256-F0052-8951 - X2 Flow Chart F1201

Download as pdf or txt
Download as pdf or txt
You are on page 1of 17

Project: LR2 Refinery project

Document Title: FLOW CHART FOR START-UP AND SHUTDOWN


Company Doc. No: 256-F0052-8951
Revision No: X2
Document Class: 1

Revision History

Rev No Rev Date Section Revised Revision Description

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

00 23/JAN/15 As marked Revised per comments

X 11/DEC/15 N/A As Built

X1 28/DEC/15 As marked As Built

Reverted back to Rev.X due to wrong


X2 06/JAN/16 Sheet 4 and 10
information
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 1 of 15

INDEX

ITEM DESCRIPTION SHEET NO.

1 Legend 2

2 Start up for Heater F1201 3

3 Shutdown for Heater F1201 15

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 2 of 15

LEGEND
Abbreviation
Start and Finish of Logic
BMS Burner Management System
CCR Central Control Room
Operator Action MCC Motor Control Center
DCS Distributed Control System
SIS(BMS) Safety Instrumented System
Indication ITR Instrument Technical Room
EWS Engineering Work Station
SER Sequence Event Recorder
Status LP Local Panel
LCS Local Control Station for Motor
FDF Forced Draft Fan
Time Delay Timer VSD Variable Speed Drive
xxx sec
PB Push Button Switch
SW Switch
xxx Press. LL ,HH FG Fuel Gas
Interlock component signal PG Pilot Gas
ESDV Shut Down Valve
SUO Start up override
xxxxx Start SG Sour Gas
Start command of push button
Local Panel PB On VG Vent Gas
MS Mid. Press. Steam

xxxxx Stop
Local Panel PB On Stop command of push button

Trip Command Trip command signal

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 3 of 15

START UP FOR HEATER F1201 Heater Stopping

RESET CONDITION 2 RESET CONDITIONS 1


PG Header Press Not L PIAL12033 PG Block Valves Closed ESDV12056/58
PG to Pilot Press Not LL PZLL12058(2oo3) (Note 1) Pilot Gas Vent valve Opened ESDV12057
FG Header Press Not L PIAL12056 FG Block Valve Closed ESDV12059/61
FG to Burner Press Not LL PZLL12059(2oo3) (Note1) FG Vent Valve Opened ESDV12060
FG to Burner Press Not HH PZHH12059(2oo3) (Note 1) Sour Gas ESDV Closed ESDV12062
Vent Gas ESDV Closed ESDV19007
Snuffing Stm ESDV Closed ESDV12067

RESET CONDITION 3
Unit 12/15/19 Not ESD UZ00001 Stack Damper PV1286B Close (DCS)
Pressure Not HH in 82-C1201 PZHH12016 UZ12095 IDF Suction Damper PV12F86A Close (DCS)
Condensate Flow Not LL FZLL12006-13
Recycle Flow Not LL FZLL12014
Recycle Flow Not LL FZLL12071-78
Not HH Level in 82-V1206 LZHH12060
Combustion Air flow Not LL FZLL12086 (Note 1) Damper Limit Switch
No HC in Heater AAH12063 Answerback Normal PZLC12F86A/PZLC12F86B

BMS Reset
Note 1 :SUO shall be applied with combustion
air flow LL (FZLL) and burner flame off (BZL)

Ready To Purge

IDF/FDF Motor Field Control Station


to Remote

IDF Start 82-K1201

IDF Run IDF flow shall be minimum as per IDF suction


damper minimum stoper

Time delay
30sec

Draft Controller PIC12086 Signal Min.


IDF Suction Damper to open
Stack damper to Open

FDF Start 82-K1202A/B

FDF Run

Combustion Air Flow Not LL


FZLL12086

From From
Sheet 4 1 Sheet 4

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 4 of 15

1
To Sheet 3 To Sheet 3

Purge Start
LP PB On

Purge Failure

Purge in Progress

Combustion Air Flow Not LL No


FZLL12086

Yes

Note : Purging time shall be


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

Purge Complete

Draft Controller PIC12086


Auto Control

FDF Suction Air Controller to


Auto (Cascade Off) FIC12086

Combustion Air Flow Controller FIC12086 SV to set


25% of fan rated flow (HS12086)

PG Leak Test

No PG Leak Test
Successful Y/N
Please refer to Control narrative
Yes Doc No. 256-F0052-8903 Attachment for
detail of leak test procedure

FG Leak Test

No FG Leak Test
Successful Y/N

Burner Firing failure Yes


(From Sheet 11,12, 13, & 14)
Pilot ignition failure X2 Reverted back to Rev. X for this sheet
(From Sheet 6, 7, 8, & 9)
2

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 5 of 15

Pilot Start
LP PB On

PG Header Vent valve PG Header Vent valve ESDV12057 Close


ESDV12057 Open PG Header Block valve ESDV12056/58 Open
PG Header Block valves
ESDV12056/58 Close
Time delay
10 sec

ESDV ESDV Limit Switch


Abnormal Answerback Normal

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

Ignition Power Enable

Normal Procedure

(If trouble occurred)


Pilot Stop
LP PB On

PG Header Block Valves ESDV12056/58 Close


PG Header Vent Valve ESDV12057Open

Check &
repaire Time delay
10 sec

ESDV ESDV Limit Switch


Abnormal Answerback Normal
No
Yes

Ignition Power Off

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 6 of 15

Pilot Ignition Order:



Pilot Ignition failure 3
Purging required Cell 1 Pilot 1 Cell 2 Pilot 1
(To sheet 4) →
Cell 1 Pilot 2 Cell 2 Pilot 2

Cell 1 Pilot 3 Cell 2 Pilot 3
Re-start from pre-purge
when over 2 times trial To
Re-start permitted within
2 times Cell 1 Pilot 18 →Cell 2 Pilot 18

Cell 1 Pilot 1 Ignition SW


Cell 1 Pilot 1 Manual Valves Open HS12F01A On

Cell 1 Pilot 1 Ignition Spark


Cell 1 Pilot 1 Ignition Spark Start
Stop

Time delay
10 sec

Cell 1 Pilot 1 Manual Valves Open

Cell 1 Pilot 1 Flame


BI12F01BA On

Cell 1 Pilot 1 Ignition Failure Time delay No


BZL12F01BA 5 sec
Yes

Cell 1 Pilot 1 Ignition Spark Stop

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 7 of 15

Pilot Ignition failure 4


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

Re-start from pre-purge


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

Cell 2 Pilot 1 Ignition SW


Cell 2 Pilot 1 Manual Valves Open
HS-12F02A On

Cell 2 Pilot 1 Ignition


Cell 2 Pilot 1 Ignition Spark Start
Spark Stop

Time delay
10 sec

Cell 2 Pilot 1 Manual Valves Open

Cell 2 Pilot 1 Flame

Cell 2 Pilot 1 Ignition Failure Time delay No


BZL1F02BA 5 sec Yes

Cell 2 Pilot 1 Ignition Spark Stop

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 8 of 15

Pilot Ignition failure 5


Purging required
(To sheet 4)

Re-start from pre-purge


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

Cell 1 Pilot 18 Manual Valves Cell 1 Pilot 18 Ignition SW


Open HSF12F01R On

Cell 1 Pilot 18 Ignition Cell 1 Pilot 18 Ignition Spark


Spark Stop Start

Time delay
10 sec

Cell 1 Pilot 18 Manual Valves


Open

Cell 1 Pilot 18 Flame


BI12F01BR On

Cell 1 Pilot 18 Ignition Failure Time delay No


BZL1201BR 5 sec
Yes

Cell 1 Pilot 18 Ignition Spark Stop

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 9 of 15

Pilot Ignition failure 6


Purging required
(To sheet 4)

Re-start from pre-purge


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

Cell 2 Pilot 18 Manual Valves Cell 2 Pilot 18 Ignition SW


Open HS12F02BR On

Cell 2 Pilot 18 Ignition Cell 2 Pilot 18 Ignition Spark


Spark Stop Start

Time delay
10 sec

Cell 2 Pilot 18 Manual Valves


Open

Cell 2 Pilot 18 Flame


BI12F02BR On

Cell 2 Pilot 18 Ignition Failure Time delay No


BZL12F02BR 5 sec
Yes

Cell 2 Pilot 18 Ignition Spark Stop

Ready to FG start

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 10 of 15

FG Press Controller PIC12066 SV set to minimum


burner firing rate (25%)
(HS12058)

Firing Start
LP PB On

FG Header Vent Valve ESDV12060 Close


FG Header Vent Valve FG Header Block Valves ESDV12059/61Open
ESDV12060 Open
FG Header Block Valves
ESDV12059/61 Close Time delay
10 sec

ESDV Limit Switch


Answerback Normal
No Yes (Normal operation)

ESDV Answer back require within 10 sec


Abnormal
(If trouble occurred)
Firing Stop
Check & LP PB On
repaire

FG Header Block Valves ESDV12059/61 Close


FG Header Vent Valve ESDV12060 Open

Check & Time delay


repaire 10 sec

ESDV ESDV Limit Switch


Abnormal Answerback Normal

No

Yes

Ready for Firing

X2 Reverted back to Rev. X for this sheet


8

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 11 of 15

Burner Firing Order:



Burner Firing Failure
Purging required 8 Cell 1 Burner 1 Cell 2 Burner 1
(To sheet 4) →
Cell 1 Burner 2 Cell 2 Burner 2

Cell 1 Burner 3 Cell 2 Burner 3
Cell 1 Burner 1 Firing
Start LP PB On To

Cell 1 Burner 18 →Cell 2 Burner 18


Cell 1 Pilot 1 Flame
BL12F01BA ON Pilot flame is burner firing condition.
Both signals require to step.

Cell 1 Burner 1 Block Valve


ESDV12053A Open

Time delay
Burner 1 Block Valve 10 sec
ESDV12053A Close

Cell 1 ESDV Limit Switch


Answerback Normal
No Yes
ESDV Answer back require within 10 sec
Abnormal
Time delay Burner ESDV open after pilot ignited,
5 sec burner firing shall be made.
Check &
repaire
No Cell 1 Burner 1 Flame
BI12F01AA On

Cell 1 Burner 1 Flame Yes


Failure BZL12F01AA

If no flame is exist 5 sec after ESDV


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

Cell 1 Burner 1 Block Valve


ESDV12053A Close

Check & Time delay


repaire 10 sec

Cell 1 ESDV Limit Switch


ESDV Answerback Normal
Abnormal No
Yes

Cell 1 Burner 1 Stop

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 12 of 15

Burner Firing Failure


9
Purging required
(To sheet 4)

Cell 2 Burner 1 Firing


Start LP PB On

Cell 2 Pilot 1 Flame Pilot flame is burner firing condition.


BL12F02BA ON Both signals require to step.

Cell 2 Burner 1 Block Valve


ESDV12055A Open

Time delay
Burner 1 Block Valve 10 sec
ESDV12055A Close

Cell 2 ESDV Limit Switch


Answerback Normal
No
ESDV Answer back require within 10 sec
Yes
Abnormal
Time delay Burner ESDV open after pilot ignited,
5 sec burner firing shall be made.
Check &
repaire
No Cell 2 Burner 1 Flame
BI12F02AA On

Cell 2 Burner 1 Flame Yes


Failure BZL12F02AA

If no flame is exist 5 sec after ESDV


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

Cell 2 Burner 1 Block Valve


ESDV12055A Close

Check & Time delay


repaire 10 sec

Cell 2 ESDV Limit Switch


ESDV Answerback Normal
Abnormal No
Yes
Cell 2 Burner 1 Stop

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 13 of 15

Burner Firing Failure


10
Purging required
(To sheet 4)

Cell 1 Burner 18 Firing


Start LP PB On

Cell 1 Pilot 18 Flame Pilot flame is burner firing condition.


BL12F01BR ON Both signals require to step.

Cell 1 Burner 18 Block Valve


ESDV12053R Open

Time delay
Burner 1 Block Valve 10 sec
ESDV12053R Close

Cell 1 ESDV Limit Switch


Answerback Normal
No
ESDV Answer back require within 10 sec
Yes
Abnormal
Time delay Burner ESDV open after pilot ignited,
5 sec burner firing shall be made.
Check &
repaire
No Cell 1 Burner 18 Flame
BL12F01AR On

Cell 1 Burner 18 Flame Yes


Failure BZL12F01AR

If no flame is exist 5 sec after ESDV


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

Cell 1 Burner 1 Block Valve


ESDV12055R Close

Check & Time delay


repaire 10 sec

Cell 1 ESDV Limit Switch


ESDV Answerback Normal
Abnormal No
Yes
Cell 1 Burner 18 Stop

11

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 14 of 15

Burner Firing Failure


11
Purging required
(To sheet 4)

Cell 2 Burner 18 Firing


Start LP PB On

Cell 2 Pilot 18 Flame Pilot flame is burner firing condition.


BL12F02BR ON Both signals require to step.

Cell 2 Burner 18 Block Valve


ESDV12055R Open

Time delay
Burner 1 Block Valve 10 sec
ESDV12055R Close

Cell 2 ESDV Limit Switch


Answerback Normal
No
ESDV Answer back require within 10 sec Yes
Abnormal
Time delay Burner ESDV open after pilot ignited,
5 sec burner firing shall be made.
Check &
repaire
No Cell 2 Burner 18 Flame
BI12F02AR On

Cell 2 Burner 18 Flame Yes


Failure BZL12F02AR

If no flame is exist 5 sec after ESDV


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

Cell 2 Burner 1 Block Valve


ESDV12055R Close

Check & Time delay


repaire 10 sec

Cell 2 ESDV Limit Switch


ESDV Answerback Normal
Abnormal No
Yes
Cell 2 Burner 18 Stop

Heater Started

FURNACE ENGINEERING INC. JOB NO. 1851 Date REV


YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2
FLOW CHART FOR START UP AND SHUTDOWN FOR F1201
Sheet 15 of 15

SHUTDOWN FOR HEATER F1201


Heater Started

Unit 12/15/19 ESD UZ00001

FDF 82-K1201A/B Trip


HC HH (2oo2) UZ12100

Heater ESD SW at CCR HS12056A UZ12081


Heater ESD SW at ITR HS12056B UZ12081
Heater ESD SW at Field HS12056C UZ12081

Combustion Air Flow LL FZLL12086 UZ12081 (2oo3)


FDF A Stop HSL12069A UZ12081
FDF B Stop HSL12069B UZ12081
PG to Pilot Press LL PZLL12058 UZ12081
PG ESDV Discrepancy UZ12081

Condensate to 82-F1201 FZLL12006-13 UZ12080


Recycle to 82-F1201 FZLL12014 UZ12080
Recycle to 82-F1201 FZLL12071-78 UZ12080
Pressure HH in 82-C1201 PZHH12016 UZ12095
FG to Burner Press LL PZLL12059 UZ12080(2oo3)
FG to Burner Press HH PZHH12059 UZ12080(2oo3)
Draft HH PZHH12063 UZ12080 (2oo3)
FG ESDV Discrepancy UZ12080
Deleted TZHH12026-33 from ESD but critical alarm

HH Temp to K1201 TZHH12098 UZ12089


FDF 82-K1201A/B Stop

Cell # 1
Pilot 1 Flame Failure BZL12F01BA O2 Analyzer power Off AT12056/12057
to UZ12081 PG Header Block Valves ESDV12056/58 Close
Pilot 18 Flame Failure BZL12F01BR (18oo18 x2)
PG Header Vent Valve ESDV12057 Open
Cell # 2 Note 1
Pilot 1 Flame Failure BZL 12F02BA
to FG Header Block Valves ESDV12059/61Close
Pilot 18 Flame Failure BZL12F02BR FG Header Vent Valve ESDV12060 Open

Cell #1
Cell # 1 Burner 1 Block Valves ESDV12053A Close
Burner 1 Flame Failure BAL 12F01AA UZ12080 to
to (4oo18)x2 Burner 18 Block Valves ESDV12053R Close
Burner 18 Flame Failure BAL 12F01AR Note 2 Cell #2
Cell # 2 Burner 1 Block Valves ESDV12055A Close
Burner 1 Flame Failure BAL 12F02AA to
to Burner 18 Block Valves ESDV12055R Close
Burner 18 Flame Failure BAL 12F02AR
Heater Shutdown

IDF 82-K1201 Stop UZ12079 Stack damper PV12F86B Open

Heater Radiant Temp LL TZLL12075 UZ12082


SG Block Valve ESDV12062 Close
HH Level in 82-V1901 LZHH19002 UZ19025
VG Block Valve ESDV19007 Close
HH Level in 82-V1902 LZHH19005 UZ19026

Snuff. Stm. To F1201 HS12055ABC UZ12078 MS to F1201 ESDV12067 Open

Note 1 18oo18 x2 pilot burner flame failure shall close PG block valve, open vent valve and initiate to
heater shutdown as UZ12080
Note 2 Each burner flame failure shall close related burner block valve
4oo18 (PER CELL) main burner flame failure shall close FG block valves, open vent valve, close individual
FG to burner block valves. Pilot shall remain operation.
FURNACE ENGINEERING INC. JOB NO. 1851 Date REV
YOKOHAMA, JAPAN. DOC. NO. 851-DSP-951 6, Jan. '16 X2

You might also like