V4-ch02-sequence Description Rev 1- Upto Seq 83 Agglomerate

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PETRONAS RAPID Project Johor, Malaysia 350 KTA LLDPE PLANT Project n° 61070F Process Design Package

Nov Vol.

VOLUME 4

CHAPTER 2

SEQUENCE DESCRIPTION

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

2012 : 4

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SPECIFICATION SEQUENCE DESCRIPTION

SEQUENCE DESCRIPTION

1

12-DEC-12

PDP Update

FMA

A. CONIL

A. CONIL

0

05-NOV-12

ISSUE FOR PDP

A.CONIL

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16-SEP-12

For comment

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DATE DD-MMM-YY

STATUS – REVISION MEMO

WRITTEN BY (name & visa)

CHECKED BY (name & visa)

APPROVED BY (name & visa)

Document revisions. © INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

CONTENTS 1.

INTRODUCTION................................................................................................................................................................ 4 1.1

2.

REFERENCE DOCUMENTS .................................................................................................................................. 4

ZIEGLER CATALYST TRANSFER: SEQUENCES SEQ-34 AND SEQ-35 ............................................................ 5 2.1 SEQUENCE SEQ-34-ZG SDX: ZIEGLER SDX CATALYST TRANSFER OPERATION............................... 5 2.1.1 DESCRIPTION ................................................................................................................................................. 8 2.1.2 FAILURE MONITORING DURING SEQUENCE ....................................................................................... 12 2.1.3 LIST OF PARAMETERS USED ................................................................................................................... 13 2.2 SEQUENCE SEQ-34-ZG NCT: ZIEGLER NCT CATALYST TRANSFER OPERATION............................. 14 2.3 SEQUENCE SEQ-35: METALLOCENE CATALYST TRANSFER OPERATION ......................................... 14

3.

MINI KILL: SEQUENCE SEQ-46 .................................................................................................................................. 16 3.1 3.2 3.3 3.4

4.

START-UP SILO AUTOMATIC RECYCLE: SEQUENCE SEQ-60 ......................................................................... 19 4.1 4.2 4.3 4.4

5.

RECYCLE OPERATION ........................................................................................................................................ 19 DESCRIPTION ........................................................................................................................................................ 19 FAILURE MONITORING........................................................................................................................................ 20 LIST OF PARAMETERS USED ............................................................................................................................ 20

POWDER SAMPLING SYSTEM: SEQUENCE SEQ-62 ........................................................................................... 21 5.1 5.2 5.3 5.4

6.

MINI KILL OPERATION ......................................................................................................................................... 16 SEQUENCE ............................................................................................................................................................. 16 PARAMETERS ........................................................................................................................................................ 18 FAILURE .................................................................................................................................................................. 18

PRINCIPLE .............................................................................................................................................................. 21 DESCRIPTION ........................................................................................................................................................ 21 FAILURE MONITORING........................................................................................................................................ 23 LIST OF PARAMETERS USED ............................................................................................................................ 24

POLYMERISATION LATERAL WITHDRAWAL: SEQUENCE SEQ-64 ................................................................ 25 6.1 WITHDRAWAL OPERATION ................................................................................................................................ 25 6.2 LINE SYNCHRONISATION ................................................................................................................................... 26 6.3 LINE OPERATION .................................................................................................................................................. 26 6.3.1 UP FLOW LINE .............................................................................................................................................. 29 6.3.2 ALARMS .......................................................................................................................................................... 29 6.3.3 FAILURE MODES .......................................................................................................................................... 29 6.4 MASTER SEQUENCE ........................................................................................................................................... 29 6.5 LINE SEQUENCE ................................................................................................................................................... 31 6.5.1 SEQUENCE DESCRIPTION ........................................................................................................................ 33 6.5.2 FAILURE MONITORING ............................................................................................................................... 38 6.5.3 ALARMS AND TRIPS .................................................................................................................................... 39 6.6 LIST OF PARAMETERS USED ............................................................................................................................ 39

7.

AGGLOMERATE DETECTION ON ROTARY VALVES: SEQUENCE SEQ-65 ................................................... 42 7.1 7.2

HARDWARE REQUIREMENT .............................................................................................................................. 42 SEQUENCE DESCRIPTION ................................................................................................................................. 42

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION 8.

AGGLOMERATE REMOVAL: SEQUENCE SEQ-83 ................................................................................................ 45 8.1 8.2 8.3 8.4

AGGLOMERATE REMOVAL OPERATION........................................................................................................ 45 DESCRIPTION ........................................................................................................................................................ 46 FAILURE MONITORING........................................................................................................................................ 46 LIST OF PARAMETERS USED ............................................................................................................................ 47

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

1.

INTRODUCTION This document defines the specification for the sequences. The licensee and detailed engineering contractor are responsible, during the detailed engineering and implementation, for ensuring that the final installed system is safe, reliable and operable. This document provides guidance in achieving these aims. To improve reading of the document, the instrument and equipment tags do not include the prefix 3200. Throughout the control PDP the words may, should, and must have the following specific meaning: May: is used where an alternative provision is acceptable to INEOS Technologies Should: is used where INEOS Technologies prefers the provision Must: is used where the provision is mandatory

1.1

REFERENCE DOCUMENTS  Instrument and process control philosophy – section on recommendations for sequence implementation  PID  Complex control  Process interlock description

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

2.

ZIEGLER CATALYST TRANSFER: SEQUENCES SEQ-34 AND SEQ-35 The sequence SEQ-34-ZG SDX manages the catalyst transfer and the SDX catalyst stock pipes. The sequence SEQ-34-ZG NCT manages the catalyst transfer and the NCT catalyst stock pipes. The sequence SEQ-35 manages the catalyst transfer and the Metallocene Catalyst stock pipes. The sequences are independent and cannot run simultaneously. This section describes the sequence for the Ziegler SDX catalyst transfer system. The sequence for the Ziegler NCT catalyst transfer and the Metallocene Catalyst transfer system is similar.

2.1

SEQUENCE SEQ-34-ZG SDX: ZIEGLER SDX CATALYST TRANSFER OPERATION The operator initiates this sequence, which controls and monitors the transfer of catalyst from the tote bin to the Catalyst Stock pipe, and then subsequently into the individual Stock lines for injection. Catalyst transfer is required approximately once every 3 days (maximum one per day), at design throughputs, depending upon grade. It takes about 20 minutes to empty a complete tote bin. A total weight of remaining catalyst system in LP/HP system is calculated (refer to complex control document). In normal operation, the Catalyst Stock pipe is isolated from the Catalyst transfer, and held at pressure typically around 4 bar above Reactor Pressure. The O2 and moisture are poisons for the catalyst. Consequently the lines must be carefully purged before transfer is initiated. The catalyst stock pipe is made up of three distinct sections, as shown in Figure below. Conveying

Between tote bin and XZV-30070

Upper section

Between XZV-30071 and XV-30075

Lower section

Between XV-30078 and the catalyst rotary valves. The outlet from the lower section is further split into lines to transfer the catalyst to the rotary valve.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

Ziegler catalyst

XV 30065

XV 30165 CV

CV

PI 30166

XV 30166

PI 30066

XV 30066

TOTE BIN (NCT)

LNP FO 30168

TOTE BIN (SDX)

LNP FO 30068

XZV 30070

XZV 30170 XZV 30071

XZV 30171 FO 30174

PIC 30170

CV

PZI 30172 XV 30174

HNP PV 30170

XV 30179

PZI 30072 HNP PV 30070

XV 30172

XV 30173 PIC 30175

PZT-40008 Reactor

XV 30073

XV 30076

XV 30175 XV 30178

PIC 30075 PV 30075

XV 30177 PZDI 30173

XV 30079

LI 30075

CV PV 30175

CV XV 30074

XV 30072

LI 30175

XV 30176

FO 30074

PIC 30070

LI 30176 PZT-40008 Reactor

XV 30075 XV 30078 CV

XV 30077 PZDI 30073

LI 30076

To Catalyst rotary valve

The sequence covers the following operating steps:  Isolation of the lower section and Depressurization of upper section to a pressure suitable for catalyst transfer

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION  Opening stock pipe from upper section to transfer section  Catalyst transfer  Re-instate catalyst injection system -

Repressurisation of upper section

-

Isolation of the transfer line from upper section

-

De-isolation of upper section from the lower section.

 Tote bin depressurization The diagram below shows the relationship between the steps of the line sequence.

Prestart

Isolate lower section and depressurize upper section

Open stock pipe upper section to convey

Catalyst transfer

Re-initiate catalyst injection system

Tote bin depressurisation

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION 2.1.1

Description Prior to start the sequence, the DCS operator must perform the following operation:  Select the SDX catalyst line with the selector CAT_SEL. The field operator must perform the following operations and checks:  The tote bin containing active catalyst under high purity low pressure nitrogen is in position on the unloading station.  All Flexible hose connections are connected.  All lines associated with the Tote bin have been thoroughly purged with high purity nitrogen to the Catalyst Vent [CV]. During this operation, the field operator will ask the DCS operator to open/close some on/off valves. Thus the valve commands must be available to the DCS operator (released by the sequence).  All manual valves are in the correct position.

STEP: Prestart Wait until

CAT_SEL position is “Ziegler SDX” and Operator confirms tote bin connected and purging complete.

Lock

CAT_SEL in “Ziegler SDX” position

If

LAL-30076 not activated then Message “Stock line not empty” Confirm continue or fail If Continue then Return to “CAT_SEL position is”ZIEGLER SDX” and operator confirms…” Line If fail then goto fail step

Endif {Verify tote bin isolated from Transfer system} Close

XV-30065, XV-30066

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION {Verify catalyst stock pipe isolated from Tote Bin} Close

XZV-30070, XZV-30071, XV-30074, XV-30079

Start

Isolate stock pipe lower section and depressurize stock pipe upper section

STEP: Isolate lower section and depressurize upper section

Close

XV-30075, XV-30078

Wait until

XV-30075, XV-30078 are closed

{Open pressure control system for lower section} Set

PIC-30075 in Man and PIC-30075.OP= 0% (PV-30075 closed)

Open

XV-30077

{Isolate pressure control for upper section} Set

PIC-30075 in Auto and ramp PIC-30075.SP= from 0 to P3

Wait until

PIC-30075.PV= +/-1 % of P3 (adjustable)

Set

PIC-30070 in Man PIC-30070.OP= 0% (PV-30070 closed)

Close

XV-30073, XV-30076, XV-30072

Wait until

XV-30073, XV-30076, XV-30072 are closed {Vent upper section}

Open

XV-30074, XV-30079

Wait until

PIC-30070.PV and PZI-30072 <= P2 + 0.5 bar (adjustable)

STEP: Open stock pipe upper section to convey section

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

Open

XZV-30070, XZV-30071

Wait until

XZV-30070 and XZV-30071 are open

Close

XV-30074 and XV-30079

Wait until

XV-30074 and XV-30079 are closed.

{Allow upper section pressures to stabilize} Wait

t2

STEP: Catalyst transfer {Pressurise Tote bin for transfer} Open

XV-30066

Wait until

PI-30066 = P1 +/- 1% (adjustable value)

{Open Tote bin outlet line to initiate transfer}

Message

“Field operator to open tote bin outlet valve”

Message

“Confirm transfer complete”

Wait until

Operator confirms transfer is completed.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

Close

XZV-30070 and XZV-30071

Wait until

XZV-30070 and XZV-30071 are closed

Start

“Reinstate catalyst injection system” step and “Tote bin depressurization” step

STEP: Reinstate catalyst injection system Run in parallel with “Tote bin depressurization” step

Message

“Confirm ready to connect upper and lower stock lines”

Wait until

Operator confirms

{Pressurise upper section} Set

PIC-30070 in MAN with PIC-30070.OP = 0%

Open

XV-30072

Set

PIC-30070 in Auto with PIC-30070.SP = P3

Wait until

PIC-30070.PV = +/- 5% of P3 (adjustable)

Message

“Upper section pressurised”

{Isolate pressure control for lower section} Set

PIC-30075.OP = 0% (valve closed)

Close

XV-30077

Wait until

XV-30077 closed

{De-isolate upper section from the lower section} Open

XV-30078 and XV-30075

Wait until

XV-30078 and XV-30075 are open

{Check for blockage} Wait

t4

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

If

LAL-30076 activated then Message pipe”

“Upper stock line blockage. Unblock catalyst stock

Wait until

Operator confirms stock pipe is unblocked

Endif

STEP: Tote bin depressurization Run in parallel with “reinstate catalyst injection system” step Close

XV-30066

Wait until

XV-30066 is closed

Open

XV-30065

Wait until

PI-30066 < P4

Close

XV-30065

Unlock and set

CAT_SEL to “No selection” position

End

2.1.2

Failure monitoring during sequence The sequence should fail under the following conditions:  Operator requests abort or,  Any valve used by the sequence fails or,  Any interlock prevents a valve from moving to the required position: -

I-3069-O: Ziegler catalyst (SDX) stock lines backflow protection

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION -

I-3070-S: Ziegler catalyst (SDX) storage HP/LP interface protection

-

I-3071-O: HP nitrogen open path to CV (SDX) protection

Failure Actions: Close XV-30067, hold timers. Recovery: restart the sequence from the start of the step where the failure occurred and reset alarms set by the sequence.

2.1.3

List of parameters used These are for guidance and are to be available to the operator for changing during commissioning. CAT_SEL

Catalyst used (operator selected) 3-positions selector: Ziegler SDX / No selection / Ziegler NCT

Pressure P1

= 2 bar

Tote bin and Transfer line pressure

P2

= 0. 2 bar

Pressure at end of upper section depressurization

P3

= 27.5 bar

Catalyst stock pipe Normal Operating Pressure

P4

= 0. 2 bar

Tote bin Depressurisation

t2

= 30 s

Stock pipe Pressure Stabilisation

t3

= 20 min

Tote bin emptying time

t4

= 2 min

Catalyst stock pipe to Injection line transfer time

Time

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION 2.2

SEQUENCE SEQ-34-ZG NCT: ZIEGLER NCT CATALYST TRANSFER OPERATION This sequence is similar to sequence SEQ-34-ZG SDX.

2.3

SEQUENCE SEQ-35: METALLOCENE CATALYST TRANSFER OPERATION This Sequence is similar to SEQ-034-ZG SDX with the following difference: There is only one set of HPLL stock pipe Metallocene catalyst.

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

Metallocene Catalyst XV 30265 CV

PI 30266

XV 30266

TOTE BIN

LNP FO 30268

XZV 30270 XZV 30271

FO 30274

PIC 30270 PZI 30272

CV XV 30274

HNP PV 30270

XV 30279

XV 30272 LI 30275

XV 30273

XV 30276

PIC 30275

XV 30275 XV 30278 CV

PV 30275

PZT-40008 Reactor

XV 30277 PZDI 30273

LI 30276

To Catalyst rotary valves

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

3.

MINI KILL: SEQUENCE SEQ-46

3.1

MINI KILL OPERATION The Mini-kill sequence is used to inject a fixed quantity of CO into the reactor in order to stop or slow the reaction rate in a controlled manner. It is separate from the Maxi-kill system, which is operated by interlock I-4021-S and is only used to kill the reaction under emergency conditions. The Mini-kill should be initiated by the operator from the control room console via a pulse type DCS switch, HS-40611 or when HP liquid injection pumps both detected stopped or Ejector booster compressor detected stopped or one of the Cooling water loop pumps detected stops. A flag Sequence 46_status will indicate if the sequence is in progress or completed. When Sequence 46 is initiated the flag is set to ON. During that time another injection cannot be initiated until the sequence is completed.

3.2

SEQUENCE STEP: Start Wait until

HS-40611 = ON Or [P-409A and P-409B status = OFF for more than x seconds (adjustable timer) (negative triggered edge) - note 1] Or [P-405A status = OFF for more than y seconds (adjustable timer) (negative triggered edge) - note 1] Or [P-405B status = OFF for more than y seconds (adjustable timer) (negative triggered edge) - note 1] Or [K-401 status = OFF for more than z seconds (adjustable timer) (negative triggered edge) - note 1]

IF

HS-40611 = ON then No-kill = 1

IF

P-409A /B stopped OR P-405A /B stopped OR K-401 stopped then No-kill = 3

Check

Flag Sequence46_status = OFF

Check

First isolation XZV-40601, second isolation XZV-40602 and purge XZV40615 are closed

Check

CO feed XZV-40611 and vent XV-40603 and XZV-40604 are open

IF

checks are not correct then warn DCS operator

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION Note 1: motor status to be able to be overriden from DCS screen by operator to avoid mini kill in case of normal stop. The override status should be shown on the catalyst injection screen to ensure that the plant is not started up with overrides in place.

STEP: CO Injection

Set

Flag Sequence46_status = ON

IF

P-409A/B stopped OR P-405A/B stopped OR K-401 stopped THEN STOP Catalyst feed rotary valves X-380A/B and X-386A/B/C

Start

Timer Tkill

Close

CO feed XZV-40611

Wait until

CO feed XZV-40611 is closed.

Close

Vent XZV-40603 and XZV-40604

Wait until

Vent XZV-40603 or XZV-40604 is closed

{The CO volume is depressurised into the reactor and flushed to the reactor with Nitrogen or ethylene). Open

First isolation XZV-40601 and second isolation XZV-40602

Wait until

First isolation XZV-40601 and second isolation XZV-40602 are open

Wait

5 seconds

Open

Purge XZV-40615

Wait

Time period (adjustable between 2-5 sec)

Close

Second isolation XZV-40602

Wait until

Second Isolation XZV-40602 is closed

Close

Purge XZV-40615

Wait until

Purge XZV-40615 is closed

Open

Vent XZV-40603 and XZV-40604

Wait

5 seconds

Close

First isolation XZV-40601

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SPECIFICATION SEQUENCE DESCRIPTION

Wait until

First isolation XZV-40601 is closed

Open

CO feed XZV-40611

Wait until

CO feed XZV-40611 is open

Stop

Timer Tkill

Set

No-kill = No-kill – 1

IF

No-kill > 0 then goto step CO injection

Set

Flag Sequence46_status = OFF

END OF SEQUENCE

3.3

PARAMETERS

No-kill

3.4

Number of times kill sequence should operate

FAILURE An alarm should be raised to the operator if the timer Tkill reaches a timeout value (30 seconds) before the end of the sequence. The sequence fails in the event of: -

Operator abort or,

-

Any valve used by the sequence fails or,

-

Interlock I-4021-S is activated

Failure Actions: -

On operator abort: stop sequence and close all valves.

-

On Interlock I-4021-S is activated: Stop sequence and close XZV-40603, XZV-40604, XZV40615

Recovery: restart the sequence from the beginning.

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SPECIFICATION SEQUENCE DESCRIPTION

4.

START-UP SILO AUTOMATIC RECYCLE: SEQUENCE SEQ-60

4.1

RECYCLE OPERATION For HD grades, the reactor must be filled with start-up powder stored in the start-up silo V-690. The powder can remain in start-up silo for several weeks before it is conveyed to the reactor. Depending on its density the powder might need then needs to be periodically recycled to avoid powder compaction in the silo. The sequence is initiated by the DCS operator or when the silo is filled up to LAH-60071. The recycling is periodically started for a given time. The sequence checks that the recycle routing is ready and initiates the recycling nitrogen conveying flow. The powder rotary valve is then started to recirculate the powder from the bottom to the top of the silo.

4.2

DESCRIPTION

STEP: Start Wait until

DCS operator starts the sequence OR LAH-60071

Wait until

Diverter XDX-60690 is set to Recycle position

STEP: Recycle Set

Nitrogen conveying FIC-60074 to AUTO with adequate SP

Wait until

Conveying blockage interlock I-6667-O is cleared

Start

Outlet rotary valve X-690

Start

Timer TRecycle

Wait until

Timer TRecycle is elapsed {Time = duration of recycling}

Stop

Outlet rotary valve X-690

Wait until

Timer TConveyLineClean {Time = time to clear conveying line}

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

Set

Nitrogen conveying FIC-60074 to MANUAL with FV-60074 closed

Wait until

Timer THoldRecycle {Time = time between each recycling}

Return to step Recycle

4.3

FAILURE MONITORING The sequence fails in the event of: -

Operator abort or,

-

Diverter valve XDX-60690 is not in recycling position or,

-

Any valve used by the sequence fails or,

-

Any interlock prevents a valve or motor moving to the position/status required by the sequence: I6667-O

Failure Actions are then: Stop rotary valve X-690, reset timers. Recovery: restart the sequence from the beginning.

4.4

LIST OF PARAMETERS USED

TRecycle

60, Oper

Recycling time

(min)

TConveyLineClean

120, Oper

time to clear conveying line

(s)

THoldRecycle

2, Oper

time between each recycling

(hr)

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SPECIFICATION SEQUENCE DESCRIPTION

5.

POWDER SAMPLING SYSTEM: SEQUENCE SEQ-62

5.1

PRINCIPLE A sequence is required to withdraw powder from the Degasser. This powder is used for off-line analysis. The sampling sequence is initiated by the operator locally by HS-60503. The sequence will withdraw a sample of powder into the holding pipe. It will degas the sample and then release the sample to the manual valve and inform the operator via the lamp that the sample is available to collect using the manual valve. The sample degassing time is automatically lengthened with powder containing Octene-1 comonomer (noted C8).

5.2

DESCRIPTION STEP: PRESTART Close

Sampling withdrawal line, vent, sample take-off, N2, XV-60531, XV60508, XZV-60509, XV-60510

Suppress

Low Nitrogen flow alarm FAL-60511

Wait until

Closed

If

XV-60531 or XV-60508 or XZV-60509 or XV-60510 fail – send message to operator

STEP: WAITING

Wait until

Local pushbutton, HS-60503 = Start

Message

“ Degasser sampling started “

Open

Vent XV-60508

Close

Withdrawal, sample take-off, N2, XV-60531, XZV-60509, XV-60510

Wait until

Vent XV-60508 is open and withdrawal, sample take-off, N2, XV60531, XZV-60509, XV-60510 are closed

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SPECIFICATION SEQUENCE DESCRIPTION

If

PZI-60514 > 0.25 bar

Message

“ Degasser sample system fault “ and XA-60514=Failed

STEP: TAKE SAMPLE Open

Withdrawal XV-60531

Wait until

Withdrawal XV-60531 is open

Wait

T1 { To be adjusted during commissioning to withdraw sufficient powder - initial value: T=2 min}

Close

Withdrawal XV-60531

STEP: DEGAS SAMPLE Wait until

Withdrawal XV-60531 is closed

Open

N2 XV-60510

Wait until

N2 XV-60510 is open

Wait

T2 { Calculated variable timer – timer longer for C8 operation }

Monitor

Nitrogen flow if FALL-60511 activated during T2, then sequence fails

Monitor

Nitrogen flow if FAL-60511 during T2, then Energise local alarm FAL-60511

When

T2 elapsed then Suppress Low Nitrogen flow alarms FAL-60511 and FALL-60511

Close

N2 XV-60510

STEP: EMPTY Wait until

N2 XV-60510 is closed and PZI-60514 < 0.25 bar

© INEOS Commercial Services UK Limited. All rights reserved. This document is the property of INEOS Commercial Services UK Limited, and the information and images it contains are strictly confidential and may not be altered or amended, copied, used or disclosed without the express permission of INEOS Commercial Services UK Limited.

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SPECIFICATION SEQUENCE DESCRIPTION

Close

Vent XV-60508

Wait until

Vent XV-60508 is closed

Open

Outlet XZV-60509

Wait until

Outlet XZV-60509 is open

Wait

T3 { 2 minutes}

Close

Outlet XZV-60509

Wait until

Outlet XZV-60509 is closed

Open

Vent XV-60508

Wait until

Vent XV-60508 is open

Open

N2 XV-60510

Wait

T4 { 30 seconds to purge any oxygen }

Close

N2 XV-60510

Wait until

N2 XV-60510 is closed and PZI-60514 < 0.25 bar

Close

Vent XV-60508 and N2 XV-60510

Energise

Lamp XL-60515 {Sample available and the operator can open the sample manual valve}

Wait until

Local pushbutton, HS-60505 = Reset sample ready lamp

De energise

Lamp XL-60515

Return to step waiting

5.3

FAILURE MONITORING The sequence should fail under the following conditions: - Field operator requests stop (Local HS-60504B stop pushbutton) or, - Control operator requests stop (DCS HS-60504A stop) or, - Any valve used by the sequence fails or, - Low Nitrogen flow alarm FALL-60511 (during “degas sample” step only, refer to above description) or, - High sample pipe pressure alarm PZAH-60514 or,

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SPECIFICATION SEQUENCE DESCRIPTION -

Any interlock that prevents a valve from moving to the required position: - I-6368-O: Nitrogen or process gas breakthrough on degasser sampling system - I-6369-S: Degasser powder sampling system operator

Failure actions are then : Close powder withdrawal XV-60531, powder vent XV-60508, powder sample take-off XZV-60509, nitrogen XV-60510 valves, reset timers and initiate local sequence failure alarm XA-60514. Recovery: restart the sequence from the start of the step where the failure occurred and reset alarms set by the sequence. Local panel: •HS-60503 to start the sequence •HS-60504B to stop the sequence •FAL-60511 lamp •PZAH-60514 lamp •XL-60515 sample ready lamp •HS-60505 to reset sample ready lamp •XA-60514 sequence failure lamp

5.4

LIST OF PARAMETERS USED

T1

2, Oper

Sampling time

(min)

To be adjusted during commissioning to withdraw sufficient powder. T2

Calc

Degassing time calculated as following:

(min)

T2 = 15 minutes if not “C8” operation. T2 = 45 minutes if “C8” operation The flag “C8” operation is calculated in the SIS and is transmitted to the DCS. Refer to interlock I-6838-S description of the “C8” calculation

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SPECIFICATION SEQUENCE DESCRIPTION

6.

POLYMERISATION LATERAL WITHDRAWAL: SEQUENCE SEQ-64

6.1

WITHDRAWAL OPERATION The withdrawal system removes polymer from the polymerisation reactor and transfers it to the degasser. It prevents direct connection between the reactor and the degassing system to reduce risk of overpressure in degasser. The rate of withdrawal is varied to control the reactor bed level. The system consists of four down flow lines and two up flow lines. Each line removes discrete batches of powder from the reactor into a lock hopper and which then discharges into the degasser. In the down flow lines powder initially settles on the valve above the lock hopper increasing the bulk density and the efficiency of the withdrawal. The up flow withdrawal lines rise from the reactor, so powder cannot settle above the lock hopper, but these lines are more effective at removing agglomerates.

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SPECIFICATION SEQUENCE DESCRIPTION

6.2

LINE SYNCHRONISATION The master withdrawal sequence synchronises the operation of the withdrawal lines in order to minimise disturbance to the degasser pressure. The total withdrawal rate (t/hr) is controlled by the reactor bed level controller (LBED) which manipulates the speed of the down flow lines. The rate for the up flow lines is set manually by the operator. The sequence keeps the total withdrawal rate constant if the rate of the up flow lines is changed by adjusting the rate of the down flow lines to compensate. The output of the bed level controller is high limited to prevent the down flow withdrawal lines being driven at a faster rate than they are capable of running. The up flow withdrawal rate is similarly limited.

Upflow_rate

LBED.OP

(from operator)

Output High Limit

Out

Out

+ -

Output High Limit

Master Sequence

Flag_A

Flag_B

Flag_C

Flag_D

Flag_E

Upflow

Upflow

Downflow

Downflow

Downflow

Line A

6.3

Line B

Line C

Line D

Line E

LINE OPERATION The normal cycle for a withdrawal from the reactor using a down flow line is as follows: Purge/Gravity fill: The take-off line or down flow lines is purged into the reactor with process gas via XV-603x8. This time is variable and depends on the withdrawal rate required. When the purge stops polymer is withdrawn from the reactor via XV-603x4 and XZV-603x3 and settles on top of XZV-603x5 for a time t(gravit).

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SPECIFICATION SEQUENCE DESCRIPTION The purge is not required on up flow lines and the purge step is a simple hold time which depends on the withdrawal rate. Fill: XZV-603x5 is opened for a time t(fill) to allow powder to flow into the lock hopper. Empty: XZV-603x6 is opened for a period t(empty) to discharge powder into Degasser. Assist: If the operator has set the assist gas on, then a period t(drop) is started while XZV-603x6 opens and lock hopper emptying prior to open XV-603x7. XV-603x7 provides gas from main loop compressor to convey the powder to the degasser. The purge/gravity period for one withdrawal overlaps the empty period for the previous withdrawal. The assist period can overlap with purge/gravity period and the fill period. In order to achieve maximum withdrawal rates the time from the DCS issuing a command to operate a valve to receiving confirmation that the valve has operated should be less than 1s. This is critical for valves XZV-603x5, XZV-603x6, XV-603x7 and XV-603x8. Any delays in the DCS processing of the sequence due to scan time limitations must also be minimised and kept below a total of 1s for each cycle of the sequence.

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SPECIFICATION SEQUENCE DESCRIPTION

Time(s) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

XV603x8

Typical timing diagram for a given down flow line XZVXZVXVpurge t(gravit) t(fill) 603x6 t(drop) 603x5 603x7 t(empty)

t(assist)

O O

C O C

O

C

O

C O

Each line has three possible operating set points: TAKE_OFF: Polymer is withdrawn from the reactor and the number of withdrawals is counted. FLUSH: This mode is used to clear the line of powder. The valves XV-603x4 and XZV-603x3 are closed isolating the line from the reactor and nitrogen fed into the line via XV-603x2 and flushed through the lock hopper. A fixed number of flush cycles are completed and then the line is switched to STOP. A line cannot be changed from TAKE-OFF to STOP without going through the FLUSH mode.

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SPECIFICATION SEQUENCE DESCRIPTION STOP: All the valves on the line are closed. The line remains in this mode until the operator modifies the set point. When the line is stopped it must be possible for the operator to take manual control over the valves if required and if interlocks acting on the relevant valves are reset.

6.3.1

Up flow Line The up flow lines are identical to the down flow lines except that the take-off line rises from the reactor instead of falling and there are no purge valves. Powder cannot fall into the withdrawal line under gravity but is conveyed into the lock hopper by the pressure difference between the reactor and the lock hopper. The sequence of operation for the up flow line is almost identical to that for the down flow line, only purge step is different: the differences are indicated in the description.

6.3.2

Alarms Blockage alarms are raised if the lock hopper fails to pressurise or depressurise or purge flow is not sufficient (purge flow alarm not used for up flow lines). The line is automatically switched to flush.

6.3.3

Failure modes The line sequence will fail if any valve fails, or an interlock stops the sequence operating or the process conditions in degasser do not allow withdrawal or the degasser outlet rotary valve is stopped. The line is switched to flush if this can be completed without further process upset; otherwise the line is switched immediately to stop.

6.4

MASTER SEQUENCE When started, this sequence is never stopped. STEP: Prestart If

Line A/B/C/D/E:PV = STOP and X-628 not running Then Line A/B/C/D/E:SP = STOP {Prevent operator start-up withdrawal if X-628 not running}

STEP: Calculations

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SPECIFICATION SEQUENCE DESCRIPTION {The following calculations are carried out continuously. It is necessary for all timers to accurately time events to better than  0.5 seconds} Set

Nup= No. of upflow lines in TAKE-OFF or FLUSH

If

Nup > 0 then {Avoid dividing by 0} If RATEup > MASSup / 1000 * MAXup_frequency* Nup then set RATEup= MASSup / 1000 * MAXup_frequency * Nup Endif Set Tup = 3600 * MASSup / 1000 / RATEup

(seconds)

Endif Ndown: Set

Ndown = No. of downflow lines in TAKE-OFF or FLUSH

If

Ndown > 0 then Set (LBED.OP) high limit = Ndown* MAXdown_frequency * MASSdown / 1000 + RATEup Set RATEdown (t/hr) = (LBED.OP) – RATEup Set Tdown = 3600 * MASSdown / 1000 / RATEdown

(seconds)

Endif STEP: Phase Control Up flow {Phase control for the up flow withdrawal lines This step operates continuously once started} Start: Wait Tup {Tup is constantly updated. The wait function must be able to adjust the waiting time} LineA: If LineA.PV = STOP and LineB.PV = STOP then goto Start If LineA.PV <> STOP then pulse flag_A Else goto Line_B: Wait Tup

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SPECIFICATION SEQUENCE DESCRIPTION

LineB: If LineB.PV <> STOP then pulse flag_B Else goto Line_A: Goto Start:

STEP: Phase Control Down flow {Phase control for the down flow withdrawal lines This step operates continuously once started} Start: Wait Tdown {Tdown is constantly updated. The wait function must be able to adjust the waiting time} LineC: If LineC.PV = STOP AND LineD.PV = STOP AND lineE.PV = STOP then goto Start If LineC.PV <> STOP then set flag_C Else goto Line_D: Wait Tdown LineD: If LineD.PV = STOP AND lineE.PV = STOP then goto Start If LineD.PV <> STOP then set flag_D Else goto Line_E: Wait Tdown LineE: If LineE.PV <> STOP then set flag_E Else goto Line_C: Goto Start:

6.5

LINE SEQUENCE This Line sub sequence controls line C take-off. Lines A, B, D, E are identical except for tags (refer to relevant PIDs for tags).

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SPECIFICATION SEQUENCE DESCRIPTION The diagram below shows the relationship between the steps of the line sequence. The valve positions should not be verified unless specifically stated.

START

Mode SP=STOP

Stop

SP=FLUSH

Flush

Purge

SP=TAKE- OFF

Take-off

Empty

Assist

Fill Counts

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SPECIFICATION SEQUENCE DESCRIPTION

Sketch for a down flow line:

Reactor XV 60301

XV 60304

HN

XV 60302

Purge FI-60301

XZV 60303

XZV 60305

XV 60308

PI-60301 Lock hopper (C)

XZV 60306

Assist Gas XV 60307

6.5.1

To Degasser

XZV 60521

Sequence Description STEP: Mode IF

LineC:SP = STOP and LineC:PV = TAKE-OFF then LineC:SP = FLUSH

IF

LineC:SP = STOP then GOTO STOP

IF

LineC:SP = FLUSH then GOTO FLUSH

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SPECIFICATION SEQUENCE DESCRIPTION

IF

LineC:SP = TAKE-OFF then GOTO TAKE-OFF

END

STEP: Stop {STEP performed when LineC:SP = STOP } Close

XV-60304, XZV-60303, XZV-60305, XZV-60306, XZV-60521, XV-60307, XV60308, XV-60302

Set

LineC:PV = STOP

Clear alarms

PAL-60301, PAH-60301, FAL-60301, SEQ-64_ALM01C, SEQ-64_ALM02C, SEQ-64_ALM03C

Set

flush_C = 0

Set

first_runC = TRUE

END

STEP: Flush { STEP performed when LineC:SP = FLUSH } Start

monitor 1

Close

XV-60304, XZV-60303, XV-60308 {XV-60308 not in upflow line}

WAIT UNTIL

XZV-60303 and XV-60308 are closed {XV-60308 not in upflow line}

Open

XZV-60521, XV-60302

Set

LineC:PV = FLUSH flush_C = flush_C + 1

IF

flush_C >= flush_max THEN Set LineC:SP = STOP

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SPECIFICATION SEQUENCE DESCRIPTION

Set

flush_C = 0

ENDIF END

STEP: Take-Off { STEP performed when LineC:SP = TAKE-OFF } Start

monitor 1 & 2

Open

XZV-60521

Close

XV-60302

WAIT UNTIL

XZV-60521 is open AND XV-60302 is closed

Open

XZV-60303 and XV-60304

Set

LineC:PV = TAKE-OFF

END

STEP: Purge {This step runs in parallel with the Empty and Assist steps} {Take off leg purge and gravity transfer of powder to take-off line} IF

LineC:PV=TAKE-OFF then Open

XV-60308 {this line does not exist for upflow lines}

ENDIF Wait until

Flag_C is set

{Confirm that the Purge flow to the take off leg is sufficient} IF

FI-60301 < F1C and XV-60304.SP = OPEN then set FAL-60301 {this line does not exist for upflow lines}

ENDIF

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SPECIFICATION SEQUENCE DESCRIPTION

Close

XV-60308 {this line does not exist for upflow lines}

WAIT

t (gravit)C

END STEP: Fill {Fill step starts only once purge and empty steps have completed} {Filling lock hopper} WAIT UNTIL

XZV-60306 closed

Open

XZV-60305

WAIT

t(fill)C

IF

PI-60301 < P1C and XV-60304.PV = OPEN then Set

PAL-60301

{Additional confirmation that XZV-60306 is closed}

{If failed to pressurise raise alarm and flush}

If LineC.SP = TAKE-OFF then LineC.SP = FLUSH Endif ENDIF Close

XZV-60305

END STEP: Empty {This step runs in parallel with the purge and assists steps} {Transfer from lock hopper to Degasser} IF

XZV-60305 not closed then raise SEQ-64_ALM01C

WAIT UNTIL

XZV-60305 closed

IF

not first_runC then

Open

{Rate limit alarm}

{Additional confirmation that XZV-60305 is closed} {Skip the empty step on first run to allow synchronisation}

XZV-60306

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SPECIFICATION SEQUENCE DESCRIPTION

WAIT IF

t(empty)C PI-60301 > P2C then Set PAH-60301 If LineC.SP = TAKE-OFF Then LineC.SP = FLUSH Endif {If failed to depressurise raise alarm and flush}

ENDIF Close

XZV-60306

ENDIF Set

First_run = FALSE

END

STEP: Assist {This step runs in parallel with the empty and purge steps} IF

assist_on then Wait until Wait

XZV-60305 closed

{Additional confirmation that XZV-60305 is closed}

t(drop)C

Open

XV-60307

Wait

t(assist)C

Close

XV-60307

ENDIF END

STEP: Counts {Increment the withdrawal counter}.

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SPECIFICATION SEQUENCE DESCRIPTION

Set

TCycC = TimerC

Reset and Start

time TimerC

IF

LineC:PV = TAKE OFF and XV-60304.PV = OPEN Actual_rate_C = 3600 / TcycC With_C = With_C + 1

ENDIF END

6.5.2

Failure Monitoring The failure monitoring detects any conditions that require the withdrawal line to be stopped. When active the failure condition must be monitored continuously. The operator interface must give a clear indication of the cause of the failure. Monitor 1 {Stop line without flush – used where there is risk of overpressure of Degasser}. IF

XZV-60305, XZV-60306, XZV-60521, failed OR an interlock prevents the sequence from operating these valves OR operator requests abort Raise

alarm SEQ-64_ALM02C

Stop

monitor 1 and monitor 2

Stop

execution of line sequence C

Set

LineC.SP = STOP

Set

LineC.PV = STOP

Close

Restart

XV-60304, XZV-60303, XZV-60305, XZV-60306, XZV-60521, XV-60308, XV60302 line sequence at Step:Mode

ENDIF END

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SPECIFICATION SEQUENCE DESCRIPTION

Monitor 2 {Stop line with flush} IF

XV-60301 is detected open, XV-60302, XV-60308, XZV-60303 Failed OR an interlock prevents the sequence from operating these valves OR I6207-O activated OR I-6338-S activated OR I-4041-S OR I-6342-S activated Raise Stop IF

failure alarm SEQ-64_ALM03C monitor 2 LineC:SP = TAKE-OFF THEN Set LineC:SP = FLUSH

ENDIF END Recovery: restart the sequence from the beginning.

6.5.3

6.6

Alarms and trips PAL-60301

Low priority

Blockage above lock hopper C

PAH-60301

Low priority

Blockage below lock hopper C

FAL-60301

Low priority

Blockage in takeoff line C {this alarm does not exist for upflow lines}

SEQ-64_ALM01C

Low priority

Line C at maximum rate

SEQ-64_ALM02C

Low priority

Line C failure – stop

SEQ-64_ALM03C

Low priority

Line C failure – flush

LIST OF PARAMETERS USED All parameters for line C are typical and are replicated for Lines A, B, D and E.

LBED.OP

Calc

Output from the bed level controller

Nup

Calc

No. of up flow lines in TAKE-OFF or FLUSH

MASSup

99.6

Nominal mass of powder per up flow withdrawal

(t/hr)

(kg)

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SPECIFICATION SEQUENCE DESCRIPTION

MAXup_frequency

136

Maximum frequency for one up flow line (Approx 3600 / (t(fill) + t(empty) + 2))

(wd/hr)

RATEup

Calc

Withdrawal rate for up flow lines

(t/hr)

Tup

Calc

Time between two up flow withdrawals

(s)

Ndown

Calc

No. of down flow lines in TAKE-OFF or FLUSH

MASSdown

132.8

Nominal mass of powder per down flow withdrawal

(kg)

MAXdown_frequency

120

Maximum frequency for one down flow line (Approx 3600 / (t(fill) + t(empty) + 2))

(wd/hr)

RATEdown

Calc

Withdrawal rate for down flow lines

(t/hr)

Tdown

Calc

Time between two down flow withdrawals

(s)

Flag_C

Calc

Flag to initiate a withdrawal (Flag is pulsed for a time sufficient for the line sequence to catch it)

t(gravit)C

7.0s

Fill time for withdrawal leg following purge

t(fill)C

10.5s

Time to fill lock hopper (Start XZV-60305 open to start close)

t(empty)C

Time to empty lock hopper (Start XZV-60306 open to start close). 17.3s for lines C,D,E; 14s for lines A,B.

assist_on

Set by operator if assist gas is required

t(drop)C

10s

Time before assist gas is applied (XZV-60306 has time to open and lock hopper (C) is emptying prior to open XV-60307)

t(assist)C

10.0s

Time that assist gas is applied

(s)

Timer used to calculate cycle time

(s)

TimerC TcycC

Meas

Measured withdrawal cycle time

(s)

Actual_rate_C

Calc

Actual line C rate

(wd/hr)

P1C

1

Lockhopper (C) low fill pressure threshold

(bar)

P2C

23

Lockhopper (C) high empty pressure threshold

(bar)

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SPECIFICATION SEQUENCE DESCRIPTION

F1C

915

FI-60301 low threshold {this threshold does not exist for up flow lines}

With_C

Calc

Withdrawal count (Reset by operator)

flush_C

Calc

Number of flushes on line C

flush_max

3

Number of flushes required

first_runC

Boolean

First run of line C

(kg/hr)

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SPECIFICATION SEQUENCE DESCRIPTION

7.

AGGLOMERATE DETECTION ON ROTARY VALVES: SEQUENCE SEQ-65 The purpose of the sequence is to “count” the agglomerates by recording and calculating current spikes that they generate when passing through the degasser outlet rotary valve and the purge column outlet rotary valve. The current spikes for the two rotary valves are independently counted. The below description is similar for both rotary valves

7.1

HARDWARE REQUIREMENT Fast response time of the entire detection system is essential to detect as much as possible spikes. The scan time of the current meter, the DCS or PLC input card and the sequence must be 50 ms. A fast scanning PLC should be used if the DCS cannot meet the requirement. The current transmitter range must be defined to measure the overcurrent. If a fast scanning PLC is used, a set of data defined below must be sent to the DCS. The DCS operator must be able to adjust the percent trigger value from the DCS.

7.2

SEQUENCE DESCRIPTION The sequence covers the following operating steps: Detection of Amp spikes is made by comparing a rolling average of current to signal drops.  Calculation of rolling average of current Store the input value every 10 seconds and keep a “rolling window” over the last 20 minutes. This is used as a floating baseline value for comparison. The “rolling window” must be able to be adjusted by adjusting the sample time: Rolling window (in mn) = (120 x sample time) / 60 The operator should have the possibility to substitute a manually entered fixed base line to calculated baseline in order to get values for the first 20 minutes after calculation start-up.  Data storages during Amp spikes When the signal is above the baseline by more than 10% (trigger value), the program will then:

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SPECIFICATION SEQUENCE DESCRIPTION -Count the number of program scans. The signal is above the trigger value to determine the trigger duration. -Store the value of spikes magnitude at each scan to determine the total spike size. -Compare the signals each scan and capture the maximum amp spike value.  Determination of Amp spikes properties when the signal drops below the trigger -Amp spike duration is calculated by multiplying the number of scans above trigger value by the system scan time. Spike duration = numbers of scan x scan rate -Amp spike size is calculated by totalizing all signal magnitude recorded above trigger value. Total Spike size = Σ recorded spike sizes -Record the maximum amp spike value. Spike magnitude = maximum of spike sizes -Then send the 3 data to the DCS for storage.  Spike data reset All the spike data will be reset 2 seconds after the signal drops below the trigger value or when a new trigger is set.  Spike data historization in DCS In parallel to those calculations, an historization of the 60 minutes moving average spike data will be performed in the DCS.

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SPECIFICATION SEQUENCE DESCRIPTION SPIKE DETECTION ALGORITHM READ NEW AMP SIGNAL FROM ROTARY FEEDER FVD EVERY SCAN (Approx 80mSEC)

NO

NO IS SPIKE DETECTION FLAG ON ? YES

SPIKE DETECTED: SET SPIKE DETECTION FLAG ON

CALCULATE SPIKE DURATION: #SCANS * SCAN RATE

INCREMENT SCAN COUNTER FOR CURRENT SPIKE : #SCANS = # SCANS 1

RESET SPIKE DATA: #SCANS SPIKE SIZE SPIKE DURATION MAX SPIKE MAGNITUDE

ASSUME ROTARY FEEDER NOT RUNNING

YES STORE THE LAST 120 AMPS SIGNALS (20 minutes)

CALCULATE BASELINE (20 min. moving AVG)

INTEGRATE SPIKE TOTAL SPIKE: SIPK SIZE = (SPIKE SIZE + CURRENT MAGNITUDE)

IS CURRENT SPIKE MAGNITUDE > MAX SPIKE MAGNITUDE

NO

IS AMP SIGNAL > 2.9 AMPS? (Note 1)

YES

SPIKE DETECTED SET SPIKE DETECTION FLAG OFF

RECORD : SKIPE SKIPE DURATION SPIKE SIZE MAX SPIKE MAGNITUDE

Once every 10 seconds

IS CURRENT AMP > X% OF BASELINE (X is adjustable)

END

NO

YES

END

SET MAX SPIKE MAGNITUDE = CURRENT SPIKE MAGNITUDE

END

SPIKE SUMMARY ALGORITHM UPDATE SPIKE MINUSTES SUMMARY COUNTERS : SKIPES Every SKIPE DURATION Every second SPIKE SIZE minute MAX SPIKE MAGNITUDE

STORE SPIKE SUMMARY MINUTE COUNTER RESULTS: SPIKES SKIPE DURATION SPIKE SIZE MAX SPIKE MAGNITUDE

CALCULATE 60 MIN MOVING AVERAGES: SPIKES SKIPE DURATION SPIKE SIZE MAX SPIKE MAGNITUDE

RESET MINUTE SUMMURY COUNTERS

HISTORIZE 60 MIN MOVING AVERAGES: SPIKES SKIPE DURATION SPIKE SIZE MAX SPIKE MAGNITUDE

END

NOTE 1: AMPS SIGNAL TRESHOLD TO BE FINALISED DURING DETAIL ENGINEERING.

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SPECIFICATION SEQUENCE DESCRIPTION

8.

AGGLOMERATE REMOVAL: SEQUENCE SEQ-83

8.1

AGGLOMERATE REMOVAL OPERATION Sequences are required to recover and remove agglomerates from the Polymer Vibrating Screen (several times per day). The sequence is initiated by the field operator from a local control panel. Under normal operation, the agglomerate withdrawal leg is open to waste stream from the screens and continually purged with a nitrogen flow. When high level alarm (LAHH-80012) is activated or on a routine basis, the field operator should initiate the sequence to allow safe discharge of the agglomerates to waste. The sequence can be started and stopped from local (HS-80020). From DCS screens the sequence can only be stopped (HS-80021). The sequence will discharge the agglomerates to a big bag. The sequence should continually monitor the status of those valves required for withdrawal and discharge.

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SPECIFICATION SEQUENCE DESCRIPTION

8.2

DESCRIPTION STEP: Start Close

outlet XV-80017

Wait until

closed

Open

inlet XV-80016

Wait until

HS-80020 = Start

Close

Inlet XV-80016

Wait until

Inlet XV-80016 is closed

Open

Outlet XV-80017

Wait

60s

IF

LAHH-80012 activated then Warn operator that the discharge pipe not empty

Close

Outlet XV-80017

Wait until

Outlet XV-80017 is closed

Return to step Start

8.3

FAILURE MONITORING The sequence fails in the event of: -

Operator abort (HS-80020/HS-80021) or,

-

Any valve used by the sequence fails or,

-

Any interlock prevents a valve moving to the position required by the sequence: - I-8260-O

Failure Actions are then: Stop sequence, close all valves, reset timers and initiate local sequence failure alarm XA-80020.

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SPECIFICATION SEQUENCE DESCRIPTION Recovery: restart the sequence from the beginning.

8.4

LIST OF PARAMETERS USED NA

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