Licensor M/s Lummus Clarifications to balance MOM Points

From: "SACHIN UPADHYAY" <sachin.upadhyay@eil.co.in>

To: "ANINDYO RAY" <a.ray@eil.co.in>, "MAINAK NANDI" <m.nandi@eil.co.in>,
"BHARATH CHANDRASEKAR" <bharath.c@eil.co.in>
Sent: Wednesday, February 26, 2020 9:26:25 AM
Subject: Fwd: CBI-E-EIL-0530 RE: EIL/E/CBI/594: Process Related queries,
Furnace related Logics & complex controls

Dear Sir,

Please find Lummus reply.

regards
Sachin
2712

From: "Vitiello, Gerard J" <Gerard.Vitiello@mcdermott.com>

To: "ATUL GUPTA" <atul.gupta@eil.co.in>, "Asplund, Harry"
<Harry.Asplund@mcdermott.com>
Cc: "Ghosh, Srikanta Kumar" <SGhosh@mcdermott.com>, "Wysoczynski, Wayne
S" <Wayne.Wysoczynski@mcdermott.com>, "M B Gohil" <MB.Gohil@hmel.in>,
"manu sehgal" <manu.sehgal@hmel.in>, "tapash pramanik"
<tapash.pramanik@hmel.in>, "Narendra Verma" <Narendra.Verma@hmel.in>,
"anshu sharma" <anshu.sharma@hmel.in>, "AVNEESH SAWHNEY"
<a.sawhney@eil.co.in>, "S K HANDA" <sk.handa@eil.co.in>, "SUNIL KUMAR
SAXENA" <sunil.saxena@eil.co.in>, "ANIL KUMAR" <akumar@eil.co.in>, "ALOK
KUMAR" <alok.kumar@eil.co.in>, "SACHIN UPADHYAY"
<sachin.upadhyay@eil.co.in>, "RAKESH KUMAR SINGH" <rakesh.singh@eil.co.in>,
"UDAY KRISHNA" <uday.krishna@eil.co.in>, "KULBHUSHAN CHAWLA"
<kb.chawla@eil.co.in>, "Tapan Kumar Koley" <Tapan.Koley@hmel.in>, "Alexander,
Lawrence M" <Lawrence.Alexander@mcdermott.com>, "Wiley, Mark A"
<Mark.Wiley@mcdermott.com>, "Email Database HMEL BEP (222334@mfiler-
bmn.mcdermott.com)" <222334@mfiler-bmn.mcdermott.com>, "Moore, Paul"
<paul.moore@mcdermott.com>
Sent: Wednesday, February 26, 2020 1:21:01 AM
Subject: CBI-E-EIL-0530 RE: EIL/E/CBI/594: Process Related queries, Furnace
related Logics & complex controls

Dear Atul:

Lummus replies are provided below in green. Any BEP documents requiring updates as per Lummus
reply will follow in separate email as soon as possible.

Regards,
 Gerard J. Vitiello 1515 Broad St.

Process Design Manager Bloomfield, NJ 07003-3096

Lummus Technology United States

Office: +1- 973-893-2577 www.mcdermott.com

Company Mobile: +1- 862-213-5014

Personal Mobile : +1- 973-896-1174

gerard.vitiello@mcdermott.com

From: ATUL GUPTA <atul.gupta@eil.co.in>

Sent: Friday, February 14, 2020 8:08 AM
To: Asplund, Harry <Harry.Asplund@mcdermott.com>
Cc: Vitiello, Gerard J <Gerard.Vitiello@mcdermott.com>; Ghosh, Srikanta Kumar
<SGhosh@mcdermott.com>; Wysoczynski, Wayne S <Wayne.Wysoczynski@mcdermott.com>; M B
Gohil <MB.Gohil@hmel.in>; manu sehgal <manu.sehgal@hmel.in>; tapash pramanik
<tapash.pramanik@hmel.in>; Narendra Verma <Narendra.Verma@hmel.in>; anshu sharma
<anshu.sharma@hmel.in>; AVNEESH SAWHNEY <a.sawhney@eil.co.in>; S K HANDA
<sk.handa@eil.co.in>; SUNIL KUMAR SAXENA <sunil.saxena@eil.co.in>; ANIL KUMAR
<akumar@eil.co.in>; ALOK KUMAR <alok.kumar@eil.co.in>; SACHIN UPADHYAY
<sachin.upadhyay@eil.co.in>; RAKESH KUMAR SINGH <rakesh.singh@eil.co.in>; UDAY KRISHNA
<uday.krishna@eil.co.in>; KULBHUSHAN CHAWLA <kb.chawla@eil.co.in>
Subject: EIL/E/CBI/594: Process Related queries, Furnace related Logics & complex controls

Dear Harry,
This is regarding the Furnace related complex loop control description and their
cause & effect diagram, following points needs Lummus clarification for configuring
the same;

1.
<Refer S.No.2 d of MOM 18BP01-GM2-911-003 dtd 7.2.20>
Loss of pilot burners fuel gas, under miscellaneous trip has been mentioned for
integral burners and hearth burners has been mentioned. As per our understanding,
applicability of note-4 (first line is for single heater trip only) and second line is only
for Hearth pilot burner trip. For the pilot burner only trip, Note -11 is also referred, We
understand the applicability of note-11 is for opening of Secondary hearth fuel gas
valve ( HV-21076, HV-21077 only).
Lummus reply: The arch temperature low temperature interlock performs two
separate interlock functions. When the arch temperature is above auto-
ignition temperature, the pilots are not needed to safely operate/commission
the hearth burners. In the event low pilot pressure occurs when the arch
temperature is above auto ignition temperature, safety logic will trip only the
pilots. If the arch temperature is below auto-ignition temperature, the pilots
may be needed to ignite hearth burners. In the event low pilot pressure occurs
when the arch temperature is below auto ignition temperature, safety logic will
trip the heater to a full trip. Hearth burner pilots ignite hearth burner primary
tips, but will not ignite staged fuel if the primary tip has not been
commissioned and the box temperature is below auto-ignition temperature. If
the arch temperature is below auto-ignition temperature, safety logic will not
allow fuel HV’s to the secondary fuel header to be opened.

2.

<Refer S.No.7 of MOM 18BP01-GM2-911-003 dtd 7.2.20>

NOTE-1 (w.r.t keeping the Dilution steam Controller in AUT/MAN mode during Partial Trip)
of C&E Diagram is contradicting with Partial Heater trip description (Pg 09/11 of Sec no
10.2.1 Process Control Description i.e Dilution steam controllers are placed in manual mode
and output is set to a position that provides appropriate preset minimum flow to the coils.
Lummus reply: The process control description is correct and the C&E
Diagram (note 1) will be corrected.

3.

<Refer S.No.9 b 2) of MOM 18BP01-GM2-911-003 dtd 7.2.20>

In page 5/11, section 10.2.1, In COT Balancing Differential Temp Controller, functional
configuration of Internal Bias (IB) to be explained in detail.
Lummus reply: When the individual coil flow controller is not in cascade
mode, an Internal Bias is calculated and continuously updated while the
controller is not in cascade mode. The internal bias will be frozen at its last
calculated value when the controller mode is changed to cascade mode. Also
when the individual coil is not set in Cascade mode, the TDC controller output
is set at 50%. If the average coil flow is 70% of range when any of the
individual flow controllers are not in cascade mode, the output of the
throughput controller will track this average and be set at 70%. When the
operator wants to activate the coil balancing, all of the individual flow
controllers will be placed in cascade mode. If every coil setpoint is 70%, every
Internal bias would be frozen at -50% to make the mode change bump-less. If
a coil’s setpoint is 71 % of the average at the moment of the modes are
changed to cascade mode, the internal bias would be -49% to ensure bump-
less mode change.

4. Some discrepancies are observed in between “Ethylene Plant process specific

application” Doc: 195711630_0 and complex control description Doc.222334 section 10.2.1;

A. <Refer S.No.9 4) a) of MOM 18BP01-GM2-911-003 dtd 7.2.20>

In COT balancing – differential temperature controller it says TDC should be configured for
setpoint tracking whereas page 2/7, it is mentioned that the TDC controller must not have set
point tracking. Presently it is assumed as “the TDC should not be configured as for setpoint
tracking.
Lummus reply: Usually the TDC setpoint should be set at zero and remain at
zero. We agree that the setpoint should not be provided with setpoint
tracking.
B. <Refer S.No.9 4) b) of MOM 18BP01-GM2-911-003 dtd 7.2.20>

Page no. 4 of 11 , section 10.2.1,

Qoute-1
This scheme allows for total feed throughput control along with individual coil flow trimming
equalizing all COTs. When none of the individual feed flow controllers are in cascade mode,
DCS sequence logic should place the throughput controller in manual and the controller
output set equal to the average coil flow controller setpoint
Unquote
is contradicting with description mentioned on page number 7 of 11.
Qoute-2
The total furnace feed flow controller must be automatically placed in MANUAL mode when
one or more of the coil flow controllers for the heater are not in CASCADE
or AUTOMATIC/REMOTE set point mode
Unquote
Presently it is assumed as “The total furnace feed flow controller must be automatically
placed in MANUAL mode when one or more of the coil flow controllers for the heater are not
in CASCADE or set point mode”. Please confirm the understanding.
Lummus reply: Agree there is a conflict between the two statements, the first
quote should be changed from “none” to “any” to be consistent.

<To be sent to LTHE for incorporation in PDB>

5. Regarding detail L referred on the XVs under furnace section, lummus has
indicated a field mounted reset as well as DCS open Switch through interlock. As the
Field mounted reset is already available for these XVs, DCS open/reset is not
required. Lummus is requested to share the specific requirement of this switch.
Lummus reply: Lummus standard design practice is to have the valve reset in
the field to ensure field operator confirms the heater and burners are ready for
the fuel valves to be opened. Having a DCS hand switch to reset the valve is
not consistent with the Lummus design practice. In summary, the open hand
switch in Detail “L” is not required which is in agreement with EIL conclusion.
Regards,

Atul Gupta| Chief General Manager-Projects | Engineers India Limited |

Engineers India Bhawan, 1, Bhikaiji Cama Place, New Delhi - 110066 |
Direct: +91 11 26762400| Tel: +91 11 26102121 Ext.: 2400|
e-mail: atul.gupta@eil.co.in | Website: www.engineersindia.com

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--
Regards
Sachin
2712

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