0-System philosopy.

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2009-12-05

TEXON AUTOMATION BOILER CONTROLS

Texon ref. no. O-9114, O-9115, O-9116, O-9117

Vessels: LNG/C ”Al Khaznah”, LNG/C ”Shahamah”, LNG/C ”Ish”, LNG/C Ghasha”

System philosophy, Scope of supply and Scope of work

1. System philosophy.

Automatic Combustion and Boil Off Gas (BOG) control

The combustion control is a fully automatic, compact and reliable combustion control system for
dual-fuel boilers on LNG carriers. The system maintains steam pressure within very close tolerances
even during rapid load changes. It governs the supply of fuel and combustion air to the boiler
furnace in close accordance with current steam demand, and permits instant and efficient engine
control. The air/fuel ratio for optimum combustion efficiency is closely controlled. Combustion trim
controller is included in the system to compensate for the (inevitable) inaccuracy in measurement
of fuel calorific values and combustion air mass. Operating parameters for steam pressure, steam
temperature, feed water level, flue gas oxygen content etc. are preset, although adjustable at any
time. The combustion is automatically controlled to compensate for variations in steam demand,
maintaining superheater outlet pressure within close tolerances under all operating conditions.

Burner Management System (BMS)

The Burner Management System is a fully automatic control system for boiler safety and easy
burner light up and shut down. Boiler safety functions are integrated in the system, with some
critical sensors (e g for drum water level, steam pressure and steam temperature) duplicated.
Cascade of burners (Automatic start/stop) is performed by BMS as per system requirements. The
boilers can be operated from a control room panel as well as from a local control panel included in
the system. Automatic control can be initiated from both panels. The system requires no manual
operations under normal operating conditions.
Change over from diesel oil to heavy fuel oil at cold boiler start is however normally done manually.

Master controller.
The master controller will calculate a “Power demand” (=load signal) from the highest of Port and
Stbd steam pressure transmitters. The Power demand signal is used for both boiler fuel controllers
in the PLC. This makes sure both boilers will have same load.

Steam temperature control.

The steam temperature controller is configurated as a cascade controller. Three superheated steam
outlet temperature sensors are measuring the final temperature. An intermediate temperature
sensor is also available, fitted on the de-superheater outlet.
A cascade controller is more efficient to keep a steady temperature and reacts quickly to changes in
load.
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Feed water level control.

The Feed water lever controller utilizes water level and steam flow transmitters and is thus a two
element controller operating the feed water control valve.

Fuel oil pump pressure control.

The Fuel oil pump pressure controller utilizes the pump outlet pressure. The pressure is modulated
by means of a by-pass control valve. The fuel pump outlet pressure is also modulated to suit the
actual requirements from the boiler controls.

CPU redundancy
 The control system utilizes redundant CPU’s with instant switchover if one CPU fails. There will
be no data loss in this case and both boilers will continue operating on the other CPU.

Communication redundancy
 Two ProfiBus networks are used to connect the I/O racks. Each I/O rack has two communication
modules. If one ProfiBus network fails, the other will instantly, without data loss, take over the
communication with the I/O-racks.

I/O redundancy
 All field devices that are common for both boilers (e g F.O. pump pressure transmitter, nitrogen
pressure transmitter etc.) are connected in a redundant I/O configuration. This means that
these sensors are connected to duplicated I/O:s.

HMI redundancy
 The network between the CPU:s and the HMI (Operator Stations) is connected as an Ethernet
ring. This means that if a switch (or a cable) is broken, the network will continue to function as
per normal.
 Operation of boilers is available via two identical operator stations. Any of these can control
both boilers.

2. Scope of supply.

PLC Cabinet in ECR

 The original cabinets are cleared from original equipment and fitted with panels made at
Texon, containing all control hardware (PLC) and connecting terminals.

Control panels for engine control room

 Controls for fuel oil, fuel gas, combustion air, water level, steam temperature and steam
dump.
 Controls for start and stop of burners
 HMI for graphic display of relevant system information
 Emergency stop buttons
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Control panels for BLP, Boiler Local Panel

 Controls for fuel oil, fuel gas, combustion air, water level and steam temperature
 Controls for start and stop of burners
 Emergency stop buttons

Pressure transmitters
The following pressure/differential pressure transmitters are supplied:
 Steam pressure
 Fuel oil (burner rail) pressure
 Fuel oil pump pressure
 Fuel gas flow
 Fuel gas pressure, boiler header
 Fuel gas pressure, main line
 Combustion air flow
 Drum water level
 Steam flow
 Feed water flow
 Steam temperature control, spray water flow
 Atomizing steam pressure
 Control air pressure
 Nitrogen pressure
 Main condenser inlet pressure
 Aux condenser inlet pressure

Temperature transmitters
The following temperature transmitters are supplied:
 Fuel oil (burner rail) temperature
 Fuel gas temperature
 Superheated steam temperature
 Intermediate steam temperature, before de-superheater
 Intermediate steam temperature, after de-superheater
 Dump steam temperature
 Main condenser cooling water outlet temperature

I/P transducers
The following I/P-transducers are supplied:
 Fuel oil (burner rail) pressure control
 Combustion air flow control (inlet vanes)
 Dump steam temperature control
 Fuel oil pump pressure control
 Atomizing steam pressure control
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Fuel oil control valve

 Control valve with high turn down ratio, one per boiler

Flame scanners
 Two IR-scanners for each burner
 Two UV-scanners for each burner

Oxygen analyzer
 One analyzer for each boiler for indication of oxygen content and for combustion trim.

3. Scope of work.
Texon will do the following:
 System design and layout
 Design of application software and programming
 Construction of PLC-cabinets, control panels and instrument panels
 Installation of the complete system on turnkey basis
 Commissioning during dock trials, sea trials and loaded passage