V4-ch04-complex Control Rev 1- Upto Pellet Flow Control

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

Nov Vol.

VOLUME 4

CHAPTER 4

COMPLEX CONTROL

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SPECIFICATION COMPLEX CONTROL

Complex Control Loops and Calculations

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SPECIFICATION COMPLEX CONTROL

TABLE OF CONTENTS

1.

INTRODUCTION ................................................................................................................................................................ 5 1.1 1.2

2.

REACTOR TEMPERATURE CONTROL ....................................................................................................................... 7 2.1 2.2 2.3 2.4 2.5

3.

35200L-000-DOD-P332-0004

NOZZLE CONTROL ......................................................................................................................................... 13 MAIN LOOP SEPARATOR LEVEL CONTROL ....................................................................................................... 13 HP LIQUID PUMPS MINIMUM FLOW CONTROL ................................................................................................... 13 CONDENSATION ............................................................................................................................................ 14

CATALYST ....................................................................................................................................................................... 15 5.1 5.2 5.3 5.4 5.5

6.

REACTOR GRID TEMPERATURE AND GRID DIFFERENTIAL TEMPERATURE ........................................................... 10 REACTOR SKIN TEMPERATURE DEVIATION....................................................................................................... 11 REACTOR TEMPERATURE TO CYCLONES TEMPERATURE DEVIATION .................................................................. 11 REACTOR DIFFERENTIAL TEMPERATURE ......................................................................................................... 12 MAIN LOOP COMPRESSOR GUIDE VANES ......................................................................................................... 12 SPRAY NOZZLE TO MAIN LOOP CONDENSER CONTROL ..................................................................................... 12

HIGH PRODUCTIVITY .................................................................................................................................................... 13 4.1 4.2 4.3 4.4

5.

MAIN TEMPERATURE CONTROLLER (TIC-40046)............................................................................................... 7 STEAM MAKE-UP FLOW FIC-40072 .................................................................................................................. 8 COOLING WATER MARGIN ................................................................................................................................ 8 ALARMS AND TRIPS ......................................................................................................................................... 9 OPERATOR INTERFACE .................................................................................................................................... 9

REACTOR MISCELLANEOUS CONTROL ................................................................................................................ 10 3.1 3.2 3.3 3.4 3.5 3.6

4.

ABBREVIATIONS .............................................................................................................................................. 6 REFERENCE DOCUMENTS ................................................................................................................................ 6

CALCULATION OF CATALYST QUANTITY IN LP/HP STOCK PIPES........................................................................ 15 CATALYST INJECTION (ZIEGLER OR METALLOCENE) ........................................................................................ 20 CATALYST INJECTION SCHEMES ..................................................................................................................... 20 INTERLOCKS AND ALARMS .............................................................................................................................. 21 OPERATOR INTERFACE .................................................................................................................................. 21

REACTOR GAS PHASE ANALYSERS (AT-40050/AT-40051)............................................................................... 22

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SPECIFICATION COMPLEX CONTROL

6.1

AT-40050/40051 GAS CHROMATOGRAPHS .................................................................................................... 22

7.

VRU MULTISTREAM ANALYSERS ............................................................................................................................ 26

8.

DEWPOINT IN REACTOR CALCULATION ............................................................................................................... 26 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8

INPUTS ......................................................................................................................................................... 27 DEW POINT CALCULATION PRINCIPLES ........................................................................................................... 28 FUGACITY CALCULATION ................................................................................................................................ 28 SUM OF LIQUID FRACTION CALCULATION ......................................................................................................... 31 DEW POINT CALCULATION ALGORITHM ............................................................................................................ 32 OPERATOR INTERFACE .................................................................................................................................. 34 ALARMS ........................................................................................................................................................ 34 ERROR HANDLING ......................................................................................................................................... 34

AVERAGE MOLECULAR MASS IN REACTOR AND IN GAS AND LIQUID PURGES ..................................... 34

9. 10.

10.1 10.2 10.3 11. 11.1 12. 12.1 12.2

ETHYLENE ................................................................................................................................................................... 36 ZIEGLER OPERATION ..................................................................................................................................... 36 METALLOCENE OPERATION ........................................................................................................................... 37 ALARMS AND TRIPS ....................................................................................................................................... 37 HYDROGEN ................................................................................................................................................................. 38 ZIEGLER AND METALLOCENE OPERATION ....................................................................................................... 39 COMONOMER ............................................................................................................................................................. 43 COMONOMER FLOW....................................................................................................................................... 43 CONTROL ..................................................................................................................................................... 44

13.

PENTANE ..................................................................................................................................................................... 46

14.

REACTOR PRESSURE CONTROL......................................................................................................................... 47

15.

REACTOR BED LEVEL ............................................................................................................................................. 50

15.1 15.2 15.3

BED LEVEL FROM PRESSURE DROP ............................................................................................................... 50 BED LEVEL CONTROLLER OUTPUT LIMITS ........................................................................................................ 53 OPERATOR INTERFACE .................................................................................................................................. 53

16.

TEAL INJECTION CONTROL................................................................................................................................... 54

17.

CHEMICAL ADDITIVES B1 AND S1 INJECTION CONTROL ............................................................................ 56

17.1 17.2

B1 INJECTION CONTROL................................................................................................................................. 56 S1 INJECTION CONTROL................................................................................................................................. 57

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SPECIFICATION COMPLEX CONTROL

18.

STRIPPING GAS FLOW TO THE DEGASSER CORRECTION ......................................................................... 58

19.

GRADE OPERATING WINDOW LIMITS (GROWL) ............................................................................................. 59

19.1 20. 20.1 20.2 20.3

OPERATOR INTERFACE FOR DEGASSING FLOWS DURING TRANSITIONS ............................................................. 62 FLUIDISATION VELOCITY IN REACTOR ............................................................................................................. 63 FLUIDISING GAS DENSITY ............................................................................................................................... 63 FLUIDISATION GAS MASS FLOW RATE .............................................................................................................. 64 FLUIDISATION VELOCITY ................................................................................................................................ 65

21.

PRODUCTION RATE ................................................................................................................................................. 66

22.

REACTOR RESIDENCE TIME, BED MASS, FLUIDISED BULK DENSITY ..................................................... 66

23.

EXTRUDER FEEDS CONTROL ............................................................................................................................... 68

23.1 23.2 23.3 23.4 23.5 24. 24.1 25.

INTRODUCTION.............................................................................................................................................. 68 POWDER FEED CONTROL ............................................................................................................................... 68 DETAILED CONTROL SCHEME OF PELLET FLOWRATE THROUGH EXTRUDER........................................................ 69 ADDITIVE FEEDS AND PELLET RERUN CONTROL ............................................................................................... 71 DETECTION OF POWDER BLOCKAGE IN THE POLYMER VIBRATING SCREEN ......................................................... 72 PELLETS FLOWRATE CONTROL .......................................................................................................................... 73 PELLETS FLOW RATE TO ELUTRIATION FROM PELLET BLENDERS ....................................................................... 73 INTERFACE BETWEEN DCS AND APC (OPTION) ............................................................................................. 74

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SPECIFICATION COMPLEX CONTROL

CONTENTS

1.

INTRODUCTION This document defines the specification for complex regulatory control, where this is not clear from the PID. 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 (along with the Instrument and Process Control Philosophy document) provides guidance in achieving these aims. Controllers listed in this specification must have the ability to have their setpoint ramped up and down by the operator. The operator must be able to enter the final setpoint and the ramp rate or time over which the setpoint is ramped. This facility is particularly useful during transitions. 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 To improve reading of the document, the instrument and equipment tags do not include the prefix3200

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SPECIFICATION COMPLEX CONTROL

1.1 Abbreviations DCS

Distributed Control System

(Main plant control system)

SIS

Safety Instrumented System

(Protective system)

PID

Process and Instrument Diagram

PV

Process value

OP

Controller or calculation block output

SP

Controller setpoint

Oper

Parameter set by operator

Calc

Calculated Parameter

Meas

Parameter given directly by a measure

IDS

Instrument Data Sheet

D.E.

Detailed Engineering Contractor

1.2 Reference documents  Instrument & Process Control Philosophy  PID‟s  Sequence Description  Process Interlock description

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SPECIFICATION COMPLEX CONTROL

2.

REACTOR TEMPERATURE CONTROL Heat is removed from the reactor gas loop by water circulating through the main loop condenser. The cooled gas and condensed liquid returns via the main loop separator to the polymerisation reactor where it cools the polymer bed. The cold water is added to the main loop condenser circulating water loop, at the inlet of the loop condenser. The reactor temperature is controlled by manipulating the setpoint for the circulating water temperature controller. The reactor temperature control system has physical characteristics that make the design of the control loop critical. Due to the exothermic nature of the reaction, at high production rates the temperature is open loop unstable. This means that it cannot be manually controlled by the operator. There are long process and measurement delays. This makes the loop susceptible to oscillation if disturbances or non-linearity are present. The temperature interacts with other parameters on the reactor particularly the separator level, the ethylene partial pressure and the reactor bed level.

2.1 Main temperature controller (TIC-40046)

Reactor outlet pipe

Reactor outlet pipe

TI 40047 PV

TI 40048 PV

HS-40001

Main loop condenser cooling water inlet

APC (Option) SP

OPER

PV TIC 40046 OP

Reactor

Main loop condenser cooling water inlet

TI 40072B PV

TI 40072A PV

HS-40072

SP

PV TIC 40072 OP

Main loop condenser inlet

PV

SP FIC 40070 OP

Cooling water to Main loop condenser inlet

FV 40070A/B

Cooling water return from Main loop condenser (Split range)

The reactor temperature is measured in the reactor gas outlet pipe using TI-40047 or TI-40048. The temperature probes are directly inserted in the process gas without Thermowell to improve the

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SPECIFICATION COMPLEX CONTROL response time. The actual measurement used is selectable by the operator via HS-40001 or automatically in the case of transmitter fault. The output of TIC-40046 resets the slave temperature controller TIC-40072 for the circulating water at the inlet of the main loop condenser. The slave temperature controller adjusts the cold cooling water flow entering the circulating water at the inlet nozzle of the main loop condenser. The circulating water temperature is measured by two temperature measurements using TI-40072A or TI-40072B. The temperature probes are directly inserted in the cooling water without Thermowell to improve the response time. The actual measurement used is selectable by the operator via HS-40072 or automatically in the case of transmitter fault. The operator has the option of using a setpoint ramp function on master controller to limit the disturbance caused by sudden setpoint changes. This ramp function ramps from the current setpoint to a new setpoint at a rate of 1.5°C/h. The ramp must stop if the operator makes a manual change to the setpoint or the controller is put into manual mode. Interlock I-4021-S (Maxi Kill) acts if the reactor temperature exceeds TIC-40046.SP by more than 5°C. Protection must be provided to prevent the operator from setting the setpoint more than 5°C below the current process variable. This is to prevent the operator accidentally initiating the interlock that acts on the difference between setpoint and process variable. The mechanical distance between the cooling water mixing point (cooling water & circulating water) and the main loop condenser inlet nozzle must be minimised to reduce the transport delays as far as possible.

2.2 Steam make-up flow FIC-40072 Steam is used to heat up part of the main cooling water loop flow in main loop condenser in order to heat the reactor during start-up. The set point is provided by the operator.

2.3 Cooling water margin The heat removal capacity of the main loop condenser is a limit on the design production capacity of the plant. As this limit is reached the temperature control will become unstable. The cooling water margin is an indication that the reactor is approaching this limit. MARGIN

= TIC-40072.PV – TI-40201

Where TIC-40072.PV

Meas

Recirculating water inlet to main loop condenser

°C

TI-40201

Meas

Fresh cooling water to main loop condenser water circulating system

°C

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SPECIFICATION COMPLEX CONTROL 2.4 Alarms and trips The following interlock act on the temperature control If TIC-40046.PV – TIC-40046.SP > 5 °C then the maxi-kill sequence, I-4021-S is initiated. Alarms are defined as follows: TIC-40046.PV – TIC-40046.SP > +/-1 °C

Low priority

TIC-40046.PV – TIC-40046.SP > +/-3 °C

High priority

MARGIN < 3 °C

High priority

Deviation alarm between TI-40047 and TI40048 when difference > +/-1 °C

Low priority

2.5 Operator interface All the components of the temperature control should be shown on a single display. The main loop separator level control and flow to the high productivity nozzles should be shown on the same display.

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SPECIFICATION COMPLEX CONTROL

3.

REACTOR MISCELLANEOUS CONTROL

3.1 Reactor grid temperature and grid differential temperature

3.1.1

Reactor grid differential temperature The reactor grid differential temperatures are used to give an indication of agglomerate formation. TDI-40001 = TI-40001 – TIC-40046.PV (Note these values will normally be negative) TDIF-40001 = TDI-40001 filtered T0. Where T0

=5

Filter time, adjustable on line

min

These calculations are repeated for TI-40002/40003/40004/40007/40008 and TDI40002/40003/40004/40007/40008. A common alarm is raised for each of the three following conditions:

3.1.2

TDI-40001 or TDI-40002 or TDI-40003 or TDI-40004 or TDI-40007 or TDI40008 > +1 °C

Low priority

TDI-40001 or TDI-40002 or TDI-40003 or TDI-40004 or TDI-40007 or TDI40008 < -10 °C

Low priority

TDIF-40001 or TDIF-40002 or TDIF-40003 or TDIF-40004 or TDIF-40007 or TDIF-40008 < -7 °C

Low priority

Reactor grid temperature Reactor grid temperature also gives an indication of agglomerate formation. TIF-40001 = Absolute value | TI-40001 – (TI-40001 filtered T1) | This calculation is repeated for TI-40002/40003/40004/40007/40008. A common low priority alarm is raised for the following condition:

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SPECIFICATION COMPLEX CONTROL

TIF-40001 or TIF-40002 or TIF-40003 or TIF-40004 or TIF-40007 or TIF-40008 > +1 °C

Low priority

Where T1

=5

Filter time, adjustable on line

min

3.2 Reactor skin temperature deviation The reactor skin temperatures are also used to give an indication of agglomerate formation. A common low priority alarm is raised if any skin temperature satisfies the following condition: Absolute value : | (TI-40010 – AVERSKIN) – [(TI-40010 – AVERSKIN) filtered T2] | > +1°C Where AVERSKIN

Calc

Average of all reactor skin temperatures, TI-40010 to TI-40038.

°C

T2

=6

Filter time, adjustable on line

h

This calculation is repeated for all reactor skin temperatures, TI-40010 to TI-40038.

3.3 Reactor temperature to cyclones temperature deviation Reactor temperature to cyclones temperature deviation gives an indication of cyclone blockage by the powder. High priority alarms are generated as follow: Absolute value: | (TI-40050 – TICF-40046.PV) – [ (TI-40050 – TICF-40046.PV) filtered T4 ] | > +1 °C Absolute value: | (TI-40051 – TICF-40046.PV) – [ (TI-40051 – TICF-40046.PV) filtered T4 ] | > +1 °C Where TICF-40046.PV = TIC-40046.PV filtered T3 T3

= 10

Filter time to compensate for time lag between reactor and cyclone temperature measurements.

sec

T4

=6

Filter time, adjustable on line

h

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SPECIFICATION COMPLEX CONTROL 3.4 Reactor differential temperature The reactor differential temperature gives an indication of the start-up of the reaction. Reactor differential temperature: TDI-40904 = TIC-40046.PV – Mo3 TZI-40064A/B/C. Where

TDI-40904

Calc

Reactor differential temperature

°C

TIC-40046.PV

Meas

Reactor temperature

°C

TZI-40064A/B/C

Meas

Reactor gas inlet temperature

°C

3.5 Main loop compressor guide vanes It should not be possible for the operator to move the main loop compressor guide vanes HV-40061 by more than 2° in a single step.

3.6 Spray nozzle to main loop condenser control Liquid is sprayed at the inlet of the main loop condenser. In case of loss of liquid flow to the spray nozzle, there is a risk of nozzle blockage by fines from process. To avoid the nozzle blockage, the nozzle is automatically flushed with process gas. If PDI-40056 < 0.3 bar then open gas valve XV-40056 If PDI-40056 > 0.5 bar then close gas valve XV-40056 The operator should be able to switch this control scheme into manual if required Where: PDI-40056 XV-40056

Meas

Difference between liquid to nozzle and inlet gas to main loop condenser

bar

Loop gas to nozzle isolation valve

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SPECIFICATION COMPLEX CONTROL

4.

HIGH PRODUCTIVITY

4.1 Nozzle control The high productivity nozzles are flushed with process gas during start-up of the reactor. As the production rate rises and condensed hydrocarbons collect in main loop separator, this liquid is injected through the nozzles. As the liquid pressure rises, the control scheme cuts off the flow of gas to the nozzles. If the liquid pressure falls then process gas flow is reinstated. If PDI-40952 < 0.5 bar then close gas valve XV-40953 If PDI-40952 > 0.8 bar then open gas valve XV-40953 The operator should be able to switch this control scheme into manual if required Where: PDI-40952 XV-40953

Meas

Difference between gas and liquid supply pressures

bar

Loop gas to nozzles isolation valve

4.2 Main loop separator Level control The level is measured in main loop separator using LZI-40901 or LZI-40902. The actual measurement used is selectable by the operator (selector LHS-40900) or automatically in the case of transmitter fault. The level control (LIC-40900) of main loop separator needs to be quick acting due to the short residence time.

4.3 HP liquid pumps minimum flow control The HP liquid injection pump(s) have a minimum flow controller FIC-40903. The total flow through the pump is calculated from the sum of the flow to the nozzles (FI-40902) and the recycle flow (FI-40901). Low limit is required on the valve output for FIC-40903 to prevent the fines settling in the recycle line. This limit should be set to keep the flow above the low alarm level for the recycle flow (FI-40901)

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SPECIFICATION COMPLEX CONTROL 4.4 Condensation The condensation rate is the proportion of the gas circulating around the loop that is condensed prior to injection into the reactor. This is calculated from the fluidising gas flow and the flow to the nozzles. COND =

FI-40902 / G *100

Where COND

Calc

Condensation rate

G

Calc

Calculated fluidising fluidisation velocity)

FI-40902

Meas

Liquid flow to nozzles

% Weight gas

flow

(see

kg/h kg/h

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SPECIFICATION COMPLEX CONTROL

5.

CATALYST

5.1 Calculation of Catalyst quantity in LP/HP stock pipes The calculated total quantity of catalyst in LP and HP stock pipes is useful information to the operator for grade transition and catalyst tote bin management (refer to sequences 34 and 35 for automated catalyst transfer). The operator can then estimate the time of operation with the remaining catalyst in the stock pipes. The volume in the two stock pipes is calculated from the geometry of vessels and various parameters that will need to be reviewed by the detailed engineering to meet the actual vessels lay-out. The following scheme shows the different parameters required for the calculations for the Ziegler SDX LP/HP stock pipes. The vessel lay-out is similar for the Ziegler NCT LP/HP stock pipes and Metallocene LP/HP stock pipes.

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SPECIFICATION COMPLEX CONTROL

LT 30075

100 %

LI-30075

LP STOCK PIPE

H2LP

H1LP

ALP% 0%

XV 30075

XV 30078

LT 30076

100 %

AHP % 0%

H2HP

H1HP

LI- 30076

HP STOCK PIPE

Rotary valve

Rotary valve

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SPECIFICATION COMPLEX CONTROL 5.1.1

Ziegler SDX LP/HP stock pipes The calculation of the volume of catalyst powder in the LP/HP stock pipes system is based on the following assumptions: -

The radar level LI-30075 is calibrated between 0% and 100% where 0% is located at a height H1LP (H1HP) from the cone bottom and 100% at the top TL of the vessel. The height will be determined by the detailed engineering after level calibration

-

When the level is below or equal to 0%, the vessel is assumed empty

-

When the level is above or equal to 100%, the vessel is assumed completely full, including the hemispheric top part

-

ALP (AHP) is the level expressed in % at the bottom TL of the vessel.

-

The total volume is the sum of the calculated volume in LP and HP stock pipes systems

-

The total weight is the total volume times the catalyst poured bulk density

LP stock pipe Volume calculation: LPVOL {the following calculation should run continuously} CONEHLP = DLP/2 * Tangent (CONEβLP/2) VOLLP1 = π/3 * [Tangent (CONEβLP/2)]2 * CONEHLP3 ALP = (CONEHLP - H1LP) / (CONEHLP + CYLHLP - H1LP) * 100 VOLLP2 = π * (DPIPELP/1000)2/4* H2LP If LI-30075 <= 0% Then LPVOL = 0 If 0% < LI-30075 < ALP Then LPVOL = π/3 * [Tangent (CONEβLP/2)]2 * [LI-30075/100 * (CYLHLP+CONEHLP-H1LP) + H1LP]3+VOLLP2 If ALP < LI-30075 < 100% Then LPVOL = VOLLP1 + VOLLP2 + π * DLP2 / 4* CYLHLP *(LI-30075 - ALP) / (100-ALP) If LI-30075 >= 100% Then LPVOL = VOLLP1 + VOLLP2+ π * (DLP)2 / 4* CYLHLP+ π * DLP3 / 22.8

Where: CONEβLP

Oper,30

Cone angle of LP stock pipe

°

DLP

Oper, 0.9906

LP stock pipe internal diameter

m

DPIPELP

Oper, 73.66

Internal diameter of pipe between LP and HP stock pipes

mm

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SPECIFICATION COMPLEX CONTROL

CONEHLP

Calc

Height of cone

m

LPVOL

Calc

LP stock pipe volume

m3

H1LP

Oper

Distance between the cone bottom and the calibrated 0% of LI-30075

m

VOLLP2

Calc

Volume of the pipe between the cone bottom and XVs – Pipe diameter = DPIPELP, pipe length = H2LP

m3

H2LP

Oper

Length of the pipe between the cone bottom and XVs

m

LI-30075

Meas

Level in LP stock pipe

%

ALP

Calc

level expressed in % at the bottom TL of the vessel

%

VOLLP1

Calc

Volume of the cone

m3

CYLHLP

Oper, 1.003

Cylinder part height

m

HP stock pipe Volume calculation: HPVOL {the following calculation should run continuously} CONEHHP = DHP/2 * Tangent (CONEβHP/2) VOLHP1 = π/3 * [Tangent (CONEβHP/2)]2 * CONEHHP3 AHP = (CONEHHP - H1HP) / (CONEHHP + CYLHHP - H1HP) * 100 VOLHP2 = π * (DPIPEHP/1000)2/4* H2HP If LI-30076 <= 0% Then HPVOL = 0 If 0% < LI-30076 < AHP Then HPVOL = π/3 * [Tangent (CONEβHP/2)]2 * [LI-30076/100 * (CYLHHP+CONEHHP-H1HP) + H1HP]3+VOLHP2 If AHP < LI-30076 < 100% Then HPVOL = VOLHP1 + VOLHP2 + π * DHP2 / 4* CYLHHP *(LI-30076 - AHP) / (100-AHP) If LI-30076 >= 100% Then HPVOL = VOLHP1 + VOLHP2+ π * (DHP)2 / 4* CYLHHP+ π * DHP3 / 22.8

Where: CONEβHP

Oper,30

Cone angle of HP stock pipe

°

DHP

Oper, 0.700

HP stock pipe internal diameter

m

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SPECIFICATION COMPLEX CONTROL

DPIPEHP

Oper, 73.66

Internal diameter of pipe between HP stock pipe and catalyst rotary valves

mm

CONEHLP

Calc

Height of cone

m

HPVOL

Calc

HP stock pipe volume

m3

H1HP

Oper

Distance between the cone bottom and the calibrated 0% of LI-30076

m

VOLHP2

Calc

Volume of the pipe between the cone bottom and rotary valves – Pipe diameter = DPIPEHP, pipe length = H2HP

m3

H2HP

Oper

Length of the pipe between the cone bottom and rotary valves

m

LI-30076

Meas

Level in HP stock pipe

%

AHP

Calc

level expressed in % at the bottom TL of the vessel

%

VOLHP1

Calc

Volume of the cone

m3

CYLHHP

Oper, 0.838

Cylinder part height

m

The total weight in the LP/HP stock pipe: TOTALWHPLP = (LPVOL + HPVOL) * Dcat Where: TOTALWHPLP

Calc

Total weight in LP/HP stock pipe

kg

Dcat

Oper

Catalyst poured bulk density

kg/m3

= 330 Ziegler SDX

5.1.2

Ziegler NCT LP/HP stock pipes The calculation of the volume of catalyst powder in the LP/HP stock pipes system is the same as Ziegler SDX stock pipes with the following table of tags/data correspondence:

LI-30175

Meas

Level in LP stock pipe

%

LI-30176

Meas

Level in HP stock pipe

%

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SPECIFICATION COMPLEX CONTROL

Dcat

Oper

Catalyst poured bulk density

kg/m3

= 420 Ziegler NCT

5.1.3

Metallocene LP/HP stock pipes The calculation of the volume of catalyst powder in the LP/HP stock pipes system is the same as Ziegler SDX stock pipes with the following table of tags/data correspondence:

LI-30275

Meas

Level in LP stock pipe

%

LI-30276

Meas

Level in HP stock pipe

%

Dcat

Oper

Catalyst poured bulk density

kg/m3

= 380 (Metallocene)

5.2 Catalyst injection (Ziegler or Metallocene) The catalyst is fed into the reactor in a continuous manner via lines equipped with variable speed rotary valves. The Ziegler SDX and NCT catalyst is delivered by rotary valves X-380A/B. The Metallocene catalyst is delivered by rotary valves X-386A/B/C . The operator enters individual speed set points for each rotary valve. The actual individual and total catalyst flow rate is calculated in the APC (Option).

5.3 Catalyst injection schemes

PV

SP SIC 30010 OP

Zg injection

PV

SP SIC 30110

Zg injection

PV

Mt injection

PV

OP

OP Zg Rotary A

SP SIC 30210

Zg Rotary B

SP SIC 30310

Mt injection

PV

OP Mt Rotary A

SP SIC 30410

Mt injection

OP Mt Rotary B

Mt Rotary C

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SPECIFICATION COMPLEX CONTROL 5.4 Interlocks and alarms Interlocks stop the rotary valves (refer to interlock descriptions).

5.5 Operator interface The catalyst injection system should have a dedicated display including the catalyst transfer sequence. Overrides for the maxi-kill interlock (I-4021-S) and the mini-kill sequence should be shown on this display to prevent the operator injecting catalyst with overrides set. The catalyst rotary valve speeds should also be shown on the display for control of the reactor composition.

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SPECIFICATION COMPLEX CONTROL

6.

REACTOR GAS PHASE ANALYSERS (AT-40050/AT-40051) . The reactor gas phase analysers AT-40050/AT-40051 are used to calculate the partial pressure of each component of the gas phase. These values are used in the control and monitoring of the gas phase composition.

6.1 AT-40050/40051 gas chromatographs

6.1.1

Hardware Analyser redundancy is required due to the criticality of the measurements. Each analyser has a cycle of approximately 6 minutes. The two analysers should be synchronised with overlapping sample times so that a new result is available every 3 minutes. The number of GC‟s regarding the heavy components from C8‟s has to be confirmed by DE. The results of each component are reported in units of volume %. The values reported are not normalised values. Each analyser typically has high and low ranges for hydrogen, hexene-1 and butene-1 and octene-1. The ranges are selected for each analyser by separate signals from the DCS. High and low range measurements are transmitted to the DCS as separate signals. A data ready signal (READ40050/40051) is provided by each analyser once new data is available to the DCS.

6.1.2

Analyser Data Handling The measurement of each component should be continuously read from each analyser. The required components are: N2

Nitrogen

AI-40050A/AI-40051A

H2

Hydrogen

AI-40050B/AI-40051B

Ma

Methane

AI-40050C/AI-40051C

Ea

Ethane

AI-40050D/AI-40051D

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SPECIFICATION COMPLEX CONTROL

C2

Ethylene

AI-40050E/AI-40051E

C4

Butene-1

AI-40050F/AI-40051F

Total inert C4

Total inert C4

AI-40050G/AI-40051G

iPt

Isopentane

AI-40050H/AI-40051H

nPt

n-pentane

AI-40050I/AI-40051I

Total inert C6

Total inert C6

AI-40050J/AI-40051J

C6

Hexene-1

AI-40050K/AI-40051K

Total inert C8

Total inert C8

AI-40050M/AI-40051M

C8

Octene-1

AI-40050N/AI-40051N

Total C10+

Total C10 and heavier

AI-40050P/AI-40051P

Separate range selectors on the DCS for each analyser should switch between high and low ranges for butene-1, hexene-1, octene-1 and hydrogen (C4HLR40050/40051, C6HLR40050/40051, C8HLR050/051, H2HLR40050/40051). The measurements on each analyser must be totalised to give an overall total (TOT40050, TOT40051) volume%. A selector (AI-40050SEL) is used to determine which analyser – AT-40050, AT-40051 or both - is to be used for control and calculations. When the DCS receives a data ready signal (READ40050/40051) it copies the current values from the relevant analyser to holding data set for validation. A selector (VALIDATE_xx) is used by the operator to switch on the validation algorithm for the relevant analyser. 

If VALIDATE_xx is set ON by the operator then if any component in the analysis has changed by more than x% of reading and y% of range from the previous validated value and the reactor pressure is above 17 barg (to avoid holding reads when the reactor gas phase is being composed), the data for the entire sample is held and the previously validated data is not overwritten. The component which failed the validation should be highlighted on the screen. An alarm should be raised if two successive analyser results fail to validate. The reactor pressure is measured by PIC40039A.PV.



If VALIDATE_xx is set OFF by the operator then the most recent analyser data replaces the previous validated data. If VALIDATE_xx is set to OFF and back to ON this is equivalent to a manual validation of the most recent data from the analysers.



If MAINT_xx is set ON by the operator then no new data from the analyser is validated and the previous validated values are kept.

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SPECIFICATION COMPLEX CONTROL 

The VALID_xx flag is set OFF if the validation has failed or MAINT_xx is set. The flag set ON when the validation is healthy (VALIDATE_xx = ON and MAINT_xx = OFF and Validation not failed). This flag will be used by the APC (if implemented) to prevent the APC models calibrating if the analyser signals are not valid. The values of x% and y% should have default values of 0.5%. These values should be displayed on the screen and be independently adjustable for each component. The validated values are used by the reactor controls. A timeout alarm is raised if the data ready signal is not received from an analyser within the expected cycle time plus 2 minutes.

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SPECIFICATION COMPLEX CONTROL

Reactor analyser (AT-40050 / AT-40051) data validation typical scheme:

TYPICAL ARRANGEMENT

MAINT AI-40050

VALIDATE AI-40050

AT-40050 C2

C2

AI-40050E

HOLD DATA

GC

AE-40050

H2 AI-40050SEL : AT-40050 or AT-40051 or both

VALIDATED DATA

Idem for all components

C4 N2

C2 H2 C4 N2

DATA READY SIGNAL READ 050

AT-40051 C2

MAINT AI-40051

AI-40051E

HOLD DATA

GC

AE-40051

VALIDATE AI-40051

Idem for all components

DATA READY SIGNAL READ 40051

A total pentane composition is calculated for use in pentane controls: C5 = iPt + nPt. Validated composition values are used to calculate the partial pressure of each component. For each component: Px = x / 100 * (PIC-40039A.PV + ATM) Where: Px

Calc

Partial pressure of component x in reactor

bara

x

Meas/ Calc

Validated quantity of component x in reactor. Example: x = C2, Validated data, AI-40050E or AI-40051E

vol%

Reactor pressure

barg

Atmospheric pressure (constant)

bara

PIC-40039A.PV ATM

= Refer to project basis

These values are used by the reactor gas phase control.

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SPECIFICATION COMPLEX CONTROL

6.1.3

Alarms

TOT40050 < 98%

Low priority

TOT40050 >102%

Low priority

TIMEOUT40050

Low priority Raised if the READ40050 signal is not raised within the expected cycle time plus 2 minutes.

The above alarms are repeated for analyser AI-40051 HOLDAI

DEVAI

6.1.4

Low priority Raised if any component is not validated. The component is highlighted in the held data Low priority Raised if any individual component differs by more than 2% between analysers. The component is highlighted for both analysers

Operator Interface The operator interface for the analysers must clearly show the data flow from the raw analyser inputs to the validated data sets. Where deviation and hold alarms are raised the component leading to the alarm must be clearly identified on the display in a similar way to standard alarms. The raw and validated data from all the GCs should be shown on a single display. Trends should be configured allowing the readings from each analyser to be easily compared.

7.

VRU MULTISTREAM ANALYSERS There are 2 multistream analysers in the VRU. The streams are located on the main gas and liquid purges. A new reading update should be available every 30 minutes, with two consecutive analysis reports before switching back to the other analyser streams.The data should be handled and validated in a similar manner to the other GCs.

8.

DEWPOINT IN REACTOR CALCULATION Operation at too high dew point temperature in the reactor can cause several problems:

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SPECIFICATION COMPLEX CONTROL •

Condensation in instrument sample lines, such as chromatograph.

•

Poor reactor temperature control

•

Liquid in lateral withdrawals

8.1 Inputs Following values are given by chromatographs. Values are the validated ones. See the previous chapter specific to gas chromatograph data handling. limits P

= PIC40039A.PV + ATMbar

Absolute Reactor pressure for calculation purpose filtered 10s

bara

ATMbar

= ATM

Atmospheric pressure

bara

0 to 25

See project basis Treact (*)

= TIC40046.PV

Reactor temperature

°C

15 to 120

N2

Meas

nitrogen concentration

Vol%

0-100

H2

Meas

hydrogen concentration

Vol%

0-100

Ma

Meas

methane concentration

Vol%

0-100

Ea

Meas

ethane concentration

Vol%

0-100

C2

Meas

ethylene concentration

Vol%

0-100

C4

Meas

butene-1 concentration

Vol%

0-100

Total inert C4

Meas

Total inert C4 concentration

Vol%

0-100

iPt

Meas

iso-pentane concentration

Vol%

0-100

nPt

Meas

n-pentane concentration

Vol%

0-100

Total inert C6

Meas

Total inert C6 concentration

Vol%

0-100

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SPECIFICATION COMPLEX CONTROL

C6

Meas

hexene-1 concentration

Vol%

0-100

Total inert C8

Meas

Total inert C8 concentration

Vol%

0-100

C8

Meas

Octene-1 concentration

Vol%

0-100

Total C10+

Meas

Total C10 and heavier concentration

Vol%

0-100

(*) not needed in the calculation. Only used to be compared with the dew point Tdew and check if the alarm has to be raised or not – see below chapter Alarms

8.2 Dew point Calculation principles The calculations are based upon vapour/liquid equilibrium theory, using the concept of “fugacity”. The principle behind the dew point temperature calculation is that given the vapour mole fractions of the components given by analysers the liquid mole fractions can be calculated. The dew point temperature is the temperature where the sum of the liquid mole fractions equates to 1. The dew point temperature is calculated by an iterative method. Where these calculations are performed within the DCS, it is recommended that the number of iterations for each calculation is optimised in order to limit the load of the DCS. The final figures from a previous run of the calculation should be used as the starting figures on the next run, whether or not these calculations have converged. As the component concentrations given by analyser are refreshed on a minute basis, the dewpoint calculation can be placed in a low priority processor thread of the DCS. Also pressure used for calculation must be filtered to avoid spurious alarm if reactor pressure measurement is noisy

8.3 Fugacity calculation A specific subroutine calculates the two partial equilibrium ratio constants (so call fugacities) for a given gas phase component at a given temperature. This subroutine is used by Xsum function described in next chapter. For each component, corresponding equations are given below.

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SPECIFICATION COMPLEX CONTROL

Subroutine Fugacity_calculation (component_i, Temp, fu0_i, fu20_i) With component_i

Input

measured by gas chromatographs

Temp

Input

Temperature

°C

fu0_i

Output

Partial equilibrium ratio constant at 0 atmosphere of component_i

(-)

fu20_i

Output

Partial equilibrium ratio constant at 20 atmosphere of component_i

(-)

It is mandatory to insure that all the fugacity values are positive. Thus, if fux_i < 0 then fux_i = 10-5

Methane (Ma) 2

3

2

3

4

fu0_i = 158.07 - 1.6799E-01 xTemp + 3.4454E-02 xTemp - 3.9703E-04 xTemp + 1.7238E-06 xTemp 5 2.6386E-09 *Temp fu20_i = fu0_i Ethylene (C2) fu0_i = 24.8798 + 7.2412E-01xTemp - 1.8314E-03xTemp + 1.2805E-05xTemp - 4.0862E-08xTemp 2

4

3

fu20_i = 33.2743 + 5.3857E-01xTemp + 1.8691E-03xTemp - 1.6762E-05x Temp + 3.2448E-08xTemp

4

Ethane (Ea) 2

3

fu0_i = 17.7528 + 3.3163E-01xTemp + 3.2595E-03xTemp - 1.8718E-05x Temp + 3.4839E-08xTemp 2

4

3

fu20_i = 19.6454 + 5.3911E-01xTemp+ 1.5470E-04xTemp - 2.6552E-06x Temp + 5.2916E-09xTemp

4

Butene-1 (C4) 2

3

fu0_i = 1.5477 + 2.5696E-02xTemp + 7.0124E-04xTemp + 3.9124E-06xTemp – 2.0088E-08xTemp 2

4

3

fu20_i = 2.5666 + 4.0012E-02xTemp + 1.5571E-03x Temp + 3.8454E-06xTemp – 4.7318E-11xTemp

4

Hydrogen (H2) fu0_i = -5.95x Temp + 1463.1 fu20_i = -6.27xTemp + 1541.6 Total inert C4 (total inert C4) 2

3

fu0_i = 1.3074 + 1.8273E-02xTemp + 6.8108E-04x Temp + 3.6642E-06xTemp - 1.8223E-08xTemp

4

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SPECIFICATION COMPLEX CONTROL 2

3

fu20_i = 2.1893 + 3.6499E-02xTemp + 1.3468E-03xTemp - 2.1498E-06x Temp - 3.1196E-09xTemp

4

n-Pentane (nPt) 2

3

fu0_i = 5.3222E-03 + 2.9795E-02xTemp - 3.0179E-04x Temp + 6.4498E-06xTemp - 1.4969E-08xTemp fu20_i = 6.5952E-01 + 1.3872E-02x Temp + 4.8373E-04xTemp 4 08xTemp

2

+ 2.6451E-06xTemp

3

4

- 1.0241E-

i-Pentane (iPt) 2

3

fu0_i = 2.0444E-01 + 2.4793E-02xTemp - 6.7204E-05xTemp + 4.9923E-06xTemp - 1.2015E-08xTemp 2

4

3

fu20_i = 6.29168E-01 + 3.4083E-02x Temp + 3.7551E-04xTemp + 2.8961E-06xTemp - 1.0270E4 08xTemp Hexene (C6) fu0_i = 10 ^ [4.71128 - 1597.816 / (Temp + 273) - (0.27 / 20 * {10 ^ [4.71128 - 1597.816 / (Temp + 273)]})] 0.27

fu20_i = fu0_i * 10

Total inert C6 (total inert C6) 2

3

fu0_i = -3.6242E-02 + 1.1304E-02xTemp - 1.3948E-04x Temp + 2.9431E-06 Temp - 4.6228E-09x Temp 2

Temp

4

4

3

fu20_i = -3.4664E-01 + 4.5829E-02xTemp - 6.8872E-04x Temp + 9.0073E-06x Temp - 2.1899E-08x

Octene-1 (C8) fu0_i = Exp(A_coef + B_coef / (Temp + 273) + C_coef * Ln(Temp + 273) + D_coef * (Temp + 273)) fu20_i= fu0_i * (A_lin + B_lin * Temp) Where: A_lin = 2.17241 B_lin = -0.00224138 A_coef = -58.46344105 B_coef = -3204.016983 C_coef = 12.79531216 D_coef = -0.025229352 Ln: Neperian Logarithm fonction Total inert C8 (Total inert C8) 2

3

fu0_i = -2.4030E-02 + 2.9400E-03x Temp - 5.9999E-05x(Temp ) + 7.3896E-07x(Temp ) + 3.0502E-10x 4 (Temp ) 2

3

fu20_i = -2.0157E-01 + 1.8082E-02x Temp - 3.9204E-04x(Temp ) + 4.1651E-06x(Temp ) - 7.5792E-09x 4 (Temp ) Total C10+ (Total C10+) fu0_i = 10 ^ (3.296399 - 1031.56 / (136.8 + Temp))

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SPECIFICATION COMPLEX CONTROL fu20_i = 10 ^ (3.949235 - 1405.34 / (203.5 + Temp)) Nitrogen (N2) fu0_i = 10000 fu20_i = 10000

8.4 Sum of liquid fraction calculation A specific function gives the sum of liquid fraction at given temperature, pressure and corrected pressure. This function is used in the Tdew main program calculation described in next chapter. Function Xsum( Temp, Press, Presscor) With: Xsum

Output

Sum of liquid fraction

Temp

Input

Temperature

°C

Press

Input

Pressure

bara

Presscor

Input

Corrected pressure

bara

For each component i: Calculate Equilibrium ratio constant for each component i Ki = ( fu0_i + (fu20_i – fu0_i) * Presscor / ( 20 * ATM bar)) * ATM bar / Press

Calculate Liquid Phase molar fraction for each component i Xi = Yi / Ki , limited so as Xi = 0 if Ki < 10e-6

Calculate liquid molar fraction sum Xsum = Σ Xi Where: Ki

Calc

Equilibrium ratio constant of component i

(-)

Yi

Meas

Molar concentration of component i in vapor phase

frac mol

0-1

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SPECIFICATION COMPLEX CONTROL

Xi

Calc

Liquid phase molar fraction of component i

frac mol

0-1

8.5 Dew point calculation algorithm This calculation uses previous defined function and subroutine Algorithm: Obtain analyser gas concentrations in %vol zi for all components in use Normalise gas concentrations Zi = zi / ∑zi and assume Yi = Zi Having P= absolute reactor pressure (in bara), calculate the corrected pressure Pcor = P x (∑Zi)

0,5

(summation does not include Hydrogen or Nitrogen)

Choose upper and lower temperatures to start the first dew point iteration: Thigh = 60°C, Tlow = 30°C

Loop: Perform the calculation below at temperatures Thigh and Tlow to obtain Xsum(Thigh P, Pcor) and Xsum(Tlow P, Pcor) respectively, then interpolate new estimate of Tdew, given by: Tdew = Thigh - (Thigh - Tlow) x (Xsum(Thigh P, Pcor) - 1) / (Xsum(Thigh P, Pcor) - Xsum(Tlow P, Pcor))

Calculate Xsum(Tdew, P, Pcor)

If Xsum(Tdew, P, Pcor) = 1 ± Converg then iterations complete, otherwise If Tdew > Thigh then Tlow = Thigh, Thigh = Tdew Else If Tdew < Tlow then Thigh = Tlow, Tlow = Tdew Else If Tlow < Tdew < Thigh then Thigh = Tdew, Tlow unchanged

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SPECIFICATION COMPLEX CONTROL

Move the limits in by ⅓ towards the dew point to prevent the algorithm becoming „stuck‟ at one of the limits: Thigh = Thigh – ((Thigh – Tlow) / 3) Tlow = Tlow + ((Thigh – Tlow) / 3)

Loop to recalculate partial equilibrium ratio constants, Xsum(Thigh , P, Pcor), Xsum(Tlow , P, Pcor), and hence Xsum(Tdew , P, Pcor)

A limitation is placed on the number of iterations executed: Maxiter

If the calculation does not converge after Maxiter, then the result is marked as non-convergent: Error_dew = 1 Where: zi

Meas

Gas concentration for component_i

Vol%

Zi

Calc

Normalised gas concentration for component_i

mol frac

0-1

Yi

Calc

Molar fraction for vapour component_i

mol frac

0-1

Xi

Calc

Molar fraction for liquid component_i

mol frac

0-1

fu0_i

Calc

Partial equilibrium ratio constant at 0 atmosphere of component_i

(-)

fu20_i

Calc

Partial equilibrium ratio constant at 20 atmosphere of component_i

(-)

Ki

Calc

Equilibrium ratio constant

Pcor

Calc

Corrected pressure

Converg

= e-5 (to be tuned)

Convergence criteria

Maxiter

= 30 (to be tuned)

Maximum number of iteration per calculation

Tlow

Calc

Calculation parameter

bara

°C

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SPECIFICATION COMPLEX CONTROL

Thigh

Calc

Calculation parameter

°C

Tdew

Calc

Dew point calculated temperature

°C

Error_dew

Calc

Dew point error: 0 = OK

bool

15 to 120

1 = Calculation Error The accuracy of Tdew is +/- 2 °C

8.6 Operator interface The operator interface on the DCS consists solely of the calculated reactor Temperature dew point Tdew along with the status of the result Error_dew, for instance normal for good and red when bad. Alarms are also attached to that point.

8.7 Alarms Reactor temperature close to dew point High Priority Error in dew point calculation Priority

TDI-40046 = Treact – Tdew <7.5 °C

Error_dew

Low

8.8 Error handling If any input has a Bad status or the maximum number of iterations is exceeded or successive results fail to converge or an unexpected error occurs then the dew point temperature calculation fails and the error indication (Error_dew) is set to 1 It is reset to 0 following a successful calculation.

9.

AVERAGE MOLECULAR MASS IN REACTOR AND IN GAS AND LIQUID PURGES The average molecular mass is required for the main reactor to calculate the fluidisation velocity The fluidising gas mean molecular mass in the reactor is given by: MM = [16xMa + 28xC2 + 56xC4 + 58xTotal inert C4 + 2xH2 + 28xN2 + 30xEa + 72xC5 + 86xTotal inert C6 + 84xC6 + 114xTotal inert C8 + 112xC8 + 142xTotal C10+] / [Ma + C2 + C4 +

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SPECIFICATION COMPLEX CONTROL Total inert C4 + H2 + N2 + Ea + C5 + Total inert C6 + C6 + Total inert C8 + C8 + Total C10+] g/mol Where: Ma

Meas

methane concentration

Vol%

C2

Meas

ethylene concentration

Vol%

C4

Meas

butene-1 concentration

Vol%

Total inert C4

Meas

Total inert C4 concentration

Vol%

H2

Meas

hydrogen concentration

Vol%

N2

Meas

nitrogen concentration

Vol%

Ea

Meas

ethane concentration

Vol%

C5

Calc

Total pentane concentration

Vol%

Total inert C6

Meas

Total inert C6 concentration

Vol%

C6

Meas

Hexene-1 concentration

Vol%

Total inert C8

Meas

Total inert C8 concentration

Vol%

C8

Meas

Octene-1 concentration

Vol%

Total C10+

Meas

Total C10 and heavier concentration

Vol%

Note that in the event of a bad value occurring in the analysers then the calculation of MM will maintain its last good value. This is important as MM is used to calculate the fluidisation gas velocity in the reactor.

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SPECIFICATION COMPLEX CONTROL

10.

ETHYLENE .

APC (Option)

PV SP

PC2

Ethylene partial pressure in Reactor

OP

OPER

PV

SP FQIC 40063 OP

Ethylene feed to Reactor

SETPOINT HIGH LIMIT from PIC-40039C.SP

FV 40063

10.1

Ziegler Operation

The partial pressure of ethylene is controlled by adjusting the flow of fresh ethylene into the loop. The output of the partial pressure controller should be in units of flow. FQIC-40063.SP

= PC2.OP

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SPECIFICATION COMPLEX CONTROL Where: FQIC-40063.SP

Oper

Setpoint of the ethylene feed flow controller

t/h

PC2.OP

Calc

Output of the ethylene partial pressure controller PC2

t/h

If the reactor pressure rises the high setpoint limit for the ethylene feed to the reactor is reduced by PIC-40039C to prevent the reactor safety valve lifting. Refer to the reactor pressure control description.

10.2

Metallocene Operation

In metallocene operation the ethylene partial pressure is not directly controlled but float between values defined in GROWL. It is manually controlled using the catalyst flow rate instead of the ethylene feed flow. The ethylene feed rate is fixed by the operator.

10.3

Alarms and trips

Alarm is defined below: Absolute value:

Low priority

|(PC2.SP - PC2.PV)| > 0.4 bar

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SPECIFICATION COMPLEX CONTROL

11.

HYDROGEN

APC (Option)

Ethylene partial pressure

H2/C2 ratio SP

OPER

RH2C2

PC2

SP

PV

X

BIAS_P

BIAS_T

SP PV PH2TRANS OP

+

SP PV

Hydrogen transition partial pressure controller

PH2 OP

Hydrogen partial pressure controller

SP Hydrogen purge

PV PH2PURGE partial pressure OP

SP FIC 60601 OP

PV

SP FQIC 40065 OP

Hydrogen feed to Reactor (high flow)

PV

SP FQIC 40062 OP

Hydrogen feed to Reactor (low flow)

H2 PURGE FLOW

VRU purge

PV

controller

PV

SP FIC 60604 OP

>

IN SPLIT RANGE OP OP FV 40065

FV 40062

FV 60601A

FV 60601B

VRU purge flow

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SPECIFICATION COMPLEX CONTROL 11.1

Ziegler and Metallocene operation

The ratio of ethylene and hydrogen partial pressures is used to control the melt index of the polymer. The setpoint for the partial pressure controller is calculated from the operator entered setpoint ratio RH2C2 and the partial pressure of ethylene. The process variable is directly calculated from the partial pressure of hydrogen and ethylene.

PH2.SP RH2C2.PV

= RH2C2.SP * PC2.PV = PH2.PV / PC2.PV (for monitoring only)

The partial pressure of hydrogen is controlled by adjusting the flow of fresh hydrogen into the loop. To assist during transitions, the fresh hydrogen flow is injected into the loop with high flow hydrogen controllers or removed more quickly by acting on the purge flow control valves. When the hydrogen partial pressure drops below the normal operating value (at a value of the hydrogen normal partial pressure minus PBIAS_T), the hydrogen transition partial pressure controller acts on the high flow hydrogen controller to quickly add more hydrogen into the loop. When the hydrogen partial pressure is above the normal operating value (at a value of the hydrogen normal partial pressure plus PBIAS_P), the hydrogen purge partial pressure controller acts on the purge flow hydrogen controller to remove part of the hydrogen in the loop. See pressure control loop.

PH2TRANS.SP

= PH2.SP – PBIAS_T

PH2PURGE.SP

= PH2.SP + PBIAS_P

FQIC-40062.SP

= PH2.OP

FQIC-40065.SP

= PH2TRANS.OP

FIC-60604.SP

= PH2PURGE.OP if selected. There is a high selector signal between FIC-60601.OP and FIC-60604.OP

FIC-60604.PV

= FIC-60601.PV

Where: RH2C2.SP

Oper

Setpoint for H2/C2 partial pressure ratio

bara/Bara

RH2C2.PV

Calc

Actual H2/C2 partial pressure ratio

bara/bara

FQIC-40062.SP

Calc

Setpoint of the hydrogen feed low flow controller

kg/h

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SPECIFICATION COMPLEX CONTROL

FQIC-40065.SP

Calc

Setpoint of the hydrogen feed high flow controller

kg/h

PH2TRANS.SP

Calc

Hydrogen transition controller SP

bara

PBIAS_T

Oper, = 0.5

Bias subtracted from normal Hydrogen partial pressure controller SP for the calculation of Hydrogen transition partial pressure controller SP

bar

PH2PURGE.SP

Calc

Hydrogen purge partial pressure controller SP

bara

PBIAS_P

Oper, = 0.5

Bias added to normal Hydrogen partial pressure controller SP for the calculation of Hydrogen purge partial pressure controller SP

bar

PH2.OP

Calc

Output of the hydrogen partial pressure controller PH2 to hydrogen low flow controller (normal operating case)

kg/h

PH2TRANS.OP

Calc

Output of the hydrogen partial pressure controller PH2TRANS to high hydrogen flow controller (transition and start-up operating cases)

kg/h

PH2PURGE.OP

Calc

Output of the hydrogen partial pressure controller PH2PURGE to purge flow control valve (transition operating case)

kg/h

FIC-60604

partial

pressure

H2 Purge flow controller from the VRU dedicated to remove quickly H2 during transitions

The limits for PH2, PH2TRANS and PH2PURGE outputs should be back calculated from the setpoint limits of FQIC-40062, FQIC-40065 and FIC-60604.

11.1.1

Hydrogen Flow control to catalyst nozzle jackets (Metallocene only)

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SPECIFICATION COMPLEX CONTROL

RH2C2 PV

X

MWH2/MWC2

Converting factor

X

Kmt

Ethylene feed to nozzle jacket

Ethylene feed to nozzle jacket

X

FIC-30212 PV

PV

SP FIC 30215 OP

FV 30215

Hydrogen feed to nozzle jacket

PV

X

PV

SP FIC 30315 OP

Hydrogen feed to nozzle jacket

FV 30315

Ethylene feed to nozzle jacket

FIC-30312

PV

FIC-30412

X

PV

SP FIC 30415 OP

Hydrogen feed to nozzle jacket

FV 30415

The catalyst injection nozzle is made of an internal tube, inserted into a concentric jacket that is flushed with a mixture of ethylene and hydrogen. The hydrogen is injected in flow ratio to the ethylene gas to the nozzle jacket. The hydrogen to ethylene gas flow ratio is determined to meet the same molar concentration ratio of hydrogen to ethylene as in the reactor. When there is process gas or Nitrogen injected instead of ethylene, the operator should stop the hydrogen flow to the nozzle jackets by closing the hydrogen control valves. FIC-30215.SP = RH2C2.PV x (MWH2/MWC2) * FIC-30212.PV x Kmt FIC-30315.SP = RH2C2.PV x (MWH2/MWC2) * FIC-30312.PV x Kmt

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SPECIFICATION COMPLEX CONTROL FIC-30415.SP = RH2C2.PV x (MWH2/MWC2) * FIC-30412.PV x Kmt

RH2C2.PV FIC-30215.SP

Calc Calc

FIC-30212.PV

Calc

FIC-30315.SP

Calc

FIC-30312.PV

Calc

FIC-30415.SP

Calc

FIC-30412.PV

Calc

MWC2 MWH2 Kmt

=28 =2 =by GROWL

Actual H2/C2 partial pressure ratio Setpoint of the hydrogen feed flow controller to catalyst nozzle J-386A Flush gas flow to catalyst nozzle J386A Setpoint of the hydrogen feed flow controller to catalyst nozzle J-386B Flush gas flow to catalyst nozzle J386B Setpoint of the hydrogen feed flow controller to catalyst nozzle J-386C Flush gas flow to catalyst nozzle J386C Molecular weight of Ethylene Molecular weight of hydrogen Factor to link H2/C2 mass concentration ratio in reactor gas phase to H2/C2 injection mass flow ratio. Change with grade by GROWL

bara/ bara kg/h kg/h kg/h kg/h kg/h kg/h kg/kmol kg/kmol

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SPECIFICATION COMPLEX CONTROL

12.

COMONOMER

12.1

Comonomer flow

APC (Option)

Comono/C2 ratio SP

Ethylene partial pressure

RCmC2

PC2

SP

OPER

PV

HS-20502 Comonomer selector

X

SP PV

Comonomer partial pressure in Reactor

PCm OP

SP FQIC 40063

Ethylene feed to reactor

PV

SP

Comonomer /ethylene flow ratio

FCmC2

PV

X IN

OP

SP FQIC 40905 OP

PV

Comonomer feed to Reactor

IN SPLIT RANGE OP OP

FV 40905B

FV 40905A

Low flow

High flow

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SPECIFICATION COMPLEX CONTROL 12.2

Control

The comonomers injected into the reactor gas phase are butene-1 and hexene-1 and octene-1. In normal operation the feed flow ratio of ethylene and comonomer is used to control the polymer density. A facility also exists to control the comonomer to ethylene partial pressure ratio for startup in Zg operation . The comonomer flows through common pumping system and header (and thus common flow control valves – refer below) from dedicated storage drums. Mixing of comonomers in the feed system is prevented by interlocks. High and low flow ranges are required for comonomer injection. The high and low flows are passing through dedicated routing with relevant flow meter and control valve. The control valves are configured in split range from FQIC-40905 which receives as process value the sum of the low and high flow. During start-up, when no condensate is available, the comonomer may be injected to main loop compressor discharge. The routing to main loop compressor discharge or main loop separator (normal routing) via either XZV-40905 or XZV-40902 is handled manually by the operator. Switching between comonomers during grade changes is done by the operator by routing on/off valves at the commoner pumps discharge as required. A common control scheme is used, parameters or measurements relevant to the selected comonomer are downloaded depending on HS-20502 setting. The setpoint for the partial pressure controller is calculated from the operator entered setpoint ratio RCmC2 and the partial pressure of ethylene. The process variable is directly calculated from the partial pressure of comonomer and ethylene.

PCm.SP

= RCmC2.SP * PC2.PV

RCmC2.PV

= PCm.PV / PC2.PV for monitoring only

The output of the partial pressure controller provides the setpoint for a flow ratio block calculation (FCmC2) which controls the ratio of fresh comonomer feed to ethylene feed into the loop.

FCmC2.SP

= PCm.OP

FQIC-40905.SP

= FCmC2.SP * FQIC-40063.PV

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SPECIFICATION COMPLEX CONTROL

FCmC2.PV

= (FQIC-40905.PV) / FQIC-40063.PV- For monitoring only

Where: RCmC2.SP

Oper

Setpoint for Como/C2 partial pressure ratio

bara/Bara

RCmC2.PV

Calc

Actual Como/C2 partial pressure ratio

bara/bara

PC2.PV

Calc

Ethylene partial pressure in gas loop

bara

PCm.OP

Calc

Output of the comonomer partial pressure controller

t/t

FCmC2.SP

Calc

Setpoint for Como/C2 flow ratio

t/t

FCmC2.PV

Calc

Actual Como/C2 flow ratio For monitoring only

t/t

FQIC-40905.SP

Calc

Setpoint of the comonomer feed flow controller

t/h

FQIC-40063.PV

Meas

Fresh Ethylene feed flow

t/h

The output and setpoint limits for FCmC2 should be back calculated from the setpoint limits of FQIC40905.Output limits for PCm should be set to the same as the setpoint limits for FCmC2.

12.2.1

Parameters and Alarms The scheme control process measurement, parameters and alarms depends on the selected comonomer:

Parameters and process measurement PCm.PV

HS-20502 = Butene-1

PC4.PV

HS-20502 = Hexene-1

PC6.PV

HS-20502 = Octene-1

PC8.PV

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SPECIFICATION COMPLEX CONTROL

13.

PENTANE

APC (Option)

OPER

SP Pentane partial pressure in Reactor

PC5

PV

OP

SP FQIC 40906 OP

PV

Pentane feed to Reactor

IN SPLIT RANGE OP OP

Pentane injection pump speed

Pentane injection pump stroke

The partial pressure of total pentane (n-pentane + isopentane) is controlled by adjusting the flow of fresh pentane into the loop via FQIC-40906 and by adjusting the speed and stroke of the pentane feeding pump P-242A. FQIC-40906.SP

= PC5.OP

Where: FQIC-40906.SP

Calc

Setpoint for the pentane feed flow controller

kg/h

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SPECIFICATION COMPLEX CONTROL

PC5.OP

14.

Calc

Output of the total pentane partial pressure controller

kg/h

REACTOR PRESSURE CONTROL

SP PIC 40039A OP

PV

+

MAIN Reactor pressure Controller

PBIASC2

PBIASPURGE

-

+

PBIASN2

Reactor pressure PT-40039

Reactor high pressure

PV

SP PIC 40039C OP

PV SP FIC 60601 OP

PV

To FQIC-40063 C2 feed high SP limit

SP PIC 40039D OP

STARTUP Reactor pressure Controller

Reactor low pressure

PV

SP PIC 40039B OP

PV

SP FIC 40061 OP

VRU purge flow

From FIC-60604.OP H2 reactor purge

Reactor nitrogen make-up

> IN SPLIT RANGE OP OP

FV 60601A

FV 60601B

VRU purge flow

PV 40039D Reactor purge flow

FV 40061 Nitrogen flow

The operator enters the required reactor pressure (as set point of PIC-40039A). This is used, with different biases, as the setpoint for the pressure controllers, PIC-40039A/B/C/D.

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SPECIFICATION COMPLEX CONTROL The main pressure controller PIC-40039A is used in normal operation when reactor powder withdrawal system is running and VRU is commissioned. A high selector determines whether FV-60601A/B receive their position setpoint from: o

FIC-60601, normally

o

Hydrogen partial pressure controller PH2PURGE to increase the purge flow (see hydrogen control).

A second override pressure controller PIC-40039B adds nitrogen by manipulating the setpoint of the nitrogen feed (FIC-60061) if the reactor pressure falls too far below the setpoint.

PIC-40039B.SP

= PIC-40039A.SP – PBIASN2

FIC-40061.SP

= PIC-40039B.OP

Where: PIC-40039A.SP

Oper

Reactor operating pressure

barg

PBIASN2

= 0.3 Oper

allowable pressure below target

bar

FIC-40061

Reactor make-up Nitrogen flow controller

If the reactor pressure increases above the normal operating pressure, a third override pressure controller PIC-40039C reduces the ethylene feed flow to the reactor by manipulating the high setpoint limit for the ethylene feed controller FQIC-40063.

PIC-40039C.SP

= PIC-40039A.SP + PBIASC2

FIC-40063.SP high limit

= PIC-40039C.OP

Where: PBIASC2

FQIC-40063

= 0.6 Oper

allowable pressure above target (initiate ethylene feed reduction)

bar

Reactor ethylene flow controller

A fourth pressure controller PIC-40039D is used during reactor start-up when withdrawal is not started or VRU is not commissioned We assume that VRU purge flow controller FIC-60601 is in MANUAL during start-up and the reactor pressure is rising and is taken into control by PIC-40039D © 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 COMPLEX CONTROL

PIC-40039D.SP

= PIC-40039A.SP + PBIASPURGE

FIC-60601.SP

= PIC-40039D.OP

Where: PBIASPURGE

FIC-60601

= 0.2 Oper

allowable pressure above target (initiate purge at start-up)

bar

VRU purge flow controller

The reactor can be depressurised automatically or initiated by the DCS operator. Depressurisation can be started by the operator opening the control valve and on/off valve from standard DCS commands/interface or automatically by interlock I-4021-S (CO maxi kill).

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SPECIFICATION COMPLEX CONTROL

15.

REACTOR BED LEVEL

LBEDB

LBEDA

Operator selector or automatic selection

PV DIC 40001 OP

SP

PV Reactor bed density

SP

LBED

Reactor bed level

OP

> SP Sequence 64

The bed level is controlled by manipulating the powder withdrawal rate from the reactor (see the withdrawal sequence SEQ-64). The level is measured using two methods: 

Differential pressure measurements



Radioactive density measurement close to the surface of the bed.

The level calculated from the differential pressure measurement is used during commissioning and start-up. The operator switches on the radioactive density measurement control once the level is steady and within the nucleonic range. There is a controller (LBED and DIC-40001) based on each of these measurements. The high output selector is an override to prevent fines carry-over.

15.1

BED Level from pressure drop

The LBED controller uses 2 different PVs selectable by the operator:

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SPECIFICATION COMPLEX CONTROL 2 PVs are calculated from the pressure drops across the bed: LBEDA and LBEDB are calculated by dividing the pressure drops across the whole bed by the pressure drop across a fixed height within the bed

15.1.1

Pressure drop coefficient (COFPD) PDI-40002 and PDI-40009 are used to give two values for the pressure drop across a section within the bed. PDI-40002 is measured between 2.0 m and 5.0 m above the grid and is used when initially filling the reactor. PDI-40009 is measured between 6.5m and 9.5 m and is generally used for normal operation. DP-40009

DP-40002

=

PDI - 40009 Filtered 600s mbar/m PDI - 40009 height difference  =

PDI - 40002 Filtered 600s mbar/m PDI - 40002 height difference 

The operator can manually select either of the DP measurements to be used for COFPD or allow automatic selection. The automatic selection uses DP-40009 if the bed level (LBED) is more than 0.5m above its top pressure tapping, otherwise it uses DP-40002. COFPD should normally indicate between 20 mbar/m and 45 mbar/m maximum.

15.1.2

Bed level calculation from pressure drop PDI-40001 and (PDI-40012 – PDI-40003) are used to give two values for the pressure drop across the bed. PDI-40001 is normally measured between 0.5m above the grid and the top of the reactor. PDI-40012 is measured from the below the grid to the top of the reactor and PDI-40003 is measured across the grid. The bed level is calculated from each of the differential pressure measurements. The two pressure drops across the reactor bed are filtered to remove noise PDIF-40001

= PDI-40001 filtered 60s

mbar

PDIF-40012

= (PDI-40012 – PDI-40003) filtered 60s

mbar

Two values for the bed level are calculated.

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SPECIFICATION COMPLEX CONTROL

15.1.3

LBEDA

=

PDIF - 40001   PDI - 40001

lower tapping height  0.5m  m

LBEDB

=

PDIF - 40012   PDI - 40003

upper tapping height  0.5 m  m

COFPD

COFPD

Alarms and trips

COFPD high

= 45 mbar (Note 1)

Low priority

COFPD low

= 20 mbar (Note 1)

Low priority

DEVCOFPD

Low priority Raised if ABS |(DP-40009 – DP-40002)| > 1 mbar/m

LBEDDEV

Low priority. Raised if ABS |(LBEDA-LBEDB)| > 0.5 m

LBED high

= 21 m

Low priority

LBED low

= 19 m

Low priority

LBEDCOMP

Low priority raised if: {( LBEDA or LBEDB<18.5 m AND nucleonic bed density > X kg/m3) OR (LBEDA or LBEDB> 21.5 m AND nucleonic bed density < Y kg/m3) Where: - nucleonic bed density is measured by DIC40001.PV - X kg/m3 is confirmed during commissioning to be equivalent to 18.5 m and - Y kg/m3 is confirmed during commissioning to be equivalent to 21.5 m.

DIC-40001.PV high

Low priority. Set at U kg/m3 where U kg/m3 is confirmed during commissioning to be equivalent to 21 m

DIC-40001.PV low

Low priority Set at V kg/m3 where V kg/m3 is confirmed during commissioning to be equivalent to 19 m

Note 1: In GROWL are defined more restricted values per grade

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SPECIFICATION COMPLEX CONTROL

15.2

Bed level controller output Limits

The output of the bed level controllers are expressed in nominal t/h and used by the withdrawal sequence to calculate the speed of the withdrawals. Output limits are calculated in the withdrawal sequence to prevent the bed level controller driving the withdrawals beyond their design capacity. See the withdrawal sequence SEQ-64 for calculation of the limits.

15.3

Operator interface

There should be a single display of the reactor loop showing all the reactor differential pressures, loop differential pressures and the density at the surface of the bed The same display should show the loop gas flow and density, the fluidisation velocity and the main loop compressor guide vane position. This display should have links to the withdrawals displays and the reactor controls display.

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SPECIFICATION COMPLEX CONTROL

16.

TEAL INJECTION CONTROL

Typical control scheme applicable to TEAL APC (OptionTEAL Only)

OPER

Additive to Ethylene flow ratio SP

IN Block calculation OP

PV

IN IN

PV FQIC-40063 Ethylene feed OP

SP Additive Flow controller OP

IN Final Elements

TEAL is the co-catalyst for Ziegler catalysts. It is also used during start-up for scavenging poisons from the reactor. In normal operation, only one pump is running. The TEAL flow rate is controlled in ratio to the ethylene flow rate. The ratio is calculated from the desired concentration of aluminium required in the powder, which is entered by the operator. The TEAL flow meters are located at each TEAL pump suction.

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SPECIFICATION COMPLEX CONTROL The total TEAL flow is calculated by summing the two pump Teal flows. During maintenance, flush with pentane must not affect the TEAL flow sum. A facility must be implemented to allow the DCS operator to set to 0 any of the flow entering the flow sum. The arrangement of TEAL pumps allows emptying of a TEAL cylinder at low speed and manual mode while the other TEAL pump speed and stroke is automatically adjusted to meet the target ratio to ethylene. The flow controller FQIC-40501 is set to achieve the required TEAL flow by adjusting the metering pump stroke and motor speed. The flow must change linearly with the controller output. The TEAL flow setpoint and the resulting aluminium concentration are calculated as follows:

FQIC - 40501.SP  (

FQIC - 40063.PV * 103 * ALC2.SP * 10-6 ) * ( MTEA/ MAl) TEACON 3

6

ALC2.PV = FQIC-40501.PV * TEACON * (MAL / MTEA) / (FQIC-40063.PV * 10 ) * 10 (for monitoring only) FQIC-40501.PV = FI-40501A + FI-40501B

Where: FQIC-40501.SP

Calc

TEAL flow controller set point

kg/h

ALC2.SP

Oper

Desired Al/C2 ratio entered by the operator

ppm w

ALC2.PV

Calc

Actual Al/C2 ratio achieved. For monitoring only

ppm w

FQIC-40063.PV

Meas

Ethylene flow

t/h

MTEA

=114

Molecular weight of TEAL

g/mol

MAL

=27

Molecular weight of Aluminium

g/mol

TEACON

=1 Oper

Weight fraction of TEAL in solvent

kg/kg

FI-40501A

Meas

TEAL injection Pump A flow

kg/h

FI-40501B

Meas

TEAL injection Pump B flow

kg/h

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SPECIFICATION COMPLEX CONTROL

17.

CHEMICAL ADDITIVES B1 AND S1 INJECTION CONTROL

17.1

B1 injection control

B1AL. SP

IN Block calculation OP

IN

PV

FQIC-40501

TEAL feed

SP B1 Flow controller OP

PV

IN Final Elements

The B1 is injected in Ziegler operation The control system is set up to adjust the flow rate of B1 injected in direct ratio to the TEAL flow rate to the loop. B1 is injected directly into the reactor. The flow controller FIC-40204 is set to achieve the required B1 flow. When the control system is switched to cascade, the B1 injection rate required is calculated in ratio to the TEAL flow. FIC-40204.SP= (FQIC-40501.PV * TEACON* B1AL.SP) * (MB1 / MTEA) / B1CON B1AL.PV = FIC-40204.PV * B1CON * (MTEA / MB1)/ (FQIC-40501.PV * TEACON) (for monitoring only)

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SPECIFICATION COMPLEX CONTROL

FIC-40204.PV

Meas

B1 flow

kg/h

B1AL.SP

Oper typically 0.05 to 0.15

Desired B1/AL molar ratio entered by the operator (there is one mole of AL per mole of TEAL)

mol/mol

B1AL.PV

Calc

Actual B1/AL ratio achieved

mol/mol

FQIC-40501.PV

Calc

TEAL flow

kg/h

B1CON

=1 Oper

Weight fraction of B1 in solvent

kg/kg

TEACON

=1 Oper

Weight fraction of TEAL in solvent

kg/kg

MTEA

= 114

TEAL molecular weight

g/mol

MWB1

= 92.58

B1 molecular weight

g/mol

The ratio block should display both the ratio setpoint and the actual calculated ratio Other interlocks (refer to interlock descriptions) close the feed isolation valve.

17.2

S1 injection control

The S1 can be used with Metallocene but is not normally injected in Metallocene operation. A control scheme is provided to allow injection under exceptional circumstances. The control system is set up to adjust the flowrate of S1 injected in direct ratio to the ethylene flow-rate to the loop. S1 is injected directly into the metallocene catalyst injection lines. The flow controller FIC-40202 is set to achieve the required S1 flow by adjusting the metering pump stroke and motor speed in split range (split range to be defined by Contractor detailed engineering Instrument specialist with pump vendor). The flow must change linearly with the controller output. When the control system is switched to cascade, the S1 injection rate required is calculated in ratio to the ethylene flow. 3

-6

FIC-40202 .SP= (FQIC-40063.PV * 10 * S1C2.SP * 10 ) / S1CON 3

-6

S1C2.PV = FIC-40202 .PV * S1CON / (FQIC-40063.PV*10 *10 ) (for monitoring only) Where:

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SPECIFICATION COMPLEX CONTROL

FIC-40202.PV S1C2.SP

S1C2.PV FQIC-40063.PV

S1CON

Meas Oper Typically 10 ppm by weight, max 20 ppm Calc Meas

=1 Oper

S1 flow Desired S1/powder ratio

kg/h ppmw

Actual S1/C2 ratio achieved Ethylene flow Filtered by 120s in the calculation. Dilution of S1 in solvent

ppmw t/h

kg/kg

The ratio block should display both the ratio setpoint and the actual calculated ratio Other interlocks (refer to interlock descriptions) close the feed isolation valve.

18.

STRIPPING GAS FLOW TO THE DEGASSER CORRECTION The stripping gas flow controllers to the degasser must be calculated as actual flow into the degasser to be in line with the stripping gas flow trip setpoints (refer to interlocks description). The vortex stripping gas flow meters give actual flow in the pipe and must be corrected with the pressure in the degasser and the pressure at the measure points. FIC-60602.PV = FT-60602 * maximum [(PI-60602 + ATM) / (PI-60529 +ATM); 1.5] Where: FIC-60602.PV

Calc

Stripping gas flow into degasser

m3/hr

FT-60602

Meas

Stripping gas flow into pipe

m3/hr

PI-60602

Meas

Pressure next FT-60602

barg

PI-60529

Meas

Pressure in degasser bottom.

barg

ATM

Refer to project basis

Atmospheric pressure

bara

Similar calculation to be done for FIC-60603 with PI-60601 and PI-60529.

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SPECIFICATION COMPLEX CONTROL

19.

GRADE OPERATING WINDOW LIMITS (GROWL) For each grade there is a set of operating parameters that define the normal operating conditions for the grade. Deviation from any of these conditions beyond defined limits should raise an alarm XAWIN. A separate display should show the current operating conditions and the optimal conditions and the limits. Any limit that is exceeded should be highlighted on the display. The operator should use a grade selector „GRADE‟ to define which grade is currently being produced in the reactor. This selector will load the current set of limits for that grade from a predefined table. Trends of all the GROWL parameters and the limits should be available to the operator. Ideally there should be a single display showing trends for all the variables. The operator should be able to adjust any of the current limits except the grade dependant parameters to reflect the current operating conditions of the plant as required. The predefined table for each grade should not be operator adjustable. These will be given initial values and then tuned in line with plant operating experience All the control parameters defined in GROWL must have a setpoint ramping facility that can be setup by the operator. The following table shows a sample of the variables required. This table should be expandable to allow additional grades and parameters to be added as required. The final variables and alarm values will be issued in the Operating Manual.

GRADE Examples:

Ethylene partial pressure Hydrogen partial pressure Hydrogen/ethylene partial pressure ratio Comonomer partial pressure Comonomer/ethylene partial pressure ratio Comonomer/ethylene flow ratio Pentane partial pressure VRU liquid purge flow

PC2 (bara)

Min tba

Zg LL6209 Normal tba

PH2 (bara)

NA

NA

NA

NA

NA

NA

RH2C2 (Bara / bara)

tba

tba

tba

tba

tba

tba

PCm (bara)

tba

tba

tba

tba

tba

tba

RCm/C2 (bara / bara)

tba

NC

tba

tba

NC

tba

FCm/C2 (kg/t)

tba

tba

tba

tba

tba

tba

PC5 (bara)

tba

tba

tba

tba

tba

FIC-60502 (kg/h)

tba

tba

tba

0.5 (cste) tba

tba

tba

Max tba

Min tba

Mt PF6212 Normal NC

Max tba

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SPECIFICATION COMPLEX CONTROL GRADE Examples:

C8-VRU liquid purge flow Reactor temperature TEAL feed S1 feed B1 feed Fluidisation velocity Pressure drop coefficient Production rate MI spec MI blending limit Density spec Density blending limit Extruder specific energy Degasser degassing flow VRU purge gas flow C8 Degasser degassing flow Purge column degassing flow

FIC-60872 (kg/h)

Min tba

Zg LL6209 Normal tba

Min tba

Mt PF6212 Normal tba

Max tba

Max tba

TIC-40046 (°C) ALC2 (ppmw) S1C2(ppmwPE) B1AL (mol/mol) Vf (cm/s) COFPD

tba tba NA tba tba tba

tba tba NA tba tba tba

tba tba NA tba tba tba

tba NA tba NA tba tba

tba NA tba NA tba tba

tba NA tba NA tba tba

PR (t/h) M_spec M_blend D_spec (kg/m3) D_blend (kg/m3)

tba tba tba tba tba tba

tba tba tba tba tba tba

tba tba tba tba tba tba

tba tba tba tba tba tba

tba tba tba tba tba tba

tba tba tba tba tba tba

FIC-60603 (m3/h)

tba

tba

tba

tba

tba

tba

FIC-60602 (kg/h) FIC-60865 (kg/h)

tba tba

tba tba

tba tba

tba tba

tba tba

tba tba

FIC-60013 (kg/h)

tba

tba

tba

tba

tba

tba

GRADE DEPENDANT PARAMETERS Group number Note 1 Catalyst CAT Comonomer Cm Compressibility factor Z Powder bulk density D_BULK (kg/m3) H2 to C2 to injection Kmt nozzles corrective factor

tba tba tba tba tba tba

tba tba tba tba tba tba

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SPECIFICATION COMPLEX CONTROL

Note 1: The SIS sends the group number to the DCS. This information is compared with group number defined in GROWL for each grade. An alarm in DCS will be issued in case of discrepancy. This alarm may happen at the start-up of the transition when operator will change of grade setting via the GROWL but has not yet fulfilled the conditions to determine the group number. In steady state the group in SIS and DCS are normally identical. NC: Not Controlled in steady state tba: to be advised – ref to Operating Manual NA: Not Applicable

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SPECIFICATION COMPLEX CONTROL

19.1

Operator interface for degassing flows during transitions

An operating interface gathering the degassing flow setpoint alarms and trips will help the operator to monitor the grade transition around the degassers and purge column. A trend example is given below. Reactor Temp Start transition – change grade in GROWL

End transition

Degasser flow

FAHH (SIS) FAH (GROWL) Degasser flow SP (GROWL)

FAL (GROWL)

Residence time 30 min

Degasser flow SP for transition (operating guideline)

FALL (SIS) Degasser flow SP (GROWL)

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SPECIFICATION COMPLEX CONTROL

20.

FLUIDISATION VELOCITY IN REACTOR The fluidisation velocity is a key variable in the operation of the reactor. It is calculated from the measured fluidisation gas flow rate around the loop. It is calculated at the top of the reactor bed.

20.1

Fluidising gas density

The fluidising gas density is calculated as follows:

FGD 

100 ATM  PIC - 40039A  MM  273  TIC - 40046  Z R

Where: FGD

Calc

Fluidising gas density

kg/m3

PIC-40039A.PV

Meas

Reactor pressure

barg

ATM

Refer to project basis

Atmospheric pressure

bara

TIC-40046.PV

Meas

Reactor temperature

°C

Z

= 0.92

Compressibility factor at reactor outlet, change with grade by GROWL

MM

Calc

Mean molecular mass

R

= 8.314

Gas constant

g/mol

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SPECIFICATION COMPLEX CONTROL

20.2

Fluidisation gas mass flow rate

The fluidisation gas flow rate is measured by a venturi flow meter. This is corrected for pressure, temperature and composition.

G

= FI-40050 * (PI-40053 +ATM) / (Pc +ATM) * (Tc + 273) / (TI-40053+273) * 0.5 (MM/Mc)]

Where: G

Calc

Corrected mass flow rate in loop

FI-40050

Meas

Uncorrected measurement

Mc

= Calc or refer IDS

Molecular mass used for the flow meter calculation at operating conditions This can be calculated from the density used for calculation if required:

Mc 

mass

loop

kg/h flow

kg/h g/mol

R (Tc  273).Dc.Z x 100 Pc  ATM

Tc

Refer IDS

Temperature used for the flow meter calculation at operating conditions

°C

Dc

Refer IDS

Density used for the flow meter calculation at operating conditions

kg/m3

Pc

Refer IDS

Pressure used for the flow meter calculation at operating conditions

barg

ATM

Refer to project basis

atmospheric pressure

bara

Z

= 0.92

compressibility factor, change with grade by GROWL

PI-40053

Meas

Pressure at the venturi meter

barg

TI-40053

Meas

Temperature at the venturi meter

°C

R

Refer elsewhere in this document

Gas constant

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SPECIFICATION COMPLEX CONTROL

20.3

Fluidisation velocity

The fluidisation velocity is developed for the flow expressed in kg/h.

The fluidisation velocity is finally calculated as follows:

VF 

G (kg/h) *100 3600 * FGD * A

G

Calc

Corrected mass flow rate in loop

kg/h

A

= 20.42

Reactor cross sectional area

m

VF

Calc

Fluidisation velocity

cm/s

FGD

Calc

Fluidising gas density

kg/m3

2

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SPECIFICATION COMPLEX CONTROL

21.

PRODUCTION RATE Calculate Production Rate in t/h, as: PR (t/h) = (FQIC-40063.PV + FQIC-40905.PV / 1000) / KCmEff PR should be filtered using a 120s first order filter

Where: FQIC-40063.PV FQIC-40905.PV KCmEff

Meas Meas Oper, 1.011

Ethylene feed rate Comonomer feed rate Comonomer and Monomer efficiency

t/h kg/h t/t

KCmEff varies slightly from grade to grade or with the plant operating conditions. An average value is used. If necessary it should be tuned to account for losses and actual impurities in the comonomer and monomer feeds.

22.

REACTOR RESIDENCE TIME, BED MASS, FLUIDISED BULK DENSITY Calculate Residence Time (hours):

Tau =

BMASS kg PR t/h  1000

Calculate mass of fluidised bed in kg, as: BMASS (kg) = D_FLBULK * A * LBED.PV 2

D_FLBULK = COFPD * 10 / g

Where: COFPD

Calc

Pressure drop per unit height

mbar/m

D_FLBULK

Calc

Fluidised bulk density

kg/m3

LBED.PV

Calc

Bed level

m

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SPECIFICATION COMPLEX CONTROL

2

A

= Refer to fluidisation velocity calculation

Reactor cross sectional area

m

g

= 9.81

Gravitational constant

m/s

Tau

Calc

Residence time

h

2

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SPECIFICATION COMPLEX CONTROL

23.

EXTRUDER FEEDS CONTROL

23.1

Introduction

This chapter defines the philosophy for the extruder feeds control including interfacing with the extruder during normal, start-up and grade changes. All control schemes and sequences must be developed by detailed engineering in conjunction with the main equipment Vendors. This section has to be read in conjunction with the extruder PDS.

23.2

Powder feed control

OP FY 80001B IN

Purge column

PV SIC 60012 OP

SP FQIC 80001 OP

FHS-80002 Start-up

PV

SP

+ -

IN FFIC xxx OP

Additives Feeders SP

PV

-

FY 80515B IN

Rerun IN FFIC 80515 OP

SP

IN

SP

Rerun Pellet Silo

PV SIC 80515 OP

OP FY 80515A

Extruder feed screw(s)

PV FI 80001A

Extruder

The operator will adjust the set point of the powder feed controller in order to maintain a suitable level in the purge column.

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SPECIFICATION COMPLEX CONTROL 23.3

Detailed control scheme of pellet flowrate through extruder

In normal operation pellet mass flow meter FE-80001 provides the process variable for the powder feed controller FQIC-80001 which controls the powder flow by manipulating the speed SIC-60012.SP of purge column outlet rotary valve. During start-up (or in the event of a failure of the flow meter) this is not possible and a calculated flow, based on the speed of the rotary valve and powder bulk density, must be used as the process variable. This calculated flow should be used during the start-up of the extruder. Switching between the two modes of control is manual (operator) and must be bumpless with the controller setpoint being aligned with the actual powder flow to prevent discrepancies between the calculation and the actual flow causing a sudden change in controlled output. The calculated powder flow rate is as follows: FQIC-80001.PV = FI-80001A or FY-80001B depending on FHS-80002 position FY-80001B.OP = SIC-60012.PV * (K1*K2)

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SPECIFICATION COMPLEX CONTROL

Where FQIC-80001

Master pellet flow controller

FI-80001A

Meas

Pellet flow

kg/h

FY-80001B.OP

Calc

Estimated powder feed rate from purge column outlet rotary speed

kg/h

FHS-80002

Powder or Pellet flow selector for Master pellet flow controller

SIC-60012.PV

Meas

Actual rotary valve speed

revs/h

K1

Oper

volume of powder fed by rotary valve Set by operator after calibration

m3 powder/rev

K2

Oper

Powder density

kg/m3

FQIC-80001.OP to be rate of change limited to smooth the transition between powder or pellet flow measurement. On line Calibration of Pellet Mass flow meter In order to maintain accuracy of the pellet mass flow meter on line frequent (> once/month) calibration is required. The Mass flow meter Vendor (Refer to Process Data Sheet) must develop a scheme in their own controller to carry this out using the blender weigh cells. This will be initiated at the Vendor Panel.

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SPECIFICATION COMPLEX CONTROL

23.4

Additive feeds and pellet rerun control

The additive flow control using loss in weight feeders will be carried out by the vendor‟s own PLC. The required flow setpoints (SP) of the feeders will be calculated by the DCS by multiplying the measured pellet flow minus the rerun pellet flow times the additive ratio setpoints. The rerun pellet flow is calculated from the rerun rotary valve speeds. An alarm must be raised on the DCS if there is a deviation between the flow set point to the additive feeder and the actual flow achieved. The additive and pellet rerun ratios will be input by the operator as part of the extruder start up sequence and can be modified thereafter as a correction for quality control or due to a grade change. Rerun pellet is subtracted from the overall pellet flow because it is assumed that this already contains the required additives. Additive flow control: -6

FFIC-80512.OP = FFIC-80512.SP*10 * [FQIC-80001.PV – FY-80515B.OP]

Where FFIC-80512.OP

Calc

Additive feeder A additive flow set point

kg/h

FFIC-80512.SP

Oper

Additive feeder A additive to powder flow ratio set point

ppmwt

FQIC-80001.PV

Meas/Calc

Pellet or powder flow

kg/h

FY-80515B.OP

Calc

Rerun pellet flow

kg/h

The rerun pellet flow is calculated from the rerun rotary speed as follows: FY-80515B.OP = SIC-80515.PV * (K3*K4) Where: SIC-80515.PV

Meas

Actual rotary valve speed

revs/h

FY-80515B.OP

Calc

Rerun pellet flow

kg/h

K3

Oper

volume of rerun pellet fed by rotary valve Set by operator after calibration

m3 powder/rev

K4

Oper

Pellet density

kg/m3

Similar calculation for other additive feeders.

© 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.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

LICENSOR REFERENCE

Rev.

Project

Unit n°

Doc. Type

Doc. Code

Sequent. n°

61070F

3200

SP

-

014

Serial n°

0014 Page

1

72 / 74

SPECIFICATION COMPLEX CONTROL Rerun pellet flow control: For the rerun pellet flow injection control, the operator sets the flow ratio of rerun pellets to powder flow The rerun pellet flow setpoint is then converted to rerun pellet rotary valve speed setpoint. FFIC-80515.OP = FFIC-80515.SP/100 * [FQIC-80001.PV –FY-80515B.OP] FY-80515A.OP = FFIC-80515.OP / (K3*K4) SIC-80515.SP = FY-80515A.OP Where: SIC-80515.SP

Calc

Rotary valve speed set point

revs/h

FFIC-80515.OP

Calc

Rerun pellet flow setpoint

kg/h

FFIC-80515.SP

Oper

Rerun pellet to powder ratio flow setpoint

% wt

K3

Oper

volume of rerun pellet fed by rotary valve Set by operator after calibration

m3 powder/rev

K4

Oper

Pellet density

kg/m3

23.5

Detection of powder blockage in the polymer vibrating screen

A blockage in the polymer vibrating screen is detected by monitoring a high difference between the powder flow at purge column outlet and the pellet flow. In case of blockage, the pellet flowrate will decrease and the powder feed controller FQIC-80001 will increase the speed of the purge column outlet rotary valve. An alarm will warn the operator when the powder flow calculated from the rotary valve speed is higher than the measured pellet flow rate. High priority alarm is generated as follow: (FY-80001B.OP – FI-80001A) filtered T5 > 1000 kg/h Where FI-80001A

Meas

Pellet flow

kg/h

FY-80001B.OP

Calc

Estimated powder feed rate from purge column outlet rotary speed

kg/h

T5

5

Filter time, adjustable on line

min

© 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.

OWNER REFERENCE

Technologies

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

LICENSOR REFERENCE

Rev.

Project

Unit n°

Doc. Type

Doc. Code

Sequent. n°

61070F

3200

SP

-

014

Serial n°

0014 Page

1

73 / 74

SPECIFICATION COMPLEX CONTROL

24.

PELLETS FLOWRATE CONTROL

24.1

Pellets flow rate to elutriation from pellet blenders

This control is out of scope of the PDP. Nevertheless it is described for guidance during detailed engineering phase. The pellets are conveyed from the homogenisation silos to elutriation. One of the homogenisation silos A or B is selected as the master by the operator and delivers the main pellet flow to the elutriation. The other slave silo complements the flow. The weight of the “master” homogenisation silo is controlled by adjusting the speed of the relevant outlet rotary valves A/B. The speed of the other homogenisation silo outlet rotary valve is then controlled in ratio. A homogenisation silo is “master” when the relevant weight controller is in cascade mode. Logic will only allow one silo weight controller to be “master”. In the description below, Pellet blender A/outlet blender rotary valve A is assumed to be the master system and Pellet blender B/outlet blender rotary valve B the slave. SIC-xxxxxA.SP = WIC-80031.OP (cascade control) SIC-xxxxxB.SP = SIC-xxxxxA.PV * SpeedHomoRatio Where: WIC-80031

Blender A weight controller (master)

WIC-80031.OP

Blender A weight controller output

SIC-xxxxxA

Blender outlet rotary controller (master)

valve

A

speed

SIC-xxxxxB

Blender outlet rotary controller (slave)

valve

B

speed

SpeedHomoRatio

Oper

Revs/h

Slave speed to master speed ratio

Rev/Rev

The ratio block should display both the ratio setpoint and the actual calculated ratio. Speed controller output limits: In order to avoid overloading the conveying line the speed controller outputs must be limited: SIC-xxxxxA.OPHIGH = TOTALSPEEDHIGH / (1+ SpeedHomoRatio)

© 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.

OWNER REFERENCE

Technologies

Project

Package

RAPID

L20

Originator

INE

Discipline

Doc. Type

Unit n°

PRO

DES

3200

LICENSOR REFERENCE

PETRONAS RAPID PROJECT 350 kta LLDPE PLANT

Rev.

Project

Unit n°

Doc. Type

Doc. Code

Sequent. n°

61070F

3200

SP

-

014

Serial n°

0014 Page

1

74 / 74

SPECIFICATION COMPLEX CONTROL SIC-xxxxxB.OPHIGH = TOTALSPEEDHIGH * SpeedHomoRatio / (1+ SpeedHomoRatio)

Where: SIC-xxxxxA.OPHIGH

Calc

Blender outlet rotary valve A max speed (master)

Revs/h

SIC-xxxxxB.OPHIGH

Calc

Blender outlet rotary valve B max speed (slave)

Revs/h

TOTALSPEEDHIGH

Oper

Maximum allowable total rotary speed

Revs/h

SIC-xxxxxA.OPHIGH and SIC-xxxxxB.OPHIGH are calculated only when WIC-80031 is in cascade mode. In addition to the calculated speed limits, conveying pressure controllers PIC-xxxxx protect against overpressure: If conveying pressure is high the speed controllers will be cut back. The pressure controller overrides the speed controllers‟ outputs. The same calculations should be made when Pellet blender B/outlet blender rotary valve B or Pellet blender C/outlet blender rotary valve C is the master system with any other slave combinations.

25.

INTERFACE BETWEEN DCS AND APC (OPTION)

Provision for APC hardware should be provided in any case: Hardware requirements: -

APC computer (PC running Windows XP or 7) in the engineers room close to the panel operator

-

One serial link w/ cables

The interface with the APC system (separate PC communicating with the DCS) should be developed within the DCS according to the communication data exchange tables. The DCS should be programmed to handle remote setpoints from the APC system and communicate data to the APC system. Some data will require further development of piece of logics and calculations within the DCS. Estimated number of I/O‟s through the serial link: about 100.

© 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.