure follows the oil pressure with a pressure difference of
about 1 - 1.5 bar. At low loads (below 30% MCR) the atomizing medium pressure will be
kept on a minimum fixed value.

DCS - Analogue Control Valve

FC-205 PID Direct Yes PICA-209
PC-209A PID Indirect Yes PICA-209
PC-209B PID Indirect Yes PICA-209
FC-206 PID Direct Yes PICA-214
PC-214A PID Indirect Yes PICA-214
PC-214B PID Indirect Yes PICA-214
PDIC-216 PID Indirect No PDIC-216
PDIC-227 PID Indirect No PDIC-227
PC-216 PID Indirect Yes PDIC-216
PC-227 PID Indirect Yes PDIC-227
NOTE:

HS-270 Switch NG to AUTO or MAN SP N.A. Operator PICA-209/
FC-205
HS-269 Switch CO to AUTO or MAN SP N.A. Operator PICA-214/
FC206
HS-227 Switch to gas or steam atomising N.A. Operator PDIC-216/
See general PDIC-227
note 3
Y-209 Automatic set point adjustment for Start PICA-209
start up program
NOTE:

1)
PZA-210 NG pressure too low LL NG trip NG TSO Block
valves
1)
PZA-212 NG pressure too high HH NG trip NG TSO Block
valves
2)
PIA-211 NG pressure low L NG trip if NG TSO Block
NG pressure high H Leak test valves
failed
2)
PIA-232 NG pressure low L Atomising NG TSO Block
NG pressure high H Gas trip if valves
Leak test
failed
1)
PZA-213 CO pressure too low LL CO trip CO + atomizing
TSO block
valves
2)
PZA-215 Atomizing steam pressure too low LL CO trip CO + atomizing
TSO block
valves
2)
PZA-217 Atomizing gas pressure too low LL CO trip CO + atomizing
TSO block
valves
1)
NOTE: IPS (SIL1)
2)
IPS

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
The maximum/minimum Heat Input per burner is:

ECR/CGO 26.7/5.34 MWth
NG 26.7/4.45 MWth
Viscosity for ECR within 8 – 10 CSt @ 190°C.

Viscosity for CGO within 0.8 – 1.3 CSt @ 100°C
Air/fuel ratio for NG minimum 1.075

Air/fuel ratio for ECR/CGO minimum 1.1
Air/fuel ratio for dual fuel firing minimum 1.1
Viscosity
When firing ECR the fuel must heated to 190°C to me et the required viscosity range of 8 –
10 CSt. To ensure a proper combustion the viscosity of the ECR must stay within the
mentioned viscosity range. To meet the required viscosity range ECR may be mixed with
CGO.
Air doors
The burners are equipped with manually operated air doors with limit switches. Prior to start
up all airs doors must be proven open to allow a start up. In case a burner is tripped or taken
out of operation the operator can decide to close the air door of the specific burner. To
operate safely, the control system accounts for the number of burners in operation and the
number of not closed air doors.
Atomizing medium
When firing ECR, CGO or a mixture of ECR/CGO atomizing steam or NG must be available.
Either all burners have gas atomizing or steam atomizing.
Remote or local operation (preliminary)

Following operator limitations are applicable:
• Controls AUTO/MAN only from DCS
• Priority concerning local or remote start/stop is at DCS
• Fuel ratio adjustment only possible from DCS
• Set point adjustments only possible from DCS

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.
•
1)
Dual fuel: ECR/CGO/NG or ECR/NG or CGO/NG, simultaneous on the same burner
•
2)
Dual fuel, simultaneous on different burners
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
ratio requirements for fuel oil.
2)
The burners will be able to fire mixtures of fuels across the boiler (i.e. one on oil, one
on gas, one on oil/gas etc. However this operation mode is not recommended.
Fuel changeover (main to secondary):
Boiler load control mode

The boiler can be operated in load control mode, fixed load mode or balancing mode. In
three operation modes the air and fuel systems are in AUTO mode.
In this case the main fuel flow will be controlled by the boiler load controller.
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. When taking the second fuel in
operation the During start up of the second fuel is on pressure control. Therefore the set
point of the maximum pressure controller (PC209B or PC214B) is lowered to the value
required for start up. The flow controller (FC-205 or FC-206) of the second fuel is in MAN
mode 0% output at a flow set point just above minimum burner load.
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 combustion air control boiler load controller.
With all the required burners in dual fuel mode When the second fuel flow set point is >
minimum, the second fuel control will be changed from pressure to switched to manual flow
control mode by increasing the pressure control set point for the maximum pressure
controller of PC-209B or PC214B to its normal value. By increasing the fuel flow set point of
the second fuel 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 AUTO
mode control has to be switched-over to the second fuel. The main fuel supply to each
burner can be stopped and the changeover is completed.
Boiler fixed flow control

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:
Changeover from NG to steam atomising and v.v. is not permitted during operation with fuel
oil due to the timing to open and close valves, causing flame instabilities and potential flame
out situation.
If a changeover is required the next the general procedure should be followed:

• Changeover the fuel to single firing of NG
• When operate at NG select required atomizing medium
• Changeover to oil or dual fuel firing
Steam Tracing:
Steam tracing will be used to compensate for heat loss of the oil system or avoid clogging of
the oil system when fuel oil is not in service.
When steam tracing is taken into operation following manual actions is required:
• Open shut off valves in oil system
• Open shut off valve in steam line
To allow for thermal expansion of the oil system with steam tracing in operation the manual
operated valves are locked open and pneumatic operated stop valves (UZ-502 and UZ-507)
must be opened by the operator.
HOLD Note: When UZ-507 should be closed than a safety relief valve is required.
3.8.3.2 Start up
To discuss: fuel temperature control (for ECR, ECR/CGO and CGO) prior to start up.
See conference notes April 3, 2007 (mechanical) and several e-mails about this
subject
HOLD: decision by JV
Basically the start up with NG will follow an automatic sequence. The start up with fuel oil will
be done manually.

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
circulation system (JV-scope). To achieve the required conditions for starting the burners the
supplied oil is circulated via UZ-502 and UZ-507. When the oil conditions are good the first
burner can be started.
When starting the boiler the pressure controllers PC-214A and PC-214B are in AUTO. Flow
controller FC-206 is in MAN mode output 0%. Controllers PC-227 and PDIC-227 or PC-216
and PDIC-216 are in AUTO (depending on selection atomizing medium). When starting the
first burner the minimum stop at the fuel control valve will ensure sufficient fuel oil to light-off
the burner. The fuel oil return line with valve UZ-507 is open to create flow to be able to
control the fuel oil pressure. This valve will be closed after the first burner is in operation.
The fuel oil control valve is positioned by the operator. The set point of controller PC-214B is
set to a low value corresponding with the required burner start load.
When three (3) burners are in operation at the required load the set point of PC-214B will be
gradually increased to its normal set point (maximum pressure set point). At the same time
flow controller FC-206 is put in AUTO and FC-206 controls the flow at the predefined boiler
load.
During start phase the 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.
During normal operation one the fuel controller shall be in AUTO. The selected atomization
controller is on AUTO in case atomization is effective.

Instrument
FIC-205 BAD FC-205 Mode to MAN Freeze
PICA-209 BAD PC- Mode to MAN Freeze
209A/B
PZA-210 BAD IPS NG trip Freeze
PIA-211 BAD IPS Abort Leakage Freeze
Proofing / NG
trip
PZA-212 BAD IPS NG trip Freeze
FIC-206 BAD FC-206 Mode to MAN Freeze
PICA-214 BAD PC- Mode to MAN Freeze
214A/B,
PDIC-227,
PDIC-216
PZA-213 BAD IPS CO + Freeze
Atomising trip
PICA-227 BAD PDIC-227 Mode to MAN Freeze
PC-217
Atomising trip
PICA-216 BAD PDIC-216 Mode to MAN Freeze
PC-216
Atomising trip
PIA-232 BAD IPS Abort Leakage Freeze
Proofing / CO
+ Atomising
trip
NOTE:
3.8.3.5 Shutdown
Basically shutdown of the boiler has to be done manually by decreasing the boiler load to
20% MCR. As soon as the boiler load is < 20% MCR first the top burners and finally the
bottom burners are stopped consecutively.
When firing in dual fuel mode first the fuel at fixed load must be taken out of operation prior
to boiler load decrease.

FY-205 Low SEL FY-212F HIC-272 HC205A
Limits the maximum flow for NG
FY-206 Low SEL FY-212D HIC-271 HC206A
Limits the maximum flow for CO
PY-209A High SEL FC-205 PC-209A
Limits the minimum flow for NG

PY-209B Low SEL PY-209A PC-209B

Limits the maximum flow for NG
PY-214A High SEL FC-206 PC-214A
Limits the minimum flow for CO
PY-214B Low SEL PY-214A PC-214B
Limits the maximum flow for CO
PY-216 High SEL PDIC-216 PC-216
Limits the minimum atomising
gas pressure
PY-216A y = x1 − x 2 PICA-216 PICA-214
PY-227 High SEL PDIC-227 PC-227
Limits the minimum atomising
steam pressure
PY-227A y = x1 − x 2 PICA-227 PICA-214
NOTE:
Ranges
FC-205 NG Controller 0 – 100 %
PC-209A NG min. pressure controller 0 - 100 %
PC-209B NG max. pressure controller 0 - 100 %
FC-206 CO Controller 0 – 100 %
PC-214A CO min. pressure controller 0 - 100 %
PC-214B CO max. pressure controller 0 - 100 %
PDIC-227 Atomizing steam pressure 0 - 100 %
controller
PC-227 Atomizing steam minimum 0 - 100 %
pressure controller
PDIC-216 Atomizing gas pressure 0 - 100 %
controller
PC-216 Atomising gas minimum 0 - 100 %
pressure controller
Y-209 Automatic set point adjustment HOLD Bar(g)
for start up
NOTE:
Alarms
TIA-222 A- Indication 180 °C
PICA-209 A+ / A- Indication To follow Bar(g)
PIA-211 A+ / A- Indication To follow Bar(g)
PICA-214 A+ / A- Indication To follow Bar(g)
PICA-227 A- Indication To follow Bar(g)
PICA-216 A- Indication To follow Bar(g)
PIA-232 A+ / A- Indication To follow Bar(g)
NOTE:

Trips
PI163 Z++ IPS – SIL1 To follow Bar(g)
PZA-210 Z-- IPS – SIL1 To follow Bar(g)
PZA-212 Z++ IPS – SIL1 To follow Bar(g)
PIA-211 A+ / A- IPS – SILa To follow Bar(g)
PZA-213 Z-- IPS – SIL HOLD To follow Bar(g)
PZA-215 Z-- IPS – SILa To follow Bar(g)
PZA-217 Z-- IPS – SILa To follow Bar(g)
PIA-232 A+ / A- IPS – SILa To follow Bar(g)
NOTE:
PZA-213: SIL classification to be defined by JV
Settings
C402 NG flow per ignition burner To follow Kg/s
HC-205A SP NG maximum load To follow t/h
HIC-272 SP NG when in MAN mode By operator t/h
HC-209A SP min. pressure NG To follow Bar(g)
HC-209B SP max. pressure NG To follow Bar(g)
HC-206A SP CO maximum load To follow kg/h
HIC-271 SP CO when in MAN mode By operator kg/h
HC-214A SP min. pressure CO To follow Bar(g)
HC-214B SP max. pressure CO To follow Bar(g)
HC-227A SP steam atomization ∆p 1.5 Bar
HC-227 SP min. atom. steam pressure To follow Bar(g)
HC-216A SP gas atomization ∆p 1.5 Bar
HC-216 SP min. atom. Gas pressure To follow Bar(g)
NOTE:
3.8.3.8 Interfaces
N/A.
During start up and shutdown the position of the following valves will be limited by means of
a mechanical minimum stop (based on one burner at minimum load):
1. Natural Gas control valve
2. ECR/CGO fuel oil control valve
3. NG atomising gas control valve
4. Atomising steam control valve
3.8.4 History


3.9 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)
P&ID
36005-105-03 Economizer System
36005-105-04 Evaporator System
PCD 113
UEFS
E-15100-TN-2395-0032 Steam Boiler Package A-15101 – Economiser System
E-15100-TN-2395-0033 Steam Boiler Package A-15101 – Evaporator System
1. Can “Heat Input On” – LY101d (Y-202) – be taken as a signal from the BMS?
Note: 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:
1. Cold Start-up OK
2. Warm Start-up
3. Hot Start-up
4. Steady Operation OK
5. Shutdown
Furthermore, this control block receives a signal from the BMS which equals the steam boiler
load at that time.
Note: NEM expect the signal from DCS
This control block will send the following signals:
1. Signal to drum level controller to inform wether the boiler load is above or below 10% MCR
(i.e. P-control or P&I–control). OK
2. Signal to FS-103, which opens/closes ON/OFF valves HAD15 AA001 and HAD15 AA002.
3. Signal to temperature controller LAB10 CT003 (TIC-207) OK
4. Signal to pressure controller LBA10 CP001 (PC-207) (SHP Steam line) OK
3.9.1 Objective
Drum level
The drum level control has the objective to maintain the required drum water level within the
specified limits, irrespective of load fluctuation and during start-up and shutdown procedures.
This is to avoid evaporator damage due to a lack of water or steam system damage due to water
carry over. Excessive boiler water shall be dumped with the blow off valve HAD10 AA471 (LICS-
202A) to the intermittent blowdown drum.
Economizer inlet temperature

Due to the firing of sulphur containing fuels the flue gas leaving the boiler can cause corrosion to
the ducting and tubes if the flue gas temperature becomes too low. Therefore the feedwater
temperature at the inlet of the external economizer is controlled at minimum level by mixing hot
and cold feedwater. By raising the feedwater temperature the flue gas temperature to the stack
will also increase which avoid sulphur dew point corrosion.
The mixed temperature will be controlled at a set point of 150°C.

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.
Changeovers from start level to normal level and from normal level to start level, when the boiler
is taken out of operation, are part of the start-up or shutdown procedure.
Automatic set point adjustment to be incorporated by JV
During start of the boiler when no steam is leaving the drum, drum level control should be
proportional to avoid too high levels as a result of the integrator action. When the steam flow is
higher than 10 % of MCR the controller is changed over to Proportional and Integral control
(P+I). signal from BMS is send to Control Block 151US-230 “Steam Boiler Start-up &
Shutdown”. From this block, a signal is send to LY101c. NOT CLEAR
When the drum level exceeds the highest allowable level the feedwater supply will be shut-off by
closing valve LAB10 AA010 (LZA-201). Upon trip by LZA-201 High High, controller FICA-203 to
MAN, output to 0%.
Economizer inlet temperature

To control the feedwater temperature at the economizer inlet the total flow coming from the
feedwater system is divided into two flows. One part will pass through the feedwater control
valve LAB10 AA022 (TIC-207A) while the other (smaller) part flows through control valve LAB10
AA032 (TIC-207B) which is heated in the feedwater pre-heater LAD10 AC001 in the drum. The
flows will be joined upstream of the external economizer to get a uniform mixed temperature.
Interaction between both control loops

Variations of drum pressure and drum level will have effect on both control valves. Variation of
the drum pressure will cause a variation in drum temperature and consequently also the
feedwater temperature at the outlet of pre-heater LAD10 AC001. To control the feedwater
temperature at 150°C the flow through LAB10 AA032 (TIC-207B) will change. This effect will
change the total feedwater flow and drum level, but is compensated by the feedforward and/or
drum level control.
Variations of the drum level will cause a change of the feedwater flow through LAB10 AA022
(TIC-207A). This will also influence the controlled feedwater temperature for the economizer inlet
and hence the flow through LAB10 AA032 (TIC-207B) will also change. To keep the control
loops stable a deviation of the drum level is also forwarded to control valve LAB10 AA032 (TIC-
207B).


LICSA-202 PID Indirect Yes -
FICA-203 PID Direct Yes TIC-207A
TC-207B PID Indirect Yes LZA-201
LY-101b FF balance - Yes -
TY-103a BFW CV - Yes -
correction
NOTE:

XS-203 Switch to activate feedforward - Switch -
control if load > 35 t/h
FS-213 Close eco circulation valves if BFW HH - -
flow is high enough during start-up
FS-213 Close eco circulation valves if BFW H Close US-531
flow is high enough during start-up US-532
FS-213 Open eco circulation valves if BFW L Open US-531
flow becomes too low during US-532
shutdown
NOTE:

1)
LZA-201A Steam drum level too high HH Close LZA-201
1)
LZA-201B
1)
LZA-201C
2)
LZA-201A Steam drum level too low LL Boiler Trip Natural gas,
2)
LZA-201B Fuel Oil and
2)
LZA-201C Atomising TSO
valves
1)
NOTE: SIL 1
2)
SIL 2
3.9.3.2 Start up
During start up of the boiler control valve LAB10 AA032 (TIC-207B) will be forced to close.
When the boiler load < 15% the output of temperature controller TC-207B and control valve TIC-
207B is in MAN mode, output 0%
We have put it on the P&ID as follows:
• In Control Block 151US-230 “Steam Boiler Start-up & Shutdown”, the steam boiler mode
is selected by operator. In case of start-up, a signal is send from control block 151US-
230 to temperature controller LAB10 CT003. When 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
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.
During normal operation the temperature controllers LICSA-202, FICA-203 and TC-207B
shall be in AUTO.
Instrument
FT-203 BAD FICA-203 Mode to MAN Freeze
TICA-207 BAD TC-207B Mode to MAN Freeze
1)
LZA-201A BAD - - Freeze
1)
LZA-201B BAD - - Freeze
1)
LZA-201C BAD - - Freeze
LT-202A BAD LICSA-202 3oo3: Freeze
LT-202B BAD Mode to MAN Freeze
LT-202C BAD Freeze
PIA-206 BAD LICSA-202 - Freeze
1)
PT-205 BAD - - Freeze
PICA-207 BAD - - Freeze
FI-204 BAD FICA-203 Mode to MAN Freeze
TICA-217 BAD - - Freeze
1)
NOTE: IPS
3.9.3.5 Shutdown
When the boiler is shutdown and burners are out operation the drum level set point has to be
gradually decreased from NL to SL.


1)
FY-204 y = C 204 ∗ x1 ∗ ρ ( x 2, x3) / ρ design FI-204 PICA-207 TICA-217
t/h
Pressure and temperature correction
for steam flow
LY-202 y = MeanValue( x1, x 2, x3) LT-202A LT-202B LT-202C
mmwc mmwc mmwc
LY-202A y = LevelCorrection( x1, x 2) 2)
PIA-206 LY-202 -
Bar(g) mmwc
LY-202B y = Setpo int Level ( x1) 3)
HEAT
INPUT ON
LY-202C y = x1 + x 2 LY-202B FY-204A
t/h t/h
FY-203 y = x1 ∗ ρ ( x 2 , p d ) / ρ (t d , p d ) FT-203 TI-205
t/h
Temperature correction for feedwater
4)
flow
LZA-201 y = 2oo3( x1, x 2, x3) LZA-201A LZA-201B LZA-201C
mmwc mmwc mmwc
LZA-201 y = LevelCorrection( x1, x 2) 2)
PT-205 LZA-201 -
Bar(g) mmwc
LY-206 y = x1 + x 2 FY-210 LICSA-202
t/h t/h
TY-207A y = x1 − x 2 FICA-203 TC-207B
% %
TY-207B y = x1 + x 2 FICA-203 TC-207B
% %
TY-207C y = x1 − x 2 HC-207C TC-207B
% %
FY-210 y = x1 + x 2 FY-204 FI-210
t/h t/h
1)
NOTE: Square root operation in DCS
2)
Calculation is drum connection layout dependant. Will be supplied on separate sheet
3)
If burners are out of operation the level set point is at (low) start level (SL).
During normal operation the level set point is at NL. During start-up the set point is
raised from SL to NL. During shutdown from NL to SL.
4)
Uncorrected flow (t/h) is calculated in vortex transmitter.
Ranges
FY-204A D-action anti swell HOLD t/h
compensation
LICSA-202 Level Controller 0 – 180 t/h
FICA-203 BFW flow controller 0 - 100 %
TC-207B Temp. Controller 0 – 100 %
NOTE:

Alarms
FY-203 A+ Indication 190 t/h
LZA-201A A- Indication -150 mm
LZA-201B A- Indication -150 mm
LZA-201C A- Indication -150 mm
LT-202A A- Indication -150 mm
LT-202B A- Indication -150 mm
LT-202C A- Indication -150 mm
LT-202A A+ Indication +150 mm
LT-202B A+ Indication +150 mm
LT-202C A+ Indication +150 mm
LZA-201A A+ Indication +150 mm
LZA-201B A+ Indication +150 mm
LZA-201C A+ Indication +150 mm
PIA-206 A+ Indication 135 Bar(g)
PIA-206 A- Indication 0 Bar(g)
NOTE:
Trips
LZA-201A Z-- SIL2 -525 mm
LZA-201B Z-- SIL2 -525 mm
LZA-201C Z-- SIL2 -525 mm
LZA-201A Z++ SIL1 +295 mm
LZA-201B Z++ SIL1 +295 mm
LZA-201C Z++ SIL1 +295 mm
NOTE:
Settings
C204 Flow constant for conversion to To follow -
t/h Type flow
measuremen
t not decided
yet
ρdesign Density at design parameters To follow Kg/m3
flow element Type Flow
measuremen
t not decided
yet
pd Boiler feedwater pressure in 158 Bar(a)
design case
td Boiler feedwater temperature in 117 °C
design case
FS-213 (HH) BFW flow high enough to switch 35 t/h
over to feedforward control
1)
FS-213 (H) BFW flow high enough to close 15 t/h
eco circulation valves
2)
FS-213 (L) BFW flow low enough to open 12 t/h
eco circulation valves

FY-203A Gain for TIC-207A HOLD -

FY-207D Gain for TIC-207B HOLD -
FY-207E Gain for TIC-207A HOLD -
LY-202B Normal level (from centerline) -25 mm
LY-202B Start level (from centerline) -400 mm
HC-207B SP BFW temp. before ext. eco 150 °C
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 Interfaces
N/A.
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
part of the evaporator system and so temperature differences between economizer and
evaporator will be negligible. When the measured feedwater flow comes above a predefined
value the valves have to be closed. In case of a shutdown the valves have to be opened
when the measures feedwater flow falls below the predefined value.
This function is defined via Steam Boiler Start-up & Shutdown Block 151US-530.
3.9.4 History


3.10 BOILER START-UP PRESSURE CONTROL
LBA10AA051 (PICA-207), PC-207, TC-254
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
3.10.1 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)
The Operator can select the above the above mentioned modes in the “Steam Boiler Start-
up & Shutdown” control block 151US-530 via selector switch 151HS-265:
• Start up
• Normal operation (connected to steam grid)
This selector switch is represented by PY-265A and PY-265B shown at PCD115
Incoming signals to this control block are:

• Operation mode (selector switch 151HS-265)
• Boiler load (% MCR) from BMS 151UZ-500 FROM DCS? JV TO CHECK
• Operating pressure ‘Main Steam Line’ – 151PICA-207 JV TO CHECK
• Operating temperature ‘Main’ Steam ‘Line’ – 151TICA-217 JV TO CHECK
Signals from this control block are sent to:

• Pressure controller 151PICA-207
• Level controller 151LICSA-202/calculation block 151LY-202B
• BFW Flow Switch FS103 (151FS-xxx)
• BFW Temperature controller 151TIC-207
Furthermore, an indication is given when the boiler is (still) in start-up mode or is at normal
operation. Normal operation is considered if the following conditions are met:
• Normal operating pressure is reached
• Normal operating temperature is reached
• Boiler load between 40 and 100% MCR
• Boiler connected to the SHP steam grid
Furthermore the Operator has to input the:

• ‘Pre-safety pressure’ (i.e. pressure at which the vent valve opens in order to avoid too
quickly open of the safety releief valve(s)
• Intended pressure when Steam Boiler is connected with the SHP Steam grid

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.
• Pre-safety function in case of too high steam pressure. (HOLD)
• Limiting too low pressure when the boiler is shutdown (prevent vacuum conditions)
(HOLD)
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 start-
up 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.
The start-up sequence is ended when all of the following conditions are met:
- Normal operating pressure is reached
- Normal operating temperature is reached
- Boiler load at 40% MCR
- Start up valve controls steam pressure at set point (normally 120 bar(g))
After or during start-up phase the main steam line and common grid can be pressurized and
pre-heated by opening of valve LBA10 AA005 (manually). At the moment that the pressure
difference over main steam valve LBA10 AA003 (MOV-201) is lower than 2 bar the main
steam valve will be released to be opened (manually by the operator). The start up valve
controls the boiler steam pressure through pressure controller PC-207. When there is a
steam demand of the grid the boiler steam pressure tends to decrease but will be kept
constant by further closing of the start up valve. When valve MOV-201 is open and start up
valve (PICA-207) is closed the master control system has to be released to control the boiler
load (boiler steam pressure or flow control) and output of controller PC-207 is put to MAN,
0%.
When LBA10 AA051 is closed the set point will be increased to a value of Y bar above the
actual set point of the main steam pressure.
DCS – Analogue Control Valve

TC-254 PID Indirect No -
PC-207 PID Direct Yes PICA-207
Temperature Low output Yes PICA-207
gradient steam limitation
1)
drum too steep
Ramp-up High output Yes PICA-207
pressure too limitation
1)
slow
1)
NOTE: See explanation at section start up

DCS – Discrete Control

HS-201 Permission to open main steam L Permission MOV-201
block valve MOV-201 if
pressure difference is low
enough
XY-207 Automatic set point switch-over See settings Switch + PC-207
for start-up with timer timer
HS-265 Switch set point during start-up See section SP change PICA-207
sequence initializations
HS-098 Switch input signal to PDS-204 See JVN
from PICA-070 or PICA-071 section
NOTE:

N.A.
NOTE:
3.10.3.2 Start up
At starting of the boiler the set point of the pressure controller PC-207 is set switched to an
appropriate value depending on the remaining pressure in the boiler the mode which is
selcted by the Operator in Steam Boiler Start-up & Shutdown block 151US-530 (i.e. Cold
Start-up, Warm Start-up or Hot Start-up, CHECK). The heat input will cause steam
production and a pressure/temperature raise in the boiler. This raise is limited by the
allowable steam drum water/steam temperature gradient and superheater (outlet Sec. SH)
steam temperature gradient. Controller TC-254 will force open or limiting the start up valve
position and so prohibiting controller PC-207 to close the start up valve under a certain
value. On the other side opening of the start-up valve must be not too much to keep the
start-up time limited. At the moment this limitation is reached the set point of PC-207 is
switched to that pressure value at which the boiler needs to be connected to the steam grid.
The maximum opening restriction HY-264 is switched-off when the steam pressure has
reached the set point value.
Controller PC-207 will be switched to MAN, 0% output when:
• Valve PICA-207 is closed and
• Valve MOV-201 is open
For steam temperature gradient see section 3.11

For start up see also section 3.19
During normal operation pressure controller PC-207 shall be in MAN, output 0% AUTO at a
value of Y bar above normal operating pressure. Temperature controller TC-254 shall be in
AUTO.

Instrument
PIA-206 BAD TC-254 Mode to MAN Freeze
PICA-207 BAD PC-207 Mode to MAN Freeze
PICA-070/ BAD Y-100 Mode to MAN Freeze
PICA-071
NOTE:
3.10.3.5 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.

TY-251A d ( x1) 2) TY-251
y=
dt
TY-251B y ≤ f max ∗ x1 + c max 1) PIA-206
Bar(g)
TY-251C y ≥ f min ∗ x1 − c min 1) PIA-206
Bar(g)
TYA-254 (H) x1 ≥ x 2 1) TY-251A TY-251B
°C/min °C/min
TYA-254 (L) x1 ≥ x 2 1) TY-251A TY-251C
°C/min °C/min
PDS-204 x1 − x 2 ≤ dP 1) PICA-207 PICA-070/
PICA-071
PY-265A High SEL HC-265A HC-265B
Start up steam pressure
PY-207A Low SEL PC-207 HY-264
Start up valve opening limited
PY-207B High SEL PY-207A TC-254
Start up valve opening limited
PY-264 High SEL PICA-207 PY-
SP reached then start up valve 265A/B
opening limiter removed
HY-264 Start up valve opening limiter PY-264
1)
NOTE: See settings.
2)
Sampling time may be up to one minute.
Ranges
PC-207 Boiler pressure Controller 0 – 100 %
TC-254 Steamdrum temp. gradient 0 – 100 %
controller
NOTE:

Alarms
PICA-207 A+ Indication 130 Bar(g)
PICA-207 A- Indication 115 Bar(g)
TYA-254 A+ Indication See °C/min
High Load calculations
increase
TYA-254 A- Indication See °C/min
Low Load calculations
decrease
NOTE:
Trips
N.A.
NOTE:
Settings
fmax Gradient for drum temperature 0.0538 -
increase (start up)
cmax Gradient for drum temperature 7 °C/min
increase (start up)
fmin Gradient for drum temperature 0.0577 -
decrease (shutdown)
cmin Gradient for drum temperature 8 °C/min
decrease (shutdown)
dP Permission to open main steam 2 Bar
valve (MOV-201) if pressure
drop across valve is low enough
HC-265A Min. SP steam pressure at cold 2 Bar(g)
start-up (PICA-207)
HC-207 SP steam pressure start-up 120 Bar(g)
(PICA-207)
XY207timer Timer to switch PC-207 from 30 seconds
MAN to AUTO
AC-265B SP steam pressure at start up 0 - 125 Bar(g)
Automatic switch puts the
measured pressure (PICA-207)
in memory (set point) when the
first burner is started.
PY-265A Boiler Steam outlet pressure at Actual Bar(g)
start-up (PICA-207) pressure
PY-265B Intended boiler steam outlet 120 Bar(g)
pressure to connect with steam
grid
PY302c Pre-safety pressure 125 (HOLD) Bar(g)
HY-264 Maximum valve opening during 30 %
start-up
NOTE:

3.10.3.8 Interfaces
N/A.
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


3.11 BOILER STEAM DESUPERHEATER TEMPERATURE CONTROL
LAE10AA014 (TICA-214), TC-212, TC-214

LAE20AA014 (TICA-215), TC-215, TC-215B
TC-202
P&ID
36005-105-05 Superheater System
PCD 116
UEFS
E-15100-TN-2395-0034 Steam Boiler Package A-15101 – Superheater System
3.11.1 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
525°C.
For steam temperature control two cascade control loops are used. The first controller
controls the final steam temperature at the outlet of the tertiary superheater by means of
control valve LAE20 AA0014 (TICA-215). The second controller is controlling the steam
temperature at the outlet of the secondary superheater by means of control valve LAE10
AA0014 (TICA-214).
Both control loops are controlling the steam temperature in such a way that the total spray
water flow to control valves LAE10 AA014 (TICA-214) and LAE20 AA014 (TICA-215) is as
much as possible divided equally over both control valves. The set point to control the steam
temperature at outlet of the secondary superheater will be load dependent. The firing/steam
unbalance occurs during load variations where the fuel input is not corresponding with the
steam pressure. The firing/steam unbalance will be used as a feed forward signal to both
control valves to anticipate on load variations.
The effect of the firing/steam unbalance can be adjusted by the gains TY-253A and TY-
253B.
To avoid entrance of not evaporated water into the superheater sections behind the
desuperheater the set point of both controllers is limited such that the steam temperature will
not become lower then a predefined value above saturation temperature. Also when the
steam temperature at the outlet of both desuperheaters becomes too high the steam
temperature will be limited.
In case the steam temperature falls below its minimum the spray water supply will be shut-
off by closing valves LAE10 AA011 (UZ-552) and/or LAE20 AA011 (UZ-562).
Upon a trip of UZ-550 and/or UZ-560 also controller TC-214 and/or TC-215 will be put to
MAN, output to 0%.
In case the final steam temperature becomes too high the boiler will be tripped.

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.

TC-212 PID Direct Yes -
TC-214 PID Direct Yes TICA-214
TY204a,b FF & SEL - Yes -
TC-215B PID Direct Yes -
TY206a,b FF & SEL - Yes -
TC-202 PID Indirect Yes -
NOTE:

1)
TZA-211 Steam Temperature too close to LL Close UZ-552
saturation.
1)
TZA-213 Steam Temperature too close to LL Close UZ-562
saturation.
No BFW supply LL Close LAE10AA011
Close LAE20AA011
MAN - 0% TC205
1)
TZA-218 Steam Temperature too high HH Boiler trip Natural gas
Fuel Oil
Atomising valves
1)
NOTE: IPS (SIL1)
3.11.3.2 Start up
During normal operation the temperature controllers TC-212/TC-214, TC-215/TC-215B and

TC-202 shall be in AUTO.
Instrument
TICA-214 BAD TC-214 Mode to MAN Freeze
1)
TZA-211 BAD - - Freeze
TIA-212 BAD TC-212 - Freeze


1)
TICA-217 BAD TC-215B Mode to MAN Freeze
1)
1)
NOTE: IPS
3.11.3.5 Shutdown

TY-202A d ( x1) 2) TIA-212
y=
dt
TY-202B y ≤ hmax ∗ x1 + k max 1) PIA-206
(H)
TY-202C y ≥ hmin ∗ x1 − k min 1) PIA-206
(L)
TYA-202 y = x1 − x 2 TY-202A TY-202B
High
TYA-202 y = x1 − x 2 TY-202A TY-202C
Low
TY-252 y = SaturationTemperature(x1) PT-205
TY-251 y = SaturationTemperature(x1) PIA-206
TY-253 ( x 2 − x1) PV SHP PV Fuel
y= steam flow flow (in %)
x1 (in %)
TY-214A y = MAX ( x1, x 2 + ∆TSAT ) TY-214B TY-251
°C °C
High SEL
TY-214B y = x1 − x 2 TC-212 TY-253B
°C °C
TY-214C y = MAX ( x1, x 2) For NG only TY-214A HC-214D
TY-253A y = x1 ∗ G253 A TY-253
TY-253B y = x1 ∗ G253 B TY-253
TY-215A y = MAX ( x1, x 2 + ∆TSAT ) TY-215B TY-251
°C °C
High SEL
TY-215B y = x1 − x 2 TC-215B TY-253A
°C °C

TY-212 y = T (x1) PV SHP

steam (t/h)
y = M ST 1 ∗ x1 + TST 1 ; if ( x1 ≤ 126 t / h)
y = M ST 2 ∗ x1 + TST 2 ; if ( x1 > 126 t / h)
Load(%) Steam(t/h) Temp.

40 72 482
70 126 478
100 180 495
UZ-550 y = CLOSE if ( x1 < x 2 + ∆TSAT ) TZA-211 TY-252

UZ-560 y = CLOSE if ( x1 < x 2 + ∆TSAT ) TZA-213 TY-252
1)
NOTE: See settings.
2)
Sampling time may be up to one minute.
Ranges
TC-212 Master Sec. Superh. Inlet 370 – 400 °C
temperature controller
TC-214 Slave Sec. Superh. Inlet 0 - 100 %
TC-215B Master Tert. Superh. Inlet 440 – 480 °C
TC-215 Slave Tert. Superh. Inlet 0 - 100 %
TC-202 Sec. Superh. Gradient controller 0 - 100 %
NOTE:
Alarms
TICA-214 A- Indication 360 °C
TICA-214 A+ Indication 395 °C
TZA-211 A- Indication 360 °C
TZA-213 A- Indication 360 °C
TZA-218 A+ Indication 535 °C
TYA-202 (H) A+ Indication See °C/min
calculation
TYA-202 (L) A- Indication See °C/min
calculation
NOTE:

Trips
TZA-211 Z-- SIL1 330 °C
TZA-213 Z-- SIL1 330 °C
TZA-218 Z++ SIL1 540 °C
NOTE:
Settings
hmax Gradient for superheater 0.4344 -
temperature increase (start up)
kmax Gradient for superheater 22 °C/min
temperature increase (start up)
hmin Gradient for superheater 0.4098 -
temperature decrease
(shutdown)
kmin Gradient for superheater 55 °C/min
temperature decrease
(shutdown)
∆TSAT Required temperature difference 30 °C
above saturation.
TMAX Maximum temperature outlet 500 °C
secondary superheater
LHV205 Lower heating value NG 47.6 kJ/t
LHV206 Lower heating value CO 39500 kJ/kg
G253A Gain for feedforward signal to HOLD -
temperature control
G253B Gain for feedforward signal to HOLD -
temperature control
MST 1 Flow constant for load -0.08 -
dependent set point
TST 1 Temperature constant for load 488 -
dependent set point
MST 2 Flow constant for load 0.3 -
dependent set point
TST 2 Temperature constant for load 440 -
dependent set point
HC-215B Set point SHP steam 515 - 525 °C
temperature outlet boiler
HC-214D Low SEL (Maximum 380 °C
temperature in case of NG
firing)
NOTE:

3.11.3.8 Interfaces
N/A.
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


3.12 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)
P&ID
36005-105-04 Evaporator System
36005-105-07 Drain System
36005-105-08 Blow Down System
36005-105-09 Sample unit
PCD 117
UEFS
E-15100-TN-2395-0036 Steam Boiler Package A-15101 – Blowdown & Drain System
E-15100-TN-2395-0043 Steam Boiler Package A-15101 – Sample Unit
3.12.1 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.
A continuous blowdown (HAD10 BR460) is provided to control the quality of the drum water and
to avoid scaling on the heat transfer areas of the drum, to avoid foaming and to assure the
quality of the produced SHP Steam.
The boiler intermittent blowdown (HAD10 BR470) might be opened during start up (swell) and is
also opened during normal operation upon a high level in the steam drum.
Industrial water (GAC10 BR010) is supplied to the water outlet of the intermittent blowdown
drum to reduce the water temperate to the sewer.
Condensate:
As condensate can occur during different start up conditions the control valve opening
position is pressure depended. To assure that all condensate is removed the main steam
drain valve LBA10 AA404 (TICA-217) will be closed if superheated conditions have been
reached. The drain valves HAH10 AA404 (FIC-204A) and HAH10 AA424 (FIC-204B) will be
closed when the boiler steam flow becomes > HC-202 t/h (see setting list below)
According to PCD117 these valves close at a certain steam flow. Steam flow is
measured and is pressure and temperature compensated.
TS404 gets a signal from FY102 which is P,T compensated.
Intermittent blowdown:
Intermittent blow down control is used during start-up and in normal operation if the water
level in the drum becomes too high and is carried out by means of a proportional controller.
The set point for this controller is adjusted to the same value as for the drum level high
alarm. The Gain for the controller can be set to 100% divided by the difference between
NWL drum level and drum level H alarm setting HOLD. The intermittent blow down control is
normally designed to allow sufficient blow down when the drum is at low pressure. To avoid
a too high blow down flow when the drum is pressurized the output to the control valve
(HAD10 AA471- LICS-202A) is limited based on the square root of the drum pressure in

C valve
accordance with the formula .
Pdrum
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
AA461.
PENDING Valve HAD10 AA460 (QISA-202) will be opened/closed by the measured conductivity.
Decision by JV
The design blowdown capacity will be < 2% of the maximum economizer flow and is
measured by HAD10 CF101 (FI-210).
Blowdown water temperature:

Blowdown water of 100°C will be mixed with industri al water to limit the temperature to the
sewer system to 50°C. Temperature control of the mi xed flows is achieved by temperature
controller TC-219. A too high temperature will be alarmed.

LC-207 PID Direct No LICS-202A
TC-219 PID Direct No TICA-219
FC-202 PID Direct No FIC-204A/B
TC-217 PID Direct No TICA-217

ZS-202B LC-207 in AUTO if LICS-202B is 100% AUTO LC-207
open
ZS-202A LICS-202B to close if LICS-202A is 0% Close LICS-202B
closed for tIBD-valve
TS-403 Close main steam line drain valve if H Close LBA10AA404
steam flow is enough superheated
during start-up
TS-404 Close superheater drain valves if H Close HAH10AA404
steam flow is during start-up HAH10AA424
LS-207 Open Close IBD block valve LICS- H Open LICS-202B
202B in case the level becomes too Close
high is low enough
QIS-202 Open CBD valve QISA-202 for t202 H Open QISA-202

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

after timer t202 is elapsed.
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:

N.A.
NOTE:
3.12.3.2 Start up
During normal operation the controllers LC-207, TC-219, FC-202 and TC-217 shall be in
AUTO.
Instrument
LIA-203 BAD - - Freeze
FI-210 BAD - - Freeze
LY-202A BAD LC-207 Mode to MAN Freeze
QIA-202 BAD - - Freeze
NOTE:

3.12.3.5 Shutdown

TS-403 y = 0% if ( x1 > TSAT ( x 2) + ∆TSAT LBA10 LBA10
CT001 CP001
else y = 100%
DELETED
TY-217 y = Tsat ( x1) + ∆TSAT ) PICA-207
SP for temperature controller at which
valve TICA-217 is closed
TY-217A C 217 A PICA-207
y=
x1
TY-217B y = MIN ( x1 (digital ), x 2 (digital )) TC-217 TY-217A
Low SEL
TS-404 y = 0% if ( x1 > x%) FY-102
else y = 100%
DELETED
FY-202A C 202 A PIA-206
y=
x1
HOLD
FY-202B y = MIN ( x1 (digital ), x 2 (digital )) FS-202 FY-202A
Output limiter
LY-206A y = x1 + ∆L206 A LICSA-202
Explain
function Signal to open IBD control valve if
drum level exceeds ∆L mm above SP
TS-404 y = 100% if ( x1 > x 2 + ∆L401b ) FY102
else y = 0%
DELETED
PY-207 C 207 PIA-206
y=
x1
HOLD
LY-207 y = MIN ( x1 , x 2 ) LC-207 PY-207
Low SEL
QIS-202 y = 100% ( for t 202 min) QIA-202
if x1 > K 202
else y = 0%
PENDING (decision by JV see

conference notes 2007-04-03)
NOTE:

Please describe:
TY403b Low Selector? NO, is output limiter YES, Low SEL
TY404b Low Selector? NO, is output limiter YES, Low SEL
Ranges
TY-403 Switch close/open 0/100 %
TY-404 Switch close/open 0/100 %
FC-202 Steam flow controller drain 0 - 100 %
valves FIC-204A/B
TC-217 Steam tempeprature controller 0 - 100 %
drain valve TICA-217
TC-219 Industrial water temperature 0 - 100 %
controller
LC-207 IBD level controller 0 - 100 %
NOTE:
Alarms
LIA-203 A+ Indication 1400 mm (above
bottom TL)
QIA-202 A+ Indication 50 µs
QIA-203 A- Indication 9.8 pH
QIA-203 A+ Indication 10.2 pH
QIA-204 A+ Indication 0.15 µs
QIA-205 A+ Indication 0.15 µs
NOTE:
Trips
N.A.
NOTE:
Settings
HC-202 Set point flow controller at which 15 t/h
drain valves FIC-204A/B will be
closed
Cvalve Constant Cvalve is the drum 0.2 Bar(g)
pressure where the control
valve LICS-202A is allowed to
open fully at controller output of
100%
tclose Timer for set point -10% (MAN 60 seconds
0% output) opening IBD control
valve LICS-202A after NWL is
reached

tIBD-valve Timer for to close valve LICS- 60 seconds

202B after IBD control valve
LICS-202A is closed
∆TSAT Required temperature difference 30 °C
above saturation.
C217A Constant which limits opening of To follow √(Bar)
the valve at higher pressures
C202A Constant which limits opening of To follow √(Bar)
∆L206 A Level margin to open IBD block 150 mm
valve LICS-202B
∆L401a Level margin to close IBO valve 160 mm
C207 Constant which limits opening of To follow √(Bar)
t202 Timer for opening CBD valve 4 hours
QISA-202
Initial, to be
PENDING (decision by JV see finalized
conference notes 2007-04-03) during
operation
LC-207 Gain for LC-207 (100%/150mm) 0.67 -
HOLD HOLD
K202 Maximum allowable conductivity As alarm µs
from
transmitter
HC-219 SP temperature controller 50 °C
NOTE:
3.12.3.8 Interfaces
N/A.
A too high level in the intermittent blowdown drum will give an alarm.
3.12.4 History


3.13 DUAL DRIVEN FD FAN
P&ID 36005-560-04-151
36005-560-04-151-002
36005-105-13
PCD
UEFS
E-15100-TN-2395-0041 Steam Boiler Package A-15101 – Dual Driven FD Fan
E-15100-TN-2395-0044 Steam Boiler Package A-15101 – Lube Oil System
Reference documents
36005-560-04-148 Operating procedure
36005-560-04-148-001 Control Narratives
3.13.1 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
motor.
The FD fan capacity is controlled with the IGV damper, which receive its signal for the
required air flow from the combustion air flow controller FC-202B. The speed of the FD Fan
and steam turbine will be kept constant over the operating range by control of the steam flow
through the steam turbine. The speed controller (UC-580) of the steam turbine controls the
position of the steam governor valve.
The lube oil is supplied by the shaft driven oil pump to the bearings of the whole FD Fan
train. The oil pressure to the bearings is controlled by pressure controller PIC-225.
Following control/safeguarding blocks:
1. KT-15161 Woodward Governor 151UC-xxx (start/stop turbine/motor & turb. control)

2. KT-15161 Bentley Nevada 151UZ-xxx (monitoring/safeguarding)
3. KT-15161 FD Fan Operation 151US-xxx (driver selection)

UC-580 PID Direct Yes UC-581
PIC-225 PID Direct Yes PIC-225

PISA-222 Lube oil pressure to bearings L Start aux.
oil pump
UC-580 R.p.m. turbine and fan 0 Stop aux.
ST-206 oil pump
TA-258 Lube oil temperature in tank H Switch
heater off

TA-258 Lube oil temperature in tank L Switch

heater on
NOTE:

UC-580 Steam turbine speed H Trip UC-581
turbine UC-???
TISA-249 Steam turbine inlet temperature S Trip UC-581
turbine UC-???
FD Fan bearings HH Trip Fan
PZA-223 Lube oil pressure to bearings LL Trip Fan
Lube oil pressure to bearings HH Trip Fan
NOTE:
Note: Trip steam turbine TISA-249 HOLD. High temperature is a SILa classification
Decision by JV
This control scheme is required to be operational during start up, shutdown, normal
operation, and take-over.
Start up/shutdown:
Start up and shutdown of the FD Fan unit can be done automatically from the DCS and
manually from a local panel (see also section start up below).
Normal operation:
The FD Fan is dual driven by a steam turbine or electric motor.
The FD Fan is normally driven by the steam turbine. The steam turbine will keep the speed
constant over the load range by admit more or less steam to the turbine. The electric motor
serves as a back up. When the steam turbine is in operation the electric motor is decoupled
and v.v.
The FD Fan train runs at the following speeds:
• Steam turbine: 4762 rpm
• FD Fan: 1500 rpm
• Electric motor: 1500 rpm
Steam for the steam turbine is coming from the HP steam system. The steam turbine outlet
is connected to the LP steam system.
Automatic take-over:
With the steam turbine in operation an automatic take-over takes place in case of a steam
turbine trip. At steam turbine trip the steam to the turbine is immediately shut off. The FD
Fan operation is continued by automatic start of the electric motor (starting time
approximately 17 seconds).
In general the driver with the highest speed will drive the FD Fan. Automatic clutches will
engage the driver with the highest speed and disengage the driver with the lower speed.
The trip signal will ramp down the speed set point of the turbine to zero. When the turbine
speed indicates no speed (for x seconds HOLD) the steam governor switches to shutdown
and the steam governor valve (UC-581) will than be closed.

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
• Auxiliary lube oil pump will start automatically if PISA-222 is LOW
1)
• 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 (pre-
heating 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:
Trip/stop electric motor

A trip or stop of the electric motor leads to a shutdown or trip of the boiler. A manual take-
over takes to much time and in this case a boiler start up procedure has to be initiated.
3.13.3.2 Start up
Start up and preparations prior to start up have to be done manually with local actions and
supervision of the operator (i.e valves in correct position, emergency cooling water available,
lube oil system ready, steam systems available, etc).
Prior to start up a selection has to be made which driver should be started.
General permissive
• Verify steam conditions are within operating range
• Steam lines pre-heated.
• Valves in correct position
• Lube oil system ready
• Verify steam turbine doesn’t accelerate/run if steam inlet/outlet valves are opened
2)
• Emergency cooling water system in circulation

2)
Note: If turbine starts running close steam valve LBG10 AA010/015
FD Fan permissive
• Verify IGV FD Fan closed to minimum stop
• Verify impeller is not rotating
• Verify FD Fan bearing temperatures are within operating range.
Steam turbine/Gearbox permissive

• Verify steam turbine/gearbox bearing temperatures are within operating range.
• Verify Woodward governor is shutdown (governor valve closed)
• Emergency trip is reset (if required) (DCS or LOCAL)
• Steam turbine housing preheated (preferred but not required).

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)
• Check oil temperature outlet oil/water cooler E-15163 (Toil < 49°C)
Ramp up of the steam turbine to nominal speed will be done according a programmed
sequence. During start up conditions of steam turbine and FD Fan need to be checked (i.e.
oil temperatures, pressures, vibrations, noise). If excessive conditions occur the steam
turbine must be shutdown.
The governor valve position will be controlled by the speed controller. The turbine runs for
(15 minutes at 500 rpm HOLD), meanwhile checking conditions of the FD Fan unit
Steam turbine in normal operation

• Governor at will ramp up speed to nominal speed (4762 rpm)
• When the oil pressure of main pump PISA-222 is within operating limits the auxiliary
lube oil pump can be switched off manually.
• Verify steam turbine, FD Fan and lube oil temperature is within operating range.
• Verify lube oil pressure when running with main pump (shaft driven)
• Verify gearbox vibration is within operating range
Start electric motor operation

When the electric motor is selected, start can be released when:
• Electric motor temperatures within temperature range.
• Lube oil system is in operation and conditions are verified.
• Electric motor permissive and lube oil permissive are fulfilled.
Note: The number of starts with the E-motor is limited (see section 3.13.3.10).
FD Fan operation
After steam turbine or electric motor is in stable operation the FD Fan runs with IGV’s in
minimum opening position.

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.
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.
Instrument
1)
TIA-231A & BAD - Manual Stop steam turbine Freeze
TIA-231B
1)
TIA-232B
1)
TIA-233B
1)
TIA234B
1)
TIA-235B &
TIA-235C
1)
TIA-236B
1)
TIA-237B
1)
TIA-238B &
TIA-238C
2)
TIA-239 BAD - Manual Stop FD-Fan Freeze
2)
TIA-240 BAD - Manual Stop FD-Fan Freeze
3)
TIA-241 BAD - Manual Stop E-motor Freeze
3)
TIA-243 BAD - Manual Stop E-motor Freeze
4)
XIA-201 BAD - Manual Stop steam turbine Freeze
ST-202A & BAD UC-580 Mode to MAN Freeze
ST-202B
ST-204 BAD - - Freeze

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
Shutdown with steam turbine

The normal shutdown procedure of the turbine has to be followed.
• IGV FD Fan to minimum position
• Activate steam turbine stop
• Speed set point is ramped to zero (slow rate)
• Auxiliary lube oil pump will start automatically if PISA-222 is LOW
3)
• When set point is zero, valve limiter is stepped to zero

• If steam turbine speed is zero, governor is shutdown and governor valve closes.
• When the speed of Steam Turbine and FD Fan = 0 rpm stop the auxiliary lube oil pump
after 60 seconds
• Close steam valves LBG10 AA010 and AA015
3)
Manual start from local panel also possible.
During shutdown the auxiliary lube oil pump is started if the lube oil pressure (PISA – 222 or
PIS – 227/327/427) is < L.
Shutdown with electric motor

• IGV FD Fan to minimum position
• Activate E-motor stop
• When the electric motor is switched off and the speed of FD Fan = 0 rpm stop the
auxiliary lube oil pump after 60 seconds
Note
It is only for a limited time allowed to keep a 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 steamdrum and superheater
headers.


????? y = stop aux. lub e oil pump if UC-580 ST-204
( x1 & x 2 = 0 rpm for t stop sec onds )
NOTE:
Ranges
PIC-225 Lube oil pressure controller 0 - 100 %
UC-580 Speed controller 0 - 100 %
NOTE:
Alarms
ST-204 A+ Indication 1550 rpm
TISA-249 A+ Indication 400 °C
1)
TIA-231A/B A+ Indication 110 °C
1)
1)
1)
1)
TIA-235A/B/C A+ Indication 105 °C
1)
1)
1)
TIA-238A/B/C A+ Indication 105 °C
2)
2)
3)
3)
4) 2
XIA-201 A+ Indication 58840 or mm/s or
6 G
5)
LISA-204 A- Indication 250 mm
6)
TA-258 A+ Indication 70 °C
7)
TA-258 A- Indication 5 °C
8)
PDIA-226 A+ Indication 1.5 Bar(a)
9)
QIA-206 A+ Indication 100 ppm
10)
PISA-222 A+ Indication 2.25 Bar(g)
11)
PISA-222 A- Indication 1.75 Bar(g)

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
Trips
UC-580/ Z+ - 5450 rpm
UZ-571
1)
SS-207 Z+ - 5500 rpm
TISA-249 S SILa 430 °C
2)
PZA-223 Z-- SIL1 1.5 Bar(g)
3)
PZA-??? Z- - 0.62 Bar(g)
1)
NOTE: Mechanical trip
2)
Trip FD Fan and driver
3)
Mechanical trip
Note: Trip steam turbine TISA-249 HOLD High temperature is a SILa classification
Decision by JV
Settings
tstop Timer to stop auxiliary lube oil 60 seconds
pump
ST-204 Fan speed for permissive to 0 or rpm
start E-motor 1500
NOTE:
3.13.3.8 Interfaces
N/A.
Following functions/signals are present:
151HS-xxx Switch in DCS To select type of driver: steam turbine or motor

151HS-xxx Switch in DCS To start/stop KT-15161
151HS-xxx Switch on local To start/stop KT-15161
panel
151HS-xxx Switch in DCS To start/stop KM-15161
151HS-xxx Switch on local To start/stop KM-15161
panel
151HS-xxx Switch on local To start/stop KT-15161

panel
151XI-xxx Switch on local To start auxiliary lube oil pump
panel
151XI-xxx Switch on local To stop auxiliary lube oil pump
panel
151XI-xxx Indication in DCS Indication that KM-15161 is ready to start
151XI-xxx Indication on local Indication that KM-15161 is ready to start
panel
151XI-xxx Indication in DCS Indication that KT-15161 is running
151XI-xxx Indication on local Indication that KT-15161 is running
panel
151XI-xxx Indication in DCS Indication that KM-15161 is running
151XI-xxx Indication on local Indication that KM-15161 is running
panel
Signal Signal Signal to MCC to start KM-15161
151US-xxx
Signal Signal Signal from MCC to confirm that KM-15161 is running
151US-xxx
Signal Indication in DCS Indication any failure
151US-xxx
Signal Indication on local Indication any failure
151US-xxx panel
151TIZA-239 Signal Trip FD Fan (stop electric motor KM-15161) upon High
High temperature HOLD (to be discussed with NEM;
refer to TZA19 and TZA20 on NEM P&ID. We know
that the steam turbine will be tripped anyway, but we
don’t know if the Fan on motor is also the be
tripped/stopped )
tripped/stopped )
tripped/stopped )
151PZA-223 Signal Trip FD Fan (stop electric motor KM-15161) upon Low
Low and High High pressure HOLD (to be discussed
with NEM; refer to PZA06 on NEM P&ID. We know
tripped/stopped )
151UZ Signal Signal from BMS 151UZ-500 to stop the Fan
151US Switch on local Emergency stop of the Fan
panel
151US-xxx Signal Permissive signal to KT-15161 Woodward Governer -
151UC-XXX that the steam turbine is allowed (or not)
to be started
151UZ-xxx Signal Running confirmation of steam turbine from KT-15161
Woodward Governer - 151UC-XXX

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

On this P&ID we have shown/made three (3) control/safeguarding blocks:
4. KT-15161 Woodward Governer - 151UC-XXX

5. KT-15161 Bentley Nevada – 151UZ-xxx
6. FD Fan KT-15161 Operation – 151US-xxx
We will send you our “Shellified” P&ID for your consideration.
FD Fan KT-15161 Operation – 151US-xxx

In this block the Operator has to select the type of driver for FD Fan K-15161.
The steam turbine KT-15161 will be started/stopped from the “KT-15161 Woodward Governer - 151UC-XXX”.
The electric motor will be started/stopped from this block.

3.14 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.
To start the standby fan KM - 15162B or KM - 15162A on detection of a low discharge

pressure PISA-205 or a discrepancy alarm on the duty fan.
US-540: Cooling Air Fans Auto Take-over

Input Logic Description Action
PISA-205 PISA-205.LO = SET KM - 15162A = START
OR OR KM - 15162B = STOP
KM - 15162A.DIS_ALARM KM - 15162A.DIS_ALARM = SET OR
OR OR KM - 15162B = START
KM - 15162B.DIS_ALARM KM - 15162B.DIS_ALARM = SET KM - 15162A = STOP
This control scheme is required to be operational during start up, shutdown, normal
operation, and take-over.
3.14.3.3 Start up
Instrument
PISA-205 BAD - - Freeze
NOTE:

3.14.3.5 Shutdown
Alarms
PISA-205 A- Indication HOLD Barg(g)
PISA-205 A-- Indication HOLD Barg(g)
NOTE:
Low discharge pressure switch PISA-205 will be automatically reset when the pressure rises
above the low switch setting.
3.14.3.8 Interfaces
3.14.4 History


3.15 SOOTBLOWER SYSTEM
P&ID 36005-105-10
36005-105-11
PISA-208, TISA-220, TISA-221
UEFS
E-15100-TN-2395-0037 Steam Boiler Package A-15101 – Sootblower System
Reference document
36005-553-04-118 Sootblower Logic Diagram
3.15.1 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.
The sootblowers operate normally a few minutes each day so the normal position for the
steam valve is to be closed and the drain valves to be opened.
The sootblower sequence will be started by the operator from the DCS. The operator can
select for either a fixed programmed sequence to be followed or a manual random
sequence. When starting the sequence warming up will commence (typically 10 to 15
minutes) and valves HCB10 AA001 (KBS-211), HCB10 AA010 (KBS-212)and HCB10
AA030 (KBS-213) are automatically opened. If the steam temperature is satisfied the
warming up valves HCB10 AA010 (KBS212) and HCB10 AA030 (KBS-213) are closed and
steam blowing can be started. Sootblowers will operate one by one usually from the hot to
the cold parts. During sootblow operation the steam lines will be kept at the required
temperature via the orifices RO-203 and RO-205 in steam lines HCB10 BR013 and BR033.
When the sootblower is inserted the steam valve is open. In retracted position the steam
valve is closed.

PISA-208 Steam supply pressure LOW Retract KBS-211
(S) sootblowers
and
stop
sequence
TISA-220 Steam temperature at drain valve HIGH Close valve KBS-212
(S)
TISA-221 Steam temperature at drain valve HIGH Close valve KBS-213
(S)
NOTE:

The boiler can be claeaned by an automatically fixed sootblowing sequence or by

manual/individual sootblowing.
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
• Preheating steam line
• If steam temperature TISA 220 > HIGH (S+), drain valve HCB10 AA010 closes
• If drain valves closed, check steam pressure PISA 208 > HIGH (S+)
• Select ‘ALL’ button (AUTO sequence selected)
• Press start button
• Sequence started for lane 1 up to 9 (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
• Power off
Manual blowing sequence:

The sequence can be started random. After the first of the selected sootblowers is finished
subsequently the other selected sootblowers will be started automatically.
• Power on
• Check all sootblowers in retracted position
• If not retracted press retract/fault reset button
• All sootblowers in retracted position
• Steam supply valve HCB10 AA001 (KBS-211) is opened
• Preheating steam line

• 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
• Power off
Instrument
PISA-208 BAD - Open valve KBS-211 Freeze
TISA-220 BAD - Close valve KBS-212 Freeze
TISA-221 BAD - Close valve KBS-213 Freeze
NOTE:
3.15.3.5 Shutdown
See start up above.
Alarms
PISA-208 A- Indication 17 Barg(g)
HOLD A+ Indication 15 minutes
(MAX blowing
time elapsed)
NOTE:
Settings
PISA-208 Retract sootblowers & stop 18 Bar(g)
sequence if pressure < LOW (S-)

TISA-220 Close drain valve KBS-212 if 280 °C

steam temperature > HIGH (S+)
TISA-221 Close drain valve KBS-213 if 280 °C
steam temperature > HIGH (S+)
TISA-220 Sootblowing suspended if steam 260 °C
temperature < LOW (S-)
TISA-221 Sootblowing suspended if steam 260 °C
temperature < LOW (S-)
HOLD Sootblower operating will retract 10 minutes
(Blowing and suspended if MAX blowing
time) time (insert + retract time) is
elapsed
NOTE:
3.15.3.8 Interfaces
Following functions/signals are present:
151HS-xxx Switch in DCS Power on/off

151HS-xxx Switch in DCS Emergency retract/fault reset push button
151HS-xxx Switch in DCS Selection sequence ‘ALL’ or ‘INDIVIDUAL’ button
151HS-xxx Switch in DCS Start button
151HS-xxx Switch in DCS (Emergency) stop button
3.15.4 History


3.16 ATOMIZING STEAM CONTROL
LBG30AA011 (PICA-115)
LBG30AA016 (TICA-081)
P&ID 36005-105-14
PCD 114
UEFS
E-15100-TN-2395-0004 Steam Boiler Package A-15101 – Atomising Steam System
3.16.1 Objective
To supply MP steam to the fuel skid with a constant superheated temperature used for
atomizing of the fuel oil in the burners.
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
control valve. Temperature control of the mixed flows is achieved by temperature controller
TC-081. Too low or high pressures and temperatures will be alarmed.
If atomizing gas or no atomizing medium is selected (NG selected) the controllers will be in MAN
mode 0% output. If atomizing steam is selected both controllers will be switched to AUTO mode.

PC-115 PID Direct Yes PICA-115

N.A.
NOTE:

N.A.
NOTE:

3.16.3.2 Start up
During normal operation the controllers PC-115 and TC-081 shall be in AUTO.
Instrument
PICA-115 BAD PC-115 Mode to MAN Freeze
NOTE:
3.16.3.5 Shutdown

N.A.
NOTE:
Ranges
PC-115 Pressure controller 0 - 100 %
TC-081 Temperature controller 0 - 100 %
NOTE:
Alarms
PICA-115 A+ Indication 20 Bar(g)
PICA-115 A- Indication 16 Bar(g)
NOTE:
Trips
N.A.
NOTE:
Settings
HC-115 SP pressure controller 18 Bar(g)
HC-081 SP temperature controller 237 °C
NOTE:

3.16.3.8 Interfaces
N/A.
The maximum allowable mixed temperature (324°C) is lower than the design temperature of the
MP steam (400°C). If the mixed temperature exceeds the allowable temperature the opening of
the MP steam control valve will be limited.
3.16.4 History


3.17 BOILER START UP AND SHUTDOWN
HLA10AA001, 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
To start up and shutdown the boiler according specific procedures. An automatic sequence
is incorporated for start up with NG. Manually start up with other fuels is possible. Boiler
shutdown will be done manually.
When starting the fuel control valves are positioned by the start sequence program or
operator. During start phase the fuel and air control will be switched to AUTO when all
burners are in operation. The boiler is disconnected from the grid by main steam valve
LBA10 AA003 (MOV-201) which is closed. The steam pressure will controlled by controller
PC-207. Start up is ended when the boiler is at 40% MCR. From that point the boiler can be
connected to the steam grid.
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
Several controllers are in MAN or AUTO mode as described in the specific start up sections
above.
For DCS control see other sections above.

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 and < 300°C
• Hot start up: defined as t drum ≥ 300 °C
START PROGRAM
Purging
The boiler shall be purged prior to the burner start according NFPA 85. Start of the FD fan at
minimum required combustion airflow would purge the boiler.
Minimum purging conditions are described in the table below. Furthermore, all burner air
dampers (6 in total) need to be open during purging. More details can be found in the Burner
System Description.
Purging due to Minimum Maximum purge air Minimum Boiler + duct

purge flow temperature (°C) time (min) purge volume
(m3/s)/kg/h (once) (m3)
Excl. Stack
Boiler 18.7/90000 35 6 1300
Table 1. Purge conditions
After purging, the 6 burner air dampers remain open with at least the minimum purge flow.
Fuel selection
The fuel selection is set in the DCS system. There are two options:
1. Natural Gas selection (for automatic start up procedure)
2. Oil selection (for manual start up procedure)
Mixed fuel operation during start up is not recommended.

NG will always be used as ignition fuel.

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, 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 start-
up the boiler correctly.
The burner starting sequence is described in the table 2 below. Burner front is shown in
figure 1 below.
Step Burner Action Nr of bur- Load per boiler Hold

number ners on burner (%) load (%) point
st
1 Burner 5 1 burner start 1 25 4.2
nd
2 Burner 4 2 burner start 2 25 8.3
rd
3 Burner 6 3 burner start 3 25 12.5 1
4 Increase load 3 burners 3 79.9 40
th
8 Burner 2 4 burner start 4 59.9 40
th
10 Burner 1 5 burner start 5 47.9 40
th
12 Burner 3 6 burner start 6 40 40 2
13 Increase load 6 burners 6 100 100
Table 2. Burning starting sequence

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
seconds.
• Drum temperature gradient within allowed range.
• Main steam temperature gradient within allowed range.
• Maximum start up valve opening = 30%
During this stage, steam temperature and pressure will increase. The boiler load and or
steam pressure will be limited when the allowable gradients are exceeded. (HOLD)
A too high steam temperature gradient will limit the load increase. A too high medium
temperature in the drum will be limited by further opening of the start up valve. Load
increase can recommence as soon as the gradients are acceptable.
This means that the load is reduced as soon as the allowable gradients has been passed.
Load increase can recommence as soon as the gradients are acceptable. (HOLD)
Load to 40%
As soon as the above conditions for hold point (1) are met, the load of the HP auxiliary boiler
is gradually increased to 40%. When the load is at 40% the last three (3) burners are started
in the sequence as given in table 2. During this stage, steam temperature and pressure will
increase further. The boiler load increase is controlled by:
• Allowable HP steam drum temperature gradient
• Allowable HP main steam temperature gradient.
During this stage, steam temperature and pressure will increase. The boiler load and or
steam pressure will be limited when the allowable gradients are exceeded.
(HOLD)
A too high steam temperature gradient will limit the load increase. A too high medium
temperature in the drum will be limited by further opening of the start up valve. Load
increase can recommence as soon as the gradients are acceptable.
This means that the load is reduced as soon as the allowable gradients has been passed.
Load increase can recommence as soon as the gradients are acceptable. (HOLD)

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:
• FW flow LAB10 CF101 is > 15 t/h for at least 60 seconds. (HOLD)
Start-up steam blow off CV LBA10 AA051(PICA-207) during start-up (0-40% load)
The control valve opens at 2 bar(g) minimum or actual pressure and controls the actual
pressure until a maximum open position of 30% is reached. With increasing boiler load, the
steam flow, pressure and temperature will rise. When the steam pressure has reached
normal set point pressure controller PC-207 is switched to MAN mode and at the same time
the 30% opening limit of PICA-207 is removed.
Pressure controller PC-207 is put in AUTO mode after a certain time (to stabilize) and then
controls the pressure at normal the operating value of 120 bar(g).
Warming up common steam system during start-up (0-40%)

The common steam system is the system downstream boiler valve LBA10 AA003 (MOV-
201) and can be warmed up by opening bypass valve LBA10 AA005 of main steam valve
LBA10 AA003 (MOV-201).
Note:
Draining of the steam system downstream boiler main steam valve is required.
Open main steam valve LBA10 AA003 (MOV-201)

As soon as the following conditions are met the main steam valve can be opened (and the
start-up blow off valve LBA10 AA051 (PICA-207) is closed):
• Steam line pressure LBA10 CP001 (PICA-207) is ≥ 120 bar(g)
• Main steam temperature LBA10 CT001 (TICA-217) ≤ 525 °C
• Differential pressure over boiler HP steam valve LBA10 AA003 (MOV-201) < 2 bar
Note:
The temperature of steam lines downstream main steam valve LBA10 AA003 should have
an acceptable level.

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:
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:

Transfer from 40% load to 100% load

The boiler load can be transferred from 40% to normal operation as soon as the following
conditions are met:
• Boiler load is 40% MCR.
• Main steam valve LBA10 AA003 (MOV-201) is opened.
• Start up valve LBA10 AA051 (PICA-207) closed.
• Boiler steam temperature and pressure control on AUTO
• Steam drum temperature gradient < allowable
• Steam temperature gradient < allowable
• Main steam line pressure LBA10 CP001 (PICA-207) is ≥120 bar(g)
• Main steam temperature LBA10 CT001 (TICA-217) ≤ 525 °C
IN OPERATION STATUS
The boiler is in operation status during normal operation. The HP auxiliary boiler is at a load
between 40 to 100 % MCR and produces steam with a constant pressure of 120 bar(g)
(maximum 125 bar(g)).
The boiler produces steam with a constant steam temperature over the boiler load range of
approx. 40 to 100%. The boiler is in operation at pressure or flow control.
N.A.
For crippled mode operation see sections above.

3.17.3.5 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)
during boiler cool down
Forced cooling of the boiler by running the FD Fan should be kept to a minimum. An alarm is
given in case the allowable steam drum pressure gradient during cool down is exceeded.
For calculations see sections above.
For initialisations see sections above.
3.17.3.8 Interfaces
Allowable temperature gradients: See section 3.10.3.6/ 7 and 3.11.3.6/7 above.
3.17.4 History


REFERENCES
3.18 DRAWINGS
PID’s
36005-104-01 Legend and symbols for P&ID's
36005-104-02 Legend and symbols for P&ID's
36005-105-01 PFD and material balance
36005-105-02 P&ID Flue gas system
36005-105-03 P&ID Economiser system
36005-105-04 P&ID Evaporator system
36005-105-05 P&ID Superheater system
36005-105-06 P&ID Main steam line
36005-105-07 P&ID Drain system
36005-105-08 P&ID Blow down system
36005-105-09 P&ID Sample unit
36005-105-10 P&ID Sootblower system boiler
36005-105-11 P&ID Sootblower system economizer
36005-105-12 P&ID Cooling air view ports
36005-105-13 P&ID Steam lines turbine
36005-105-14 P&ID Atomizing steam desuperheater station
36005-105-15 P&ID Cooling water
36005-105-16 P&ID Instrument air
36005-105-17 P&ID Burner piping system
36005-560-04-151 P&ID Dual drive Fan

36005-560-04-151-002 P&ID Lubrication system (dual drive fan)
36005-824-04-151-002/003/004 P&ID Common skid
36005-824-04-151-005/006/007 P&ID Local burner fuel system
3.19 DOCUMENTS
Operating data
36005-103-01 Performance data
36005-103-38 Material balance
36005-646-01 Process control diagrams
Reference documents
36005-824-04-148 Burner system description (including control and safeguarding)
36005-560-04-148 Operating procedure Dual Driven FD Fan
36005-560-04-148-001 Control Narratives Dual Driven FD Fan
36005-553-04-118 Sootblower Logic Diagram
36005-646-01 Functional Control Diagrams (LATER)

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY REPORT TEMPLATE.DOT PCFS NEM_R2.doc Page 92 of 92

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ABB Lummus Global B.V.

120.011 04217 E-15100-TN-5306-0001

Dept./Sect. Project Document Number

SHELL EASTERN PETROLEUM (PTE) LTD.

SHELL ECC PROJECT

STEAM PRODUCTION & DISTRIBUTION

PROCESS CONTROL FUNCTIONAL SPECIFICATION

2.00 2006-10-31 Revised Approved for Design RVO GRI GDS

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

1. BACKGROUND PROCESS INFORMATION 4

1.1 PROCESS AND PROJECT 4

1.2 STEAM AND POWER GENERATION / DISTRIBUTION SYSTEM 6

1.3 CONDENSATE TREATMENT AND RECOVERY SYSTEMS 7

1.4 DESALINATED WATER 9

1.5 DEMINERALISED WATER 10

2.1 STEAM SYSTEM 11

3. DETAILED CONTROL NARRATIVES 14

3.4 STEAM BOILERS, A-15101/2/3, STEAM LOAD CONTROL 14

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

3.5 SHP/HP STEAM DESUPERHEATER, J-15101A/B, PRESSURE CONTROL 17

3.6 BOILER COMBUSTION AIR CONTROL 24

3.7 GAS/FUEL OIL CONTROL 31

3.9 BOILER START-UP PRESSURE CONTROL 47

3.10 BOILER STEAM DESUPERHEATER TEMPERATURE CONTROL 53

3.11 BOILER DRAIN AND BLOWDOWN CONTROL 59

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

1. BACKGROUND PROCESS INFORMATION

1.1 PROCESS AND PROJECT

Medium Pressure Desuperheated (MPD) steam is produced by desuperheating MPS steam.

Low Pressure Desuperheated (LPD) steam is produced by desuperheating of LPS steam,

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

The Demineralised Water is pumped from the tank to:

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

1.2 STEAM AND POWER GENERATION / DISTRIBUTION SYSTEM

1.2.1 Super High Pressure (SHP) Steam

All three turbines are designed as a combination of extraction/condensing type turbine to

1.2.2 High Pressure (HP) Steam

HP steam is extracted from the CGC turbine and used:

1.2.3 Medium Pressure Desuperheated (MPD) Steam

MP steam is extracted from the PG turbine and used:

1.2.4 Medium Pressure Desuperheated (MPD) Steam

MPD steam is extracted from the MP steam system and used:

1.2.5 Low Pressure (LP) Steam

1.2.6 Low Pressure Desuperheated (LPD) Steam

1.2.7 Letdown Stations

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

1.2.8 Steam Boilers

1.2.9 Power Generation System

A power generator driven by an extracting/condensing steam turbine is provided to supply

1.2.10 Blowdown and Flash Drums

1.3 CONDENSATE TREATMENT AND RECOVERY SYSTEMS

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

1.3.6 Condensate Treatment

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

A sodium-analyser is installed downstream the Cation Exchangers in order to monitor

In order to monitor any breakthrough of compounds which shall be adsorbed by the

Backwash & Regeneration

1.4 DESALINATED WATER

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

1.5 DEMINERALISED WATER

The Demineralised Water System consists of:

LGN SREP 04-3001-02.008 (Rev 0, May 2005) HOUDINI PROCESS TECHNOLOGY

2.1 STEAM SYSTEM