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Philosophy of Control for Complex Logics

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  • 8/20/2019 Philosophy of Control for Complex Logics

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    MUMBAI REFINERY Rev. Date: 20/01/2010

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    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    C'APTER ( &

    P'ILOSOP'Y OF CONTROL

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 1 %

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    TABLE OF CONTENT

    1.0 PREFACE............................................................................................................&

    S!+e................................................................................................................................&

    Le-e..............................................................................................................................&

    2.0 OERALL PLANT CONTROL P'ILOSOP'Y...................................................

    $.0 COMPLE3 CONTROL SYSTEMS.....................................................................11

    $.1 Fee S4,-e D,45 6%%#D#027 P,e884,e Ct,9 6PIC#120&7.................................11

    $.2 Fee S4,-e D,45 Leve9 Ct,9 6LIC#120 'S#120;7.......................................1$

    $.$ Ma7.......................................................................................................1"

    $. 'DT Rea!t, E94et St,=++e, Fee Te5+e,at4,e Ct,9 6TIC#1>107.............21

    $.; 'DF Rea!t, E94et Te5+e,at4,e Ct,9 6TIC#1>027.....................................2&

    $.> 'DT Rea!t, C*a,-e 'eate, O4t9et Te5+e,at4,e Ct,9 6TIC#1"0>7..............2;

    $." 'DT Rea!t, Te5+e,at4,e Ct,9 6TIC#201%/2012/201&/201;7........................2"

    $.% MSD? Fee D=e,et=a9 P,e884,e Ct,9 6PDIC#21027....................................$1

    $.10 Rea!t, L+ P,e884,e Ct,9 6PIC#$20"/'S#$212/FIC#$202/FIC#210;7.........$2

    $.11 Lea A5=e Te5+e,at4,e Ct,9 6DTIC#2$0"7..................................................$

    $.12 ?a8* ?ate, S4,-e D,45 6%%#D#1$7 P,e884,e Ct,9 6PIC#2&017.....................$>

    $.1$ 'DF Fee Te5+e,at4,e Ct,9 6TIC#2027........................................................$%

    $.1& MSD? C*a,-e 'eate, O4t9et Te5+e,at4,e Ct,9 6TIC#2;0>7.........................&1

    $.1 MSD? Rea!t, Te5+e,at4,e Ct,9 6TIC#2"0"/2"11/2"1&7.............................&$$.1; 'DF Rea!t, Te5+e,at4,e Ct,9 6TIC#2%0$/2%027..........................................&;

    $.1> 'TS O'D/Re!@!9e Ga8 E!*a-e, 6%%#E#0>7 Re!@!9e Ga8 O4t9et

    Te5+e,at4,e Ct,9 6TIC#$0027.........................................................................&%

    $.1" 'TS L=4=/F,a!. Btt5 E!*a-e, 6%%#E#1&A/B7 P,4!t St,=++e, Fee

    Te5+e,at4,e Ct,9 6TIC#$0017.........................................................................1

    $.1% P,4!t St,=++e, 9eve9 Ct,9/F9 Ct,9 t a!. F,a!. C*a,-e 'eate, %%#F#

    0$ LIC#$$0$/FIC#$$02/FIC#$$0&7..........................................................................$

    $.20 a!. F,a!. C*a,-e 'eate, O4t9et Te5+e,at4,e Ct,9 6TIC#$07...................

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 2 %

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    $.21 Fee/F,a!. Btt5 E!*a-e, 6%%#E#01A/B7 Ra=ate Fee Te5+e,at4,e

    Ct,9 6TIC#&10$7..............................................................................................."

    $.22 ?a,5 Fee/F,a!. Btt5 E!*a-e, 6%%#E#1>A/B7 Deae O=9 O4t9et

    Te5+e,at4,e Ct,9 6TIC#&1017.........................................................................;0

    $.2$ a!445 F,a!. P45+a,4 Ret4, Te5+e,at4,e Ct,9 6TIC#&2017..............;2

    $.2& A5=e De-a88=- D,45 6%%#D#1&7 P,e884,e Ct,9 6PIC#&>0%7......................;&

    $.2 S4, ?ate, De-a88=- D,45 6%%#D#17 P,e884,e Ct,9 6PIC#&>0&7..............;;

    $.2; 'eate, 6%%#F#017 Da5+e, Ct,9 6PIC#1"0/'IC#1"0/'S#1"107......................;"

    $.2> Deae O=9 P,4!t C9e, 6%%#AFC#0;7 Te5+e,at4,e Ct,9 6TIC#&10&7....>1

    $.2" P,4!t St,=++e, Ove,*ea A!!4549at, 6%%#D#107 Leve9 Ct,9 6LIC#

    $&10/FIC#$&0&A/FIC#$&0&B7................................................................................>$

    $.2% a!445 F,a!. Ove,*ea A!!4549at, 6%%#D#117 Leve9 Ct,9 6LIC#$%02/FIC#

    &10&A/FIC#&10&B7................................................................................................>

    $.$0 a!445 F,a!. Ove,*ea Te5+ Ct,9 6%%#T#07 Re94 Ct,9 6TIC#$>02/FIC#

    $>0$7.....................................................................................................................>"

    $.$1 'eav@ D=8t=99ate St,=++e, 6%%#T#0>7 Leve9 Ct,9 6LIC#$"017............................"0

    $.$2 LPG a+,=e, 6%%#D#2;7 Leve9 Ct,9 6LIC#%017 / P,e884,e !t,9 6PIC#

    %0&7....................................................................................................................."2

    $.$$ S4, ?ate, De-a88=- D,45 6%%#D#17 Leve9 Ct,9 6LIC#&>017...................."&

    $.$& ?a8* ?ate, F9 Ct,9 6FIC#2&01 / FIC#21017 , ?a8* ate, C945 6%%#T#

    0$7 a 't St,=++e, O'D C9e, 6%%#AFC#017................................................";

    &.0 PUMP AUTO START/STOP CONTROL SYSTEM............................................"%

    &.1 A4t Sta,t /St+ S@8te5 6I#&%7 , C98e B9 S@8te5 P45+ 6%%#P#

    1"A/B7...................................................................................................................%0

    &.2 A4t Sta,t /St+ S@8te5 6I#2017 , Ba!

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    1.0 PREFACE

    S!+e

    This narrative describes the plant control systems by instrumentation.

    The purposes of this document are as follows:

    (1) To explain control systems to those who are not familiar with instrumentation

    symbols or functional logic diagrams.

    (2) To define purpose and algorithm of each control system.

    Complex control include split range control cascade control and dual range control.

    This document does not cover simple control loops.

    Le-e

    !C" !istributed Control "ystem

    #$ #rocess $alue (%nput) to !C" controller 

    "# "et #oint of Controller 

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    RMB R'D Pa-e & %

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    2.0 OERALL PLANT CONTROL P'ILOSOP'Y

    O=9 C*a,-e a Fee S4,-e D,45

    &il charge is received at the battery limits from tan'age. n offsite pump provides

    sufficient pressure to pass through low temperature heat exchanger (**+,1-)

    filtration (**/%0,1) Coalescer (**!2,) and enter the /eed "urge !rum (**!,1).

    &il charge flow to the unit is controlled by **!,1 level which is cascaded to a flow

    controller. handswitch ("12,) is provided to allow selection of flow control to either 

    the normal unit charge controller (/%C12,1) or the special startup feed (wetting and

    sulfiding stoc') control valve (0$12,3). /rom the /eed "urge !rum the feed is

    boosted to high pressure by the ooster pump (**#45-) /eed Charge #ump (**#

    ,2-) and sent to the 6arm /eed - /ractionator ottom +xchanger (**+17-) and

    the /eed - !T 8eactor +ffluent +xchangers (**+,5--C). The oil charge to the

    !T is on straight flow control.

    Mauench flow rates. The !T 8eactor consists of four beds of catalyst

    to limit the overall exotherm in the !T. Two thirds of the expected exotherm is

    eliminated by means of >uench to the outlet of the first second and third beds. The

    >uench gas enters on flow control reset by bed inlet and-or outlet temperature. nadditional >uench gas connection is provided to the inlet of the reactor for fast trim

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    temperature control if re>uired during an upset condition and for use in controlling the

    wetting exotherm on startup. oth Treat ;as and ?uench ;as to the !T 8eactor is

    supplied from the 8ecycle ;as Compressor (**C,2-).

    'DT E94et St,=++e,

    The !T +ffluent "tripper (**T,1) removes 2" and =5 from the !T effluent

    stream with fresh incoming ma'eup hydrogen. The stripper can function through a

    reasonable temperature range but will operate close to 1

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    (**+5*). 0ean amine and wash water flow rates to their respective towers are both on

    simple flow control.

    MSD? a 'DF Rea!t, Te5+e,at4,e Ct,9

    The control philosophy for the 9"!6 8eactor is identical to that of the !T 8eactor.

    The 9"!6 reactor temperature is controlled by adusting the furnace firing rate. The

    9"!6 8eactor (**8,2) consists of three bed of catalyst to control the overall

    exotherm. The maority of the expected (gross) exotherm is eliminated by means of 

    8ecycle ;as >uench to the outlet of the first and second beds. The >uench gas enters

    on flow control (reset by bed inlet - outlet temperature). n additional >uench gasconnection is provided to the inlet of the reactor for fast trim temperature control during

    an upset condition and for use in controlling the wetting exotherm on startup.

    The !/ 8eactor (**8,5) exotherm is expected to be negligible in normal operation.

    The !/ inlet temperature is controlled through bypassing of 9"!6 /eed around the

    **+,--C. The !/ 8eactor consists of two beds of catalyst. The inlet to each bed

    is e>uipped with hydrogen >uench connections. The >uench hydrogen to the first bed

    enters the reactor inlet line on flow control (reset by either reactor inlet temperature) andprovides trim temperature control and for the bed wetting exotherm during the initial

    startup. n additional >uench inection point is provided at the inlet to the second bed

    for similar reasons.

    P,4!t Se+a,at, Te5+e,at4,e Ct,9

    !/ 8eactor effluent is sent to the 9"!6 8eactor /eed-!/ +ffluent +xchanger (**

    +,2--C). This exchanger will be in use during endofrun (+&8) conditionsB but at

    startofrun ("&8) the duty is expected to be near Dero. The !/ 8eactor effluent

    temperature leaving the exchanger is controlled by bypassing oil feed around the

    exchanger. The intent of this is to provide a controlled temperature to the igh

    Temperature "eparator ET"F (**!,4). "eparator li>uid product is discharged on flow

    control reset by drum level to the T" 0i>uid - /ractionator ottoms +xchanger (**+

    14-) and then to the #roduct "tripper tower (**T,4). T" vapor is cooled by

    exchange with the Treated ;as (**+,7) then aircooled (**/C,2) then water

    cooled (**+,

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    ;as purity. n additional amount of light hydrocarbon will be condensed in this drum

    which is sent on flow control reset by level where it combines with the light

    hydrocarbons condensed in the !T 0ow Temperature separator (**!,2) and the

    combined stream is heated by exchange with !ewaxed 0ube #roduct (**+13) before

    entering **T,4.

    %n order to protect against a highpressure blowthrough of gas from the separators to

    the fractionation section both **!,4 and **!,3 separators are e>uipped with low

    level switch interloc's. These interloc's operate a chopper valve and act to close the

    product flow control valves by means of airactivated solenoids located on the air supply

    to the valves.

    Re!@!9e Ga8 a U=t P,e884,e Ct,9

    9a'ep ydrogen ;as is inected into the unit at the !T +ffluent "tripper as

    described above. %n order to maintain 8ecycle ;as hydrogen purity it is necessary to

    continuously purge a small portion of gas from the unit. The purge gas stream is ta'en

    from the 8ecycle Compressor "uction A& !rum (**!,) overhead line. The unit

    pressure controller is also located on the 8ecycle Compressor "uction A& !rum. The

    pressure control signal from #%C52,< goes to a hand switch (**"5212) to control

    either the 9a'ep ;as rate or the unit purge gas rate. &nce selected the other 

    remains left on straight flow control. The unit was designed with a purge allowance of 

    2G of the 8ecycle ;as 8ate. The ma'eup hydrogen re>uirements are minimiDed when

    setting the purge gas rate at some minimum value. This allows the pressure controller to

    bring in ma'eup hydrogen as re>uired to maintain unit pressure.

    /or stable operation of 9"!6 reactor it is necessary to have stable !T effluentstripper operation. ence it is preferred to have constant ma'eup as flow rate to **T

    ,1 and reactor section pressure is controlled by varying purge rate.

    'P St,=++e, Se!t=

    The igh #ressure "tripper is a steam stripped column designed to remove naphtha

    and lighter boiling components from the li>uid product stream. There is no external heat

    source for this column. $apor traffic is generated solely from the sensible heat of the

    feed. "tripping steam is introduced on flow control to the bottom of the # "tripper.

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    The amount of naphtha product produced is small. The endpoint of the naphtha is

    controlled by the tower top temperature which resets the reflux rate. #ressure control

    of the tower is accomplished by throttling the vapor product which is sent to 8efinery

    /uel ;as eader. The amount of reflux can be controlled somewhat by regulating the

    igh Temperature "eparator Temperature as described earlier. The =aphtha endpoint

    and degree of stripping will in turn influence the flashpoint of the distillate product in the

    $acuum /ractionator.

    "tripped li>uid product from the bottom of the # "tripper is sent on flow control (reset

    by level) to the $acuum /ractionator Charge eater (**/,5). The stripper contains a

    large li>uid inventory to ensure stable operation of the eater. s **/,5 is two pass

    furnace flow is e>ually divided between two passes by individual flow controllers which

    are reset by column level.

    a!445 F,a!t=at= Se!t=

    The $acuum /ractionation "ection consists of four vessels the $acuum /ractionator 

    (**T,3) the !ewaxed &il $acuum !ryer (**T,) the eavy !istillate "tripper (**T

    ,7) and the eavy !istillate $acuum !ryer (**T,

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    for **/,5. ny hydrocarbon li>uid from the Condensate 8eceiver is pumped to **!

    11 inlet. ny sour water is pumped to the "our water !egassing !rum (**!13).

    The hydrocarbons that have condensed in **!11 are pumped (**#,* -) under 

    level control and the stream split into two parts. The first is returned to the $acuum

    /ractionator as top reflux under flow control that is cascaded to overhead temperature.

    The second part is watercooled (**+15) and leaves the unit as 0ight !istillate product

    under flow control that is cascaded to the **!11 level.

      heavy distillate product is withdrawn from below the second pac'ed section and

    pressured to the eavy !istillate "tripper (**T,7). /low to **T,7 is set by **T,7

    bottoms level control. The distillate product is steam stripped to remove lighter distillate

    and sent to the eavy !istillate $acuum !ryer (**T,

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    $.0 COMPLE3 CONTROL SYSTEMS

    $.1 Fee S4,-e D,45 6%%#D#027 P,e884,e Ct,9 6PIC#120&7

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

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       T   &   /   0      8   +

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       /   8   &

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        ,    4     .

    C&=T8&0 $(0$+ +=%=; G

       C   &   =   T   8   &   0   0   +   8   &   :   T   #   :   T   G

       3   ,   G

       4   7 .   3   G

       3   2 .   3   G

       #   8   +   "   "   :   8   +   %   =   C   8   +      "   +

       /   8   &   9   *   *     !     2   ,

       /   +   +   !

       /   +   +   !   "   :   8   ;   +   !   8   :   9   (   *   *     !     ,   1   )   #   8

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    $.2 Fee S4,-e D,45 Leve9 Ct,9 6LIC#120 'S#120;7

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    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1uid (startup) oil flow to be controlled.

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       "   T      8   T     :   #

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       T   &   *   *     +     1   7

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       /   +   +   !

       /   $

       /   %   C

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       /   8   &   9   "   T   &   8      ;   +

       /   C

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       /   +   +   !

          "

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       *   *     /   %   0     ,   1

       *   *     !     2   ,

       0   %   C

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       0      

       0      0

       1   2   ,   1

       /   0   :   "      %   =   ;   &   %   0   H

       #   8   +   "   :   0   /   %   !   %   =   ;

       0   %   ?   :   %   !

       /   8   &   9   "   T   &   8      ;   +

       0   $

       /   C

       1   2   ,   3

       =   &   8   9      0   &   #   +   8      T   %   &   =

       "   #

       /   T   1   2   ,   1

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    $.$ Ma

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    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    control spill bac' flow. This configuration always ensures suction pressure at the

    compressor H thereby avoid serious trips while ensuring constant discharge pressure.

    %n addition to that pressure controller will give high-low alarm (#152

  • 8/20/2019 Philosophy of Control for Complex Logics

    17/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

       9   9 -   D -   0   7   A

       9   9 -   C -   0   1   A

       9   9 -   C -   0   1   A

       9   9 -   E -   0   9   A

       9   9 -   D -   0   8   A

       1   S   T    S   T   A   G   E

       2   N   D    S   T   A   G   E

       9   9 -   E -   1   1   A

       9   9 -   C -   0   1   A

       3   R   D    S

       T   A   G   E

       9   9 -   E -   1   0   A

       9   9 -   D -   0   9   A

       T   O   9   9 -   T -   0   1

       M

       A   K   E   U   P   G   A   S   F   R   O   M   O   S   B   L

       S   W   R

       S   W   S

       S   W   S

       S   W   R

       S   W   R

       S   W   S

       P   V   1   4   0   2

       F   O

       P   I   C

       1   4   0   2

       P   Y

       1   3   2   8

       P   I   C

       1   3   2   8

       P   A   

       P   A   L

       M

       N   C

       N   C

       N   C

       "   %   9   #   0   %   /   %   +   !      0   &   C   A   !

       %      ;   8      9

       9      A   +    :   #   ;      "   C   &   9   #

       8   +   "   "   &   8   (   *   *    C    ,   1      )   "   :   C   T   %   &

       =

       /   %   ; .   5

       #   8   +   "   "   :   8   +   C   &   =   T   8   &

       0   (   #   %   C    1   4   ,   2   -   1   5   2   <   -   #   I    1   5   2   <   )

       P   V   1   3   8   1

       P   I   C

       1   3   8   1

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 1> %

  • 8/20/2019 Philosophy of Control for Complex Logics

    18/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.& Ma/PY#12>7

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

  • 8/20/2019 Philosophy of Control for Complex Logics

    19/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    the compressor H thereby avoid serious trips while ensuring constant discharge

    pressure.

    %n addition to that pressure controller will give high-low alarm (#1327-#01327)

    as applicable on !C".

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 1% %

  • 8/20/2019 Philosophy of Control for Complex Logics

    20/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

       9   9 -   D -   0   7   B

       9   9 -   C -   0   1   B

       9   9 -   C -   0   1   B

       9   9 -   E -   0   9   B

       9   9 -   D -   0   8   B

       1   S   T    S   T   A   G   E

       2   N   D    S   T   A   G   E

       9   9 -   E -   1   1   B

       9   9 -   C -   0   1   B

       3   R   D    S

       T   A   G   E

       9   9 -   E -   1   0   B

       9   9 -   D -   0   9   B

       T   O   9   9 -   T -   0   1

       M   A   K   E   U   P   G   A   S   F   R   O   M   O   S   B   L

       S   W   R

       S   W   S

       S   W   S

       S   W   R

       S   W   R

       S   W   S

       P   V   1   !   0   2

       F   O

       P   I   C

       1   !   0   2

       P   Y

       1   "   2   7

       P   I   C

       1   "   2   7

       P   A   

       P   A   L

       M

       N   C

       N   C

       N   C

       "   %   9   #   0   %   /   %   +   !      0   &   C   A   !

       %      ;   8      9

       9      A   +    :   #   ;      "   C   &   9   #

       8   +   "   "   &   8   (   *   *    C    ,   1      )   "   :   C   T   %   &

       =

       /   %   ; .   4

       #   8   +   "   "   :   8   +   C   &   =   T   8   &

       0   (   #   %   C    1      ,   2   -   1   3   2   7   -   #   I    1   3   2   7   )

       P   I   C

       1   3   8   1

       P   V   1   3   8   1

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 20 %

  • 8/20/2019 Philosophy of Control for Complex Logics

    21/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $. 'DT Rea!t, E94et St,=++e, Fee Te5+e,at4,e Ct,9 6TIC#1>107

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

  • 8/20/2019 Philosophy of Control for Complex Logics

    22/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    to close H the inlet valve T$171,C will start to open allowing more recycle gas flow to

    pass through the exchanger thereby increasing heat transfer. %nlet valve T$171,C is

    provided with mechanical min. stop (4,G) to avoid exchanger running dry H thereby

    preventing damage to it. %n this range oil feed valve T$171, is fully open allowing the

    max. oil flow through the exchanger H no bypass is there.

    %n addition to that temperature controller will give high alarm (T171,) as applicable

    on !C".

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 22 %

  • 8/20/2019 Philosophy of Control for Complex Logics

    23/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

          !   T   8   +      C   T   &   8   +   /   /   0   :   +   =   T

       /   8   &   9   *   *     8     ,   1

       T   %   C

       1   7   1   ,

       /   +   +   !

       /   8   &   9   *   *     +     1   7      -   

       !   :      0      C   T   %   =   ;

       T   &   *   *     /     ,   1

       T   &   *   *     T     ,   1

       T   $

       1   7   1   ,   

       "   %   9   #   0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       T   +   9   #   +   8      T   :   8   +   C   &   =   T   8   &   0   (   T   %   C     1   7   1   ,   )

         T     $   )    1     7

        1    ,    (

      T  $ ) 1  7

     1  ,  .

       1   ,   ,   G

       1   ,   ,   G

       (   4   ,   G   )

       T   %   C     1   7   1   ,

          "   #   0   %   T   8      =   ;   +   C   &   =   /   %   ;   :   8   

       T   %   &   =  

       /   %   ; .  J   3

          !   T   8   +      C   T   &   8   +   /   /   0   :   +   =   T   "   T   8   %   #   #   +   8   /   +   +   !

       /   &

       /   C

       *   *

         +     ,   5      -      -   C

    C&=T8&0 $(0$+ +=%=; G

       C   &   =   T   8   &   0   0   +   8   &   :   T   #   :   T   G

          !   T   8   +      C   T   &   8   +   /   /   0   :   +   =   T

       9   %   = .   "   T   &   #    ,

       G

       T      

       9   %   = .

       "   T   &   #

       8   +   C   I   C   0   +   ;      "

       /   8   &   9   *   *     +     ,   7

       T   $

       1   7   1   ,   C

       /   &

       9

       %   = .

       "   T

       &   #

       T   $

       1   7   1   ,   

       /   C

       T   $

       1   7   1   ,   !

       /   +   +   !

         T     $   )    1     7    1

        ,     C

      T  $ ) 1  7

     1  ,  !

       3   ,   G

       T   +   9   #   +   8      T   :   8   +   %   =   C   8   +      "   +

       !   :   

       0      C   T   %   =   ;

       (   3   ,     1   ,   ,   G

       )

       (   ,     3   ,   G   )

          &   T   %   =

          &   T   &   :   T

       C   &   0

       !   %   =

       C   &   0   !   &   :   T

       &   %   0

       ;      "

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 2$ %

  • 8/20/2019 Philosophy of Control for Complex Logics

    24/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.; 'DF Rea!t, E94et Te5+e,at4,e Ct,9 6TIC#1>027

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

  • 8/20/2019 Philosophy of Control for Complex Logics

    25/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

          !   /   8   +      C   T   &   8   +   /   /   0   :   +   =   T

       /   8   &   9   *   *     8     ,   5

       T   %   C

       1   7   ,   2

       "   T   8   %   #   #   +   8   9   "   !   6   /   +   +   !

       /   8   &   9   *   *     T     ,   1

       !   :      0      C   T   %   =   ;

       T   &   *   *     +     ,         -      -   C

       T   &   *   *     !     ,   4

       T   $

       T   $

       1   7   ,   2   

       "   %   9   #   0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       T   +   9   #   +   8      T   :   8   +   C   &   =   T   8   &   0   (   T   %   C     1   7   ,   2   )

         T      $   )     1

         7    ,     2     (

       T   $  )  1   7   ,   2   .

       1   ,   ,   G

       1   ,   ,   G

       (   4   ,   G   )

       T   %   C     1   7   ,   2

          !   :      0   8      =   ;   +   C   &   =   /   %   ;   :   8   

       T   %   &   =  

       /

       %   ; .  J   

       

       !   /   8   +      C   T   &   8   +   /   /   0   :   +   =   T

       /   &

       /   C

       *   *

         +     ,   2      -      -   C

    C&=T8&0 $(0$+ +=%=; G

       C   &   =   T   8   &   0   0   +   8   &   :   T   #   :   T

       G

       1   7   ,   2   

          !   /   8   +      C   T   &   8   +   /   /   0   :   +   =   T

       "   T   8   %   #   #   +   8   9   "   !   6   /   +   +   !

       9   %   = .   "   T   &   #    ,

       G

       T      

       9   %   = .

       "   T   &   #

       T   +   9   #   +   8      T   :   8   +   %   =   C   8   +      "   +

          &   T   %   =

          &   T   &   :   T

       C   &   0   !   %   =

       C   &   0   !   &   :   T

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 2 %

  • 8/20/2019 Philosophy of Control for Complex Logics

    26/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.> 'DT Rea!t, C*a,-e 'eate, O4t9et Te5+e,at4,e Ct,9 6TIC#1"0>7

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

  • 8/20/2019 Philosophy of Control for Complex Logics

    27/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

       *   *     /     ,   1

       /

       +   +   !

       T

       &   *   *     8     ,   1

       /   :

       +   0   ;      "

       /   8   &   9   *   *     !     1   2

       #   %   C

       1   *   ,   1

       #   $

       1   *   ,   1

       #      

       T   %   C

       1   <   ,   7

       T      

       *   *     /     ,   1

          :   8   =   +   8

       "   %   9   #   0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       /   %   ; .  J   7

          !   T   8   +      C   T   &   8   C         8   ;   +      +      T

       +   8   &   :   T   0   +   T

       "   #

       /   C

       T      0

       #      0

       T   +   9   #   +   8      T   :   8   +   C   &   =   T   8   &   0   (   T   %   C

         1   <   ,   7   )

       /   :   8   =      C   +   &   :   T   0   +   T

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 2> %

  • 8/20/2019 Philosophy of Control for Complex Logics

    28/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $." 'DT Rea!t, Te5+e,at4,e Ct,9 6TIC#201%/2012/201&/201;7

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

  • 8/20/2019 Philosophy of Control for Complex Logics

    29/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.".$ De8!,=+t=

    /or each catalyst bed inlet ( eight thermocouples in total) and outlet ( eight

    thermocouples in total) temperatures are measured. ed %nlet (except top bed) and

    &utlet (except bottom bed) Tis are averaged in a calculation (TI) bloc'. The target bed

    outlet temperature is entered by operator based on the operating case and catalyst run

    length. veraged out bed outlet temperature is compared to the operator entered set

    point and this difference is used to reset the bed inlet target temperature with a time

    delay of 3 min. (adustable). The bed inlet target temperature is compared to the actual

    average inlet temperature (every 1 min. adustable). The difference between these two

    values is used to reset >uench flow.

    /or top bed reactor inlet temperature (T%2,1*) is used instead of bed top temperature

    (T%2,1, ). /or bottom bed the reactor outlet temperature (T%2,1

  • 8/20/2019 Philosophy of Control for Complex Logics

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    BED-3

    99-R-01

     TO 99-E-03 A#B#C

    FROM 99-F-01

    SP

    SP

    PV

    SP

    FROM 99-C-02A#B

    SP

    BED TOP

    BED BOTTOM

    BED TOP

    BED

    BED TOP

    BED TOP

    PV

    PV

    PV

    PV

    PV

    PV

     TAL

     TO 99-F-01

     TO 99-F-01

     TO 99-F-01

    #F-02 TRIP

     TO 99-F-01

    #F-02 TRIP

    #F-02 TRIP

     BOTTOM

    BED

     BOTTOM

    BED

     BOTTOM

    #F-02 TRIP

     TIC

    2013

     TIC

    201"

     TIC

    2018

     TIC

    2011

     TY

    2014

    #$

    #$

     TY

    2012

     TI

    2013

     TA

     TA

    A-

    FT

    2004

    FT

    2003A#B

    FT

    2002

    FV

    2004

    FV

    2003

    FV

    2002

    FV

    2001

    FO

    FO

    FO

    FO

    #$

    FIC

    2003

    FT

    2001

     TI

    2011

     TA

     TA

    A-

     TI

    2010

     TA

     TA

    A-

     TI

    2012

     TA

     TA

    A-

     TI

    2014

     TA

     TA

    A-

     TY

    201!

     TIC

    201! TAL

    PV

     TI

    2017

     TA

     TA

    A-

     TI

    201!

     TA

     TA

    A-

     TI

    201"

     TA

     TA

    A-

    FIC

    2004

     TY

    201"

     TIC

    2014

     TA

     TA

     TY

    2013

     TIC

    2012

     TA

     TA

     TAL

    FIC

    2002

     TY

    2011

     TIC

    2019

     TA

     TA

     TAL

    FIC

    2001

     TI

    2018

     TA

     TA

     TI

    2019

    BED-1

    BED-2

    BED-4

    I

    3

    #$

    #$

    #$

    I

    3

    I

    3

    I

    3

       "   %   9   #   0   %   /   %   +   !      0   &   C   A   !

       %      ;   8      9

          !   T   8   +      C   T   &   8   (   *   *    8

        ,   1   )   T   +   9   #   +   8      T   :   8   +

       /   %   ; .   <

       C   &   =   T   8   &   0   (   T   %   C    2   ,   1   *   -   2   ,   1   2   -   2   ,   1   4   -   2   ,   1      )

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e $0 %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.% MSD? Fee D=e,et=a9 P,e884,e Ct,9 6PDIC#21027

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1uired to maintain a high enough differential

    pressure between **T,1 and treated recycle hydrogen from the wash water tower (**

    T,5) to ensure that li>uid flows to **+,--C.

    $.%.2 S=5+9==e B9!< D=a-,a5 MSD? Fee D=e,et=a9 P,e884,e Ct,9 6PDIC#21027

    8efer /%;. * on "heet =o 54.

    $.%.$ De8!,=+t=

    The #ressure !ifferential Controller #!%C21,2 receives signal from #T21,2 which

    measure pressure of **T,1 &verhead. This signal is then compared with signal from

    #T21,2 which measures the pressure of treated gas from wash water tower (**T,5)

    to upstream of shell side inlet of !T stripper &verhead-Treat ;as +xchanger (**+

    ,4-). ased on these values the controller will then act to manipulate the control

    valve located at the treated gas stream to ensure a pressure gradient is maintained

    between **T,1 and **+,--C. y maintaining this the bottoms stream will be

    able to flow to **+,--C and 9"!6 8eactor (**8,2).

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e $1 %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.10 Rea!t, L+ P,e884,e Ct,9 6PIC#$20"/'S#$212/FIC#$202/FIC#210;7

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    by operator and the #ressure Controller #%C52,< controls the flow of purge gas

    out of the unit via cascade control of /%C52,2-/$52,2.

    /ixed #urge ;as (/%C52,2 set by operator) and variable 9a'eup ;as (#%C

    52,< cascade with /%C21,):

    !C" operator shall select the destination of the signal from #%C52,< to /%C21,

    with the help of and "witch "5212.The output of the controller /%C21, shall

    be used by computation bloc' (/I21,2 and /I21,) to give the set point to the

    flow controllers (/%C21,2 and /$21, respectively). %n ,3,G output range all

    the ma'eup 2 is directed towards **T,1 H used as stripping gas. %f the

    re>uirement of 2 is higher (i.e. /%C21, output is LM 3,G) to maintain reaction

    operating pressure then bypass valves /$21, will be opened. This is done to

    avoid overloading of the stripper. The stripping ydrogen valve is provided with a

    soft higher limiter to limit opening of valve H avoid excess stripping 2 in **T,1.

     lso the bypass valve /$21, is provided with low limiter (2G adustable) to

    'eep the system live with small 2 flow through bypass loop. 8ecycle ;as can

    also be used for stripping the !T +ffluent in **T,1 which is on a separate flow

    controller /%C211,. The output of the controller /%C21,2 and /%C211, shall be

    used by computation bloc' (/I211,) to calculate the total amount of stripping gas

    flow to the stripper (/%212,).

     

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e $$ %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

       "   %   9   #

       0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       0   +      =

          9   %   =   +   T   +   9   #   +   8      T   :   8   +

       /   %   ; .   1   ,

       C   &   =

       T   8   &   0   (   !   T   %   C     2   5   ,   <   )

       T   O

        9   9 -   D -   0

       3

       T   O

        9   9 -   D -   1

       4

       T   O

        T -   0

       4

       9   9 -   T -   0

       2

       L   E   A   N   A   M   I   N   E   F   R   O   M

        A   R   U

          D   T   L   T   S   O   V      D

       V   A   P   O   U   R

       F   R   O   M

        9   9 -   D -   0

       2

       9   9 -   P -   1

       1   A   #   B

       9   9 -   D -   2

       3

       2   0

       1 3   2

       L   P   C   O   N   D   E   N   S   A   T   E

       L   P   S   T   E   A   M

       9   9 -   E -   1

       !

       F   C

       T   I

       2   3   2   1

       T   A   

       T   A   L

       D   T   I   C

       2   3   0   8

       D   T   A   L

       T   I

       2   3   0   2

       T   A   

       T   A   L

       T   V

       2   3   0   8

       T   T

       2   3   0   8   A

       T   T

       2   3   0   8

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e $; %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.12 ?a8* ?ate, S4,-e D,45 6%%#D#1$7 P,e884,e Ct,9 6PIC#2&017

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

       T   &   /   0      8   +

       /   :   +   0   ;      "

       #   $

       2   4   ,   1   

       #   $

       2   4   ,   1   

       2   4   ,   1

       (   ,     4   7 .   3   G   )

       (   3   2 .   3     1   ,   ,   G   )

       "   #   0   %   T   8      =   ;   +

       /   8   &   9      +      !

       +   8

       "   %   9

       #   0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       /   %   ; .     1   1

       #   8   +

       "   "   :   8   +   C   &   =   T   8   &   0   (   #   %   C     2   4   ,   1   )

       /   C

       /   ,

       *   *     !     1   5

       1   ,   ,   G

       1   ,   ,   G

       ,   G

       #   %   C     2   4   ,   1

          "   #   0   %   T   8      =   ;   +   C   &   =   /   %   ;   :   8      T   %   &   =  

      #  $ )  2 4

      , 1  .

       6      "      6      T   +   8

       T   &   *   *     T     ,   5

       $   %      *   *     #     1   ,      -   

         #     $   )    2    4

        ,    1    (

    C&=T8&0 $(0$+ +=%=; G

       C   &   =   T   8   &   0   0   +   8   &   :   T   #   :   T   G

       3   ,   G

       4   7 .   3   G

       3   2 .   3   G

       #   8   +   "   "   :   8   +   %   =   C   8   +      "   +

       /   8   &   9   *   *     +

         1   <

          /   6

       6      "

          6      T   +   8   "   :   8   ;   +   !   8   :   9   (   *   *     !     1   5   )

       #   %   C

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e $" %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.1$ 'DF Fee Te5+e,at4,e Ct,9 6TIC#2027

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

  • 8/20/2019 Philosophy of Control for Complex Logics

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

       9   "   !   6

       8   +      C   T   &   8   +   /   /   0   :   +   =   T

       /   8   &   9   *   *     8     ,   2

       T   %   C

       2   3   ,   2

       9   "   !   6

       8   +      C   T   &   8   0   %   ? .   /   +   +   !

       /   8   &   9   *   *     +     ,   2      -      -   C

       !   :      0      C   T   %   =   ;

       T   &   *   *     /     ,   2

       T   &   *   *     8     ,   5

       T   $

       T   $

       2   3   ,   2   

       "   %   9

       #   0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       C   &

       =   T   8   &   0   (   T   %   C     2   3   ,   2   )

         T      $   )     2

         3    ,     2     (

       T   $  )   2   3   ,   2   .

       1   ,   ,   G

       1   ,   ,   G

       (   4   ,   G   )

       T   %   C     2   3   ,   2

          !   :      0   8      =   ;   +   C   &   =   /   %   ;   :   8   

       T   %   &   =  

       /   %   ;

     .  J   1   2

          !

       /   /   +   +   !   T   +   9   #   +   8      T   :   8   +

       /   &

       /   C

       *   *     +     ,         -      -   C

    C&=T8&0 $(0$+ +=%=; G

       C   &   =   T   8   &   0   0   +   8   &   :   T   #   :   T   G

       2   3   ,   2   

       9   %   = .   "   T   &   #    ,

       G

       T      

       9   "   !   6

       8   +      C   T   &   8   +   /   /   0   :   +   =   T

       9   "   !   6

       8   +      C   T   &   8   C         8   ;   +

       9   %   = .

       "   T   &   #

       T   +   9   #   +   8      T   :   8   +   %   =   C   8   +      "   +

          &   T   %   =

          &   T   &   :   T

       C   &   0   !

       %   =

       C   &   0   !   &   :   T

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e &0 %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.1& MSD? C*a,-e 'eate, O4t9et Te5+e,at4,e Ct,9 6TIC#2;0>7

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

       9   "   !   6   8   +      C   T   &   8

       C         8   ;   +

       T

       &   *   *     8     ,   2

       /   :

       +   0   ;      "

       /   8   &   9   *   *     !     1   2

       #   %   C

       2   7   ,   5

       #   $

       2   7   ,   5

       #      

       T   %   C

       2      ,   7

       T      

          :   8   =   +   8

       "   %   9   #   0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       /   %   ; .  J   1   5

       9   "   !   6   C         8   ;   +      +      T   +   8   &   :   T

       0   +   T   T   +   9   #   +   8      T   :   8   +

       "   #

       /   C

       T      0

       #      0

       *   *     /     ,   2

       *   *     /     ,   2

       C   &   =   T   8   &   0   (   T   %   C     2      ,   7   )

       /   :   8   =      C   +   &   :   T   0   +   T

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e &2 %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.1 MSD? Rea!t, Te5+e,at4,e Ct,9 6TIC#2"0"/2"11/2"1&7

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1uire interbed >uenching. Temperature re>uired tocarry out the dewaxing reactions which increases gradually throughout the run as the

    catalyst ages is controlled by adusting **8,2 feed inlet temperature through

    manipulation of **/,2 firing rate and by the inlet and inter bed >uench flow rates. The

    9"!6 8eactor consists of three beds of catalyst. To limit the overall exotherm in the

    9"!6 two thirds of the expected exotherm is eliminated by means of >uench to the

    outlet of the first and second beds. The >uench gas enters on flow control reset by

    averaged bed inlet and averaged bed outlet temperature. n additional >uench gas

    connection is provided to the inlet of the reactor for fast trim temperature control if 

    re>uired during an upset condition and for use in controlling the wetting exotherm on

    startup.

    8eactor temperature control is vital to good catalyst performance and should be

    controlled to K - ,.3,C. !epending upon the age of the catalyst feed >uality feed rate

    and the desired conversion a target 6eighted verage ed Temperature (6T) must

    be maintained for each bed. /urther the temperature rise across each bed must be

    'ept below a set targetB this is especially important during runaway reaction.

    $.1.2 S=5+9==e B9!< D=a-,a5 MSD? Rea!t, Te5+e,at4,e Ct,9 6TIC#2"0"/2"11/2"1&7

    8efer /%;. 14 on "heet =o 43.

    $.1.$ De8!,=+t=

    /or each catalyst bed inlet ( eight thermocouples in total) and outlet ( eight

    thermocouples in total) temperatures are measured. ed %nlet (except top bed) and

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e &$ %

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    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    &utlet (except bottom bed) Tis are averaged in a calculation (TI) bloc'. The target bed

    outlet temperature is entered by operator based on the operating case and catalyst run

    length. veraged out bed outlet temperature is compared to the operator entered set

    point and this difference is used to reset the bed inlet target temperature with a time

    delay of 3 min. (adustable). The bed inlet target temperature is compared to the actual

    average inlet temperature (every 1 min. adustable). The difference between these two

    values is used to reset >uench flow.

    /or top bed reactor inlet temperature (T%2

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    99-R-02

     TO 99-E-0! A#B#C

    FROM 99-F-02

    SP

    PV

    SP

    FROM 99-C-02A#B

    SP

    BED TOP

    BED BOTTOM

    BED TOP

    BED TOP

    PV

    PV

    PV

    PV

     TO 99-F-01

     TO 99-F-01

    #F-02 TRIP

     TO 99-F-01

    #F-02 TRIP

    BED

     BOTTOM

    BED

     BOTTOM

    #F-02 TRIP

     TIC

    2803

     TIC

    281"

     TIC

    2807

    #$

     TY

    2811

     TI

    2803

     TA TA

    A-

    FT

    2803

    FT

    2802A#B

    FV

    2803

    FV

    2802

    FV

    2801

    FO

    FO

    FO

    #$

    FT

    2801

     TI

    2807

     TA TA

    A-

     TI

    2820

     TA TA

    A-

     TI

    2811

     TA TA

    A-

     TY

    2814

     TIC

    2814 TAL

    PV

     TI

    2812

     TA

     TA

    A-

     TI

    2814

     TA TA

    A-

    FIC

    2803

     TY

    2803

     TIC

    2811

     TA TA

     TAL

    FIC

    2802 TY

    2807

     TIC

    2808

     TA

     TA

     TAL

    FIC

    2801

     TI

    281"

     TA TA

     TI

    2808

    BED-1

    BED-2

    BED-3

    I

    8

    #$

    #$

    I

    8

    I8

       "   %   9   #

       0   %   /   %   +   !      0   &   C   A   !   %      ;   8   

       9

       9   "   !   6

       8   +      C   T   &   8   (   *   *     8     ,   2   )   T   +   9   #   +   8      T   :   8   +

       /   %   ; .   1   4

       C   &   =

       T   8   &   0   (   T   %   C     2   <   ,   <   -   2   <   1   1   -   2   <   1   4   )

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e & %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.1; 'DF Rea!t, Te5+e,at4,e Ct,9 6TIC#2%0$/2%027

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1uench flow to the !/ 8eactor. The !/ 8eactor consists of two beds of 

    catalyst. The !/ 8eactor (**8,5) exotherm is expected to be negligible in normal

    operation. The !/ inlet temperature is controlled through bypassing of 9"!6 /eed

    around the **+,. The >uench gas enters on flow control reset by averaged bed inlet

    temperature. n additional >uench gas connection is provided to the inlet of the reactor 

    for fast trim temperature control if re>uired during an upset condition and for use in

    controlling the wetting exotherm on startup.

    $.1;.2 S=5+9==e B9!< D=a-,a5 'DF Rea!t, Te5+e,at4,e Ct,9 6TIC#2%0$/2%027

    8efer /%;. 13 on "heet =o 4

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    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.1;.& De==t=8

    /or the 9"!6 8eactor **8,5 there are 2 >uench gas flows:

    ed %nleted

    Temp.

     verageCalculation

    &utleted

    Temp.

     verageCalculation

    ed&utletTemp.

    Controller 

    ed%nlet

    Temp.Controller 

    /lowController 

    1 T%2*15()

    T%2*,<()

    T%C2 %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    99-R-03

     TO 99-E-02 A#B#C

    FROM 99-E-0! A#B#C

    PV

    SP

    FROM 99-C-02A#B

    SP

    BED TOP

    BED TOP

     TO 99-F-01

    BED BOTTOM

    #F-02 TRIP

    BED BOTTOM

     TO 99-F-01

    #F-02 TRIP

    FT

    2901FV

    2901

    FV

    2902

    FO

    FO

    FT

    2902

     TI

    2908

     TA TA

    A-

     TI

    2913

     TA TA

    A-

     TY

    2902

     TIC

    2902 TAL

    PV

     TI

    290"

     TA TA

    A-

     TI

    2902

     TA TA

    A-

    FIC

    2901

     TIC

    2903

     TA

     TA

     TAL

    FIC

    2902

     TI

    2901

     TA

     TA

     TI

    2903

    BED-1

    BED-2

    I

    9

    #$

    I

    9

       "   %   9   #

       0   %   /   %   +   !      0   &   C   A   !   %      ;   8   

       9

          !   /

       8   +      C   T   &   8   (   *   *     8     ,   5   )   T   +

       9   #   +   8      T   :   8   +

       /   %   ; .

       1   3

       C   &   =

       T   8   &   0   (   T   %   C     2   *   ,   5   -   2   *   ,   2   )

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e &" %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.1> 'TS O'D/Re!@!9e Ga8 E!*a-e, 6%%#E#0>7 Re!@!9e Ga8 O4t9et Te5+e,at4,eCt,9 6TIC#$0027

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1.2 S=5+9==e B9!< D=a-,a5 'TS O'D/Re!@!9e Ga8 E!*a-e, 6%%#E#0>7Re!@!9e Ga8 O4t9et Te5+e,at4,e Ct,9 6TIC#$0027

    8efer /%;. 1 on "heet =o 3,.

    $.1>.$ De8!,=+t=

    8ecycle ;as outlet temperature controller T%C5,,2 is dual acting controller. T%C5,,2

    controls 8ecycle ;as outlet temperature from **+,7 through control valves T$5,,2

    and T$5,,2 by controlling the relative flows through exchanger **+,7 and its

    bypass.

    6hen the 8ecycle ;as outlet temperature from **+,7 increases than the set point

    T%C5,,2 will pass less flow through the **+,7 i.e. bypass valve T$5,,2 starts to

    open and %nlet valve T$5,,2 will start to close. 8everse action will be followed when

    the 8ecycle ;as outlet temperature from **+,7 decreases i. e. start to close **+,7

    bypass valve T$5,,2 and start to open the inlet valve T$5,,2. %n addition inlet

    valve T$5,,2 is provided with min. stop to prevent exchanger running dry.

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e &% %

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    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

          T   "   "   +   #      8      T   &   8   &   $      !

       /   8   &   9   *   *     !     ,   4

       T   %   C

       5   ,   ,   2

       8   +   C   I   C   0   +   ;      "

       /   8   &   9   *   *     C     ,   2      -   

       T   &   *   *     +     ,   5      -      -   C

       T   &   *   *        /   C     ,   2

       T   $

       T   $

       5   ,   ,   2   

       "   %   9   #   0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       8   +

       C   I   C   0   +   ;      "   &   :   T   0   +   T   T   +   9   #   +   8   

       T   :   8   +   C   &   =   T   8   &   0   (   T   %   C     5   ,   ,   2   )     T      $

       )    5    ,    ,

         2     .

       T   $  )   5   ,   ,   2  (

       1   ,   ,   G

       1   ,   ,   G

       T   %   C     5   ,   ,   2

          !   :      0   8      =   ;   +   C   &   =   /   %   ;   :   8   

       T   %   &   =  

       /   %   ; .  J   1   

          T   "   &   $      !   -   8   +   C   I   C   0   +   ;      "   +   N   C      

       =   ;   +   8   (   *   *     +     ,   7   ) 

       /   &   /

       C

       *   *     +     ,   7

    C&=T8&0 $(0$+ +=%=; G

       C   &   =   T   8   &   0   0   +   8   &   :   T   #   :   T

       G

       5   ,   ,   2   

       ,   G

       !   :      0      C   T   %   =   ;

          T   "   "   +   #      8      T   &   8   &   $      !

       8   +   C   I   C   0   +   ;      "

       4   ,   G

       9   %   = .   "   T   &   #

       9   %   = .

       "   T   &   #

       T   +   9   #   +   8      T   :   8   +   %   =   C   8   +      "   +

          &   T   %   =

          &   T   &   :   T

       C   &   0

       !   %   =

       C   &   0   !   &   :   T

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 0 %

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    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.1" 'TS L=4=/F,a!. Btt5 E!*a-e, 6%%#E#1&A/B7 P,4!t St,=++e, FeeTe5+e,at4,e Ct,9 6TIC#$0017

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1uid from **!,4 exchange heat with !ewaxed &il from $acuum !ryer (**T,) in

    T" 0i>uid-/rac. ottom +xchanger (**+14-) and then routed to the #roduct

    "tripper (**T,4). Control of the #roduct stripper feed temperature is accomplished by

    T%C5,,1 by bypassing !ewaxed &il around the exchanger.

     

    $.1".2 S=5+9==e B9!< D=a-,a5 'TS L=4=/F,a!. Btt5 E!*a-e, 6%%#E#1&A/B7'TS L=4= O4t9et Te5+e,at4,e Ct,9 6TIC#$0017

    8efer /%;. 17 on "heet =o 32.

    $.1".$ De8!,=+t=

    #roduct stripper feed temperature controller T%C5,,1 is dual acting controller. T%C5,,1

    controls #roduct stripper feed temperature from **+14- through control valves T$

    5,,1 and T$5,,1 by controlling the relative flows through exchanger **+14-

    and its bypass.

    6hen the #roduct stripper feed temperature from **+14- increases than the set

    point T%C5,,1 will pass less flow through the **+14- i.e. bypass valve T$5,,1

    starts to open and %nlet valve T$5,,1 will start to close. 8everse action will be

    followed when the #roduct stripper feed temperature from **+14- decreases i. e.

    start to close **+14- bypass valve T$5,,1 and start to open the inlet valve T$

    5,,1.

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e 1 %

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  • 8/20/2019 Philosophy of Control for Complex Logics

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.1% P,4!t St,=++e, 9eve9 Ct,9/F9 Ct,9 t a!. F,a!. C*a,-e 'eate, %%#F#0$LIC#$$0$/FIC#$$02/FIC#$$0&7

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1uid product flow to the $ac. /rac.

    Charge eater (**/,5). lso the middle value of above /Ts shall be used by

    computation bloc' (/I55,4) to calculate the difference between two flows and it will

    give high difference alarm (/!) as applicable on !C".

    %n addition to that level controller will give high-low alarm (055,5-0055,5) asapplicable on !C".

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e $ %

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    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

       "   %   9

       #   0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       #   8   &   !   :   C   T   "   T   8   %   #   #   +   8   0   +   $   +   0   C   &   =   T

       8   &   0   -   /   0   &   6   C   &   =   T   8   &   0   T   &   $      C .

       /   %   ;

     .   1   <

       /   8      C .   C         8   ;   +      +      T   +   8   *   *     /     ,   5   (   0

       %   C     5   5   ,   5   -   /   %   C     5   5   ,   2   -   /   %   C     5   5   ,   4   )

       9   9 -   T -   0   4

       T   O   V   A   C   U   U   M   F   R   A   C   T   I   O   N   A   T   O   R

       C      A   R   G   E      E   A   T

       E   R   S      U   T   D   O   W   N

       9   9 -   F -   0   3

       T   O   V   A   C   U   U   M   F   R   A   C   T   I   O   N   A   T   O   R

       C      A   R   G   E      E   A   T

       E   R   9   9 -   F -   0   3

       L   I   '   U   I   D   F   R   O   M   9   9 -   D -   2   3 *

       2  +  +   3

       9   9 -   E -   1   4 *   9   9 -   E -   1   "

       M   I   D   D   L   E   V   A   L   U   E

       T   O   V   A   C   U   U   M   F   R   A   C   T   I   O   N   A   T   O   R

       C      A   R   G   E      E   A   T

       E   R   9   9 -   F -   0   3

       2  +  +   3

       F   D   I

       3   3   0   4

       F   D   A   

       F   Y   3   3   0   4

       F   I

       3   3   0   "

       F   Y   3   3   0   2

       F   C

       I   3   7

       F   T   3   3   0

       4

       A *   B *   C

       F   V   3   3   0   4

       F   I   C   3   3   0   4

       S   E   T   P   T

       F   A   

       F   A   L

       P   V

       F   C

       I   3   7

       L   I   C   3   3   0   3

       L   A   

       L   A   L

       F   T   3   3   0   2

       A *   B *   C

       F   V   3   3   0   2

       L   T   3   3   0   3

       F   I   C   3   3   0   2   S

       E   T   P   T

       F   A   

       F   A   L

       P   V

       M   I   D   D   L   E

       V   A   L   U   E

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e & %

  • 8/20/2019 Philosophy of Control for Complex Logics

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.20 a!. F,a!. C*a,-e 'eate, O4t9et Te5+e,at4,e Ct,9 6TIC#$07

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

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    MUMBAI REFINERY Rev. Date: 20/01/2010

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    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    more opening of /$5,1 H corresponding high flow of fuel oil to the burner. %f the

    outlet temperature increases the actions will be vice versa.

    "5,1 will be on /uel ;as mode controlling fuel gas flow rate with /ixed /uel

    &il /low rate to maintain the furnace outlet temperature when furnace is run in

    dual fired mode:

    %n addition to that temperature controller will give high and low temperature alarm (T

    53,3 H T053,3) pressure controller will give high and low flow alarm (#5,1 H

    #05,1) and flow controller will give high and low flow alarm (/5,1 H /05,1)

    as applicable on !C".

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e ; %

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  • 8/20/2019 Philosophy of Control for Complex Logics

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    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.21 Fee/F,a!. Btt5 E!*a-e, 6%%#E#01A/B7 Ra=ate Fee Te5+e,at4,e Ct,96TIC#&10$7

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

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    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

       :   =   %   T   /   +   +   !

       /   8   &   9   "   T   &   8      ;   +

       T   %   C

       4   1   ,   5

       !   +   6      N   +   !   &   %   0

       /   8   &   9   *   *     +     1   7      -   

       !   :      0      C   T   %   =   ;

       T   &   *   *        /   C     ,         -   

       T   &   *   *     /   %   0     ,   1

       T   $

       "   %   9   #   0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       8      /   /   %   =      T   +   /   +   +   !   T   +   9   #   +   8      T   :   8   +

       C   &   =   T   8   &   0   (   T   %   C     4   1   ,   5   )

         T      $   )     4

         1    ,    5     .

       T   $  )  4  1   ,   5  (

       1   ,   ,   G

       1   ,   ,   G

       T   %   C     4   1   ,   5

          !   :      0   8      =   ;   +   C   &   =   /   %   ;   :   8   

       T   %   &   =  

       /   %   ; .  J   2   ,

       /   +

       +   !   -   /   8      C .      &   T   T   &   9   +   N   C         =   ;   +

       8   (   *   *     +     ,   1      -      ) 

       /   C

       *

       *     +     ,   1      -   

    C&=T8&0 $(0$+ +=%=; G

       C   &   =   T   8   &   0   0   +   8   &   :   T   #   :   T

       G

       4   1   ,   5   

       ,   G

       T      

       !   +   6      N   +   !   &   %   0

       T   $

       4   1   ,   5   

       /   &

       :   =   %   T   /   +   +   !

       T   +   9   #   +   8      T   :   8   +   %   =   C   8   +      "   +

          &   T

       %   =

          &   T   &   :   T

       C   &   0   !   %   =

       C   &   0   !   &   :   T

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e % %

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    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.22 ?a,5 Fee/F,a!. Btt5 E!*a-e, 6%%#E#1>A/B7 Deae O=9 O4t9etTe5+e,at4,e Ct,9 6TIC#&1017

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

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    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

       /   +   +   !

       /   8   &   9   *   *     #     ,   2      -   

       T   %   C

       4   1   ,   1

       !   +   6      N   +   !   &   %   0

       /   8   &   9   *   *     +     1   3      -   

       T   &   *   *     +     ,   1      -   

       T   &   *   *     +     ,   5      -      -   C

       T   $

       T   $

       4   1   ,   1   

       "   %   9   #   0   %   /   %   +   !      0   &   C   A   !   %      ;   8      9

       !   +

       6      N   +   !   &   %   0   &   :   T   0   +   T   T   +   9   #   +   8      T   :   8   +   C   &   =   T   8   &   0   (   T   %   C     5   ,   ,   2   )     T

          $   )     4

         1    ,     1     (

       T   $  )  4  1   ,  1   .

       1   ,   ,   G

       1   ,   ,   G

       T   %   C     4   1   ,   1

          !   :      0   8      =   ;   +   C   &   =   /   %   ;   :   8   

       T   %   &   =  

       /   %   ; .  J   2   1

       6      8   9   /   +   +   !   -   /   8      C .      &   T   T   &   9   +   N   C         =   ;   +   8   (   *   *     +     1   7      -      ) 

       /   &   /

       C

       *

       *     +     1   7      -   

    C&=T8&0 $(0$+ +=%=; G

       C   &   =   T   8   &   0   0   +   8   &   :   T   #   :   T

       G

       4   1   ,   1   

       ,   G

       !   :      0      C   T   %   =   ;

       !   +   6      N   +   !   &   %   0

       /   +   +   !

       T   +   9   #   +   8      T   :   8   +   %   =   C   8   +   

       "   +

          &   T

       %   =

          &   T   &   :   T

       C   &   0   !   %   =

       C   &   0   !   &   :   T

    PREPARED BY C'EC)ED BY C*a+te, ( &

    RMB R'D Pa-e ;1 %

  • 8/20/2019 Philosophy of Control for Complex Logics

    62/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

    $.2$ a!445 F,a!. P45+a,4 Ret4, Te5+e,at4,e Ct,9 6TIC#&2017

    This specification should be read in conunction with the following:

    (1) #H%! =o.: 1

  • 8/20/2019 Philosophy of Control for Complex Logics

    63/95

    MUMBAI REFINERY Rev. Date: 20/01/2010

    LOBS QUALITY UPGRADATIONPROJECT

    D!. N. 1"#$1""#M#%%#01#&&00Rev. N. 1

      


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