PROJECT:

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AMMONIA TANK CAPACITY 20,000 DOUBLE WALL

TAR-13-09 BOG GRESIK
INDONESIA
TAR-13-09-C309 rev.2

AMMONIA TANK CAPACITY 20,000

DOUBLE WALL
PT REKAYASA INDUSTRI
2013
CONTROL NARRATIVE OF
AMMONIA REFRIGERATION
PACKAGE

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OUTLINE OF CONTROL SYSTEM

GENERAL
(1) This system consist of 3 Compressor Skids, 1 Condenser Skid and 1 KO-Reevaporator Skid. In this document, Tag Names used will be specific to each
compressor package. For instance, slide valve for compressor A will be ZT-01A, for
compressor B will be ZT-01B and compressor C will be ZT-01C. In short,
representation will be in this format; e.g. ZT-01A/B/C.

(2) Each Compressor Package can be operated individually using Tank Pressure signal
from DCS, PY-864 which is used to control the Slide Valve ZT-01A/B/C operation.
All 3 Compressor Packages can also be operated in Parallel in the Autostage Mode
using PY-864. The possible sequence of startup for the 3 compressor packages are as
followed: ABC, BCA, CAB, ACB, BAC and CBA.

(3) This system can be started up in the following modes;i) LOP Local Start Mode:
-

Each Compressor Skid has a Local Operator Panel (LOP). When the Selector
Switch HS-02CA/B/C is switched to LOCAL, this specific compressor will
then be able to be started in this Mode by pressing the Start Pushbutton HS02AA/B/C. The same rules apply when stopping the Compressor in this
Mode with Stop Pushbutton HS-02BA/B/C.

ii) HMI Local Start Mode

-

When Selector Switch HS-02CA/B/C is switched to REMOTE, the

compressor package no longer is allowed to be started or stopped from the
LOP. Other criteria are as follow; On the HMI, under Common HOA page
the Package System Mode should be set to LOCAL and the Autostage
Selection should be set to NON-AUTOSTAGE. The HMI Start/Stop Buttons
are available on the individual Compressors HOA Page 1.

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iii) Remote Start Mode

-

This mode has the similar criteria as of (ii), except under Common HOA
page the Package System Mode should be set to REMOTE. In this Mode,
individual compressors can be started from DCS which has Remote
Start/Stop Pushbuttons for individual compressor packages.

iv) HMI Autostage Start Mode

-

The criteria to run the system in this mode are, Selector Switch SEL-01A/B/C
is switched to REMOTE, under HMI Common HOA page the Package
System Mode should be set to LOCAL and the Autostage Selection should be
set to AUTOSTAGE. In this Mode, all compressors are controlled within the
Logic program. The Lead Compressor will kick start when PY-864 reaches
more than 40 g/cmG (Adjustable Setpoint).The 1st and 2nd Lag Compressors
will be started or stopped according to PY-864. During this Mode, when PY864 drops below 26 g/cmG (Adjustable Setpoint), the system will commence
stop sequence starting from the 2nd Lag, 1st Lag then the Lead Compressor.

v) Remote Autostage Start Mode

-

The criteria to run the system in this mode are similar to (iv), except under
HMI Common HOA page the Package System Mode should be set to
REMOTE. The Start and Stop criteria is exactly the same as (iv).

(4) Detail process and control explanation can be found in the next section under Control
Philosophy.

(5) Note that all the sequence for start, monitoring, alarms and trips will be active all the
time.

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CONTROL PHILOSOPY

System Process Control

(1) As mentioned each compressor package can run independent of the other 2 compressor
packages or run in parallel together with the other 2 compressor packages. The system
is designed to control the suction pressure and liquid receiver level.

(2) When chosen to run independently, operator can decide on how many compressor
packages to run depending on the load requirement. The compressor package started
will go through the standard start sequence.
i) After completed idling, after 30 sec (unload position) the compressor slide valve
ZT-01A/B/C will load and unload depending on the PID Loop PIC-01A/B/C. In
this PID Loop, the PV used is PY-864.

ii) The Capacity Control for the specific compressor package can also be set to
MANUAL if required. In this mode the compressor slide valve is activated to
LOAD or UNLOAD by manipulating the soft keys at the control panel HMI.

iii) Another method of manual capacity control will be switching the control mode
for PIC-01A/B/C to MANUAL. Operator MUST input the desired slide valve
position in the Man CV.
(3) When chosen to run in Autostage mode, all compressor packages will be control
within the logic program. After selecting the sequence of which the compressors
should start and ensuring all criteria are met, the operator will be able to engage the
autostage process by selecting the AutoStage Softkey on the HMI. When PY-864
reaches more than 40 g/cmG (Adjustable Setpoint), the lead compressor will start up
and will go through the standard start sequence. All slide valves will still be control
using PIC-01A/B/C.

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i) When the lead compressor is loaded up to 100%, a 30 seconds timer will be

activated and start counting as long as the slide valve of the lead compressor
maintained at 100% (adjustable setpoint). After the 30 seconds, if PY-864
reaches more than 40 g/cmG (Adjustable Setpoint), 1st lag compressor will be
started and will again go through the standard start sequence. At this point the
lead compressor will locked at 100%. The same process will go through for the
2nd lag compressor if the 1st lag compressors slide valve reached 100% and
PY864 reaches more than 40 g/cmG (Adjustable Setpoint), the 2nd lag
compressor will start and 1st lag compressor locked at 100%.
ii) When the load requirement drops, the 2nd lag compressor will start to unload.
When this compressor unloads nearly to its minimum idling position ~15%
(adjustable setpoint), a 30 seconds timer will be activated and start counting as
long as the slide valve of the 2nd lag compressor maintained ~15%. After 30
seconds, the slide valve of the 1st lag compressor will be unlocked. Once the 1st
lag compressor reaches 75% (adjustable setpoint) and locked, the 2nd lag
compressor will be unlock and start unloading to 0%. At this point, the 1st lag
compressor will be unlocked. The same process will go through for the 1st lag
compressor if its slide valve reached ~15% and maintained. When the lead
compressor unloads to 75%, the 1st lag compressor will unload and proceed to
normal shutdown.

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iii) At any time if PY-864 drops below 26 g/cmG (Adjustable Setpoint), the
compressors will go through the normal shutdown sequence in the order reverse
of the sequence selection. The last started compressor will shutdown first.

iv) When the system is running in autostage control, operator can switch the
compressors to individual control. The process is not reversible once the
compressor packages are switched to individual control. The operator can do the
following;-

Switch one of the HS-02CA/B/C selector switch to LOCAL on the LOP. The
compressor package with the selector switch changed to LOCAL will be
allowed to be shutdown in LOP mode. The other 2 compressor packages will
be switched to HMI Local mode and allowed to be shut down from HMI
individually. If the system is started from Remote Autostage, the package
mode will automatically switch from Remote to LOCAL.

Disengage

the Autostage Selection to NON-AUTOSTAGE. All of the 3

compressor packages will be automatically switched to HMI Local Mode. If

the system is started from Remote Autostage, the package mode will
automatically switch from Remote to LOCAL.
(4) During Autostage operation, the sequence selection will be re-organized by the logic
program in the event if one of the compressor packages experienced a trip. For
instance, if the original sequence is ABC, when C trips, the sequence will remain the
same. But if B trips, the sequence will become ACB. If A trips, the sequence will
become BCA. The package that trips will always be given the last in the sequence.

(5) It is important to take note that for remote autostage, only 3 selections are available:
ABC, BCA and CAB. In the event if the logic program re-organized the sequence due
to one of the compressor packages trip and the sequence is not one of the three
selections for remote autostage (e.g. ACB), the logic program will automatically
switch back to HMI Autostage Mode.

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(6) Two PID Loops are operational as a common process, LIC-01 and LIC-02. LIC-01
controls and maintains the level of Liquid NH3 in the Liquid Receiver by means of
controlling the opening and closing of the Liquid Level Control Valve LCV-1501.
LIC-02 controls the sub-cooling of the system by controlling the liquid going into the
economizer via LCV-101.

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SEQUENCE OF OPERATION

Preparation of Compressors for Starting

Starting the compressors requires that all permissive conditions be satisfied. It is a good practice to
prepare all compressors to be ready for startup even if the compressor is no required to run at the
point of time.

PERMISSIVE CHECKS
i)

Confirm that all oil pumps are in AUTO MODE.

ii)

Confirm that all PID loops are in AUTO MODE at the PID screens in the HMI

iii)

Confirm that the slide valve capacity of each compressor is in AUTO MODE.

iv)

Confirm that slide valve capacity of each compressor is at min. position. (SV < 5%).

v)

Confirm that Main motor is not locked. That includes Max num. of starts in one hour (4
starts allowed), Last running condition was bigger than 20 minutes and Oil pump was in
stop condition more than 10 minutes.

vi)

Confirm that ALL solenoid valves are in AUTO MODE, including the solenoid valves of
the common skids

Tag
XV-201A/B/C
XV-071
XV-072A/B/C
XV-073A/B/C
PCV-101A/B/C
LCV-1501
LCV-101

Description
Economizer On/Off Valve
Suction Drum Liquid Level On/Off Valve
Oil Return Valve
Blowdown Valve
Oil Pressure Control Valve
Liquid Receiver Level Control Valve
Economizer Level Control Valve

Position
Close
Close
Close
Close
Close
Close
Close

Note: the Common valves XV-071, LCV-1501 and LCV-101 are enabled if at (open or close ) if at
least one compressor is running.

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AMMONIA TANK CAPACITY 20,000 DOUBLE WALL

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Normal Compressor Start Sequence

The following explains the start sequence for 1 compressor package. In the event of more than 1
compressor package is started, the common instruments will take priority of the first compressors
command. The start sequence is standard for all 3 compressors regardless of the Startup Mode.

Once the compressor is started, the following sequence is executed via the programmed logic in the
PLC control panel:

a. The control start sequence will confirm that all the permissive signals are in the safe position
for compressor start. (See above). That includes the Slide valve ZT-01A/B/C at minimum
position < 5%. If the ZT-01 is not < 5% because last start up was due for a trip condition, the
operator most manually start the Oil pump and sent unload command from the HMI until ZT01 A/B/C is less than 5%. Then manually stop the Oil pump and wait for the 10 minutes Oil
pump stop timer. Permissive signal will turn green in the HMIs Start Sequence Page. If the
signal remained red, the compressor-starting sequence does not proceed.

b. Automatically check if TRIP conditions other than the permissive conditions do exist. If
common and package TRIP conditions do not exist, the starting sequence continues. Otherwise,
the compressor-starting sequence does not proceed.
c. The solenoid valve SV-1501 and PID LOOP for LIQUID RECEIVER LEVEL CONTROL
VALVE (LCV-1501) will be energized and PID controller LIC-01 will starts to control Liquid
Level in the Liquid Receiver by monitoring LT-01.
d. The solenoid valve SV-101 and PID LOOP for ECONOMIZER LIQUID LEVEL CONTROL
VALVE (LCV-101) will be energized and PID controller LIC-02 will start to control Liquid
Level in the Economizer by monitoring LT-2.

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e. Verify that PT-03A/B/C (discharge pressure) is less than 5 kg/cm, (adjustable set point). That
is minimum skid pressure to continue the startup sequence. If the pressure is bigger than the set
point, the Logic will open the XV-073 Blowdown valve until PT-03 < Startup set point. Once
XV-073 is closed the sequence continue whit the next step.

f. A signal is generated to start the oil pump motor 32-MP-802-A/B/C and a readback signal from
the MCC, for the oil pump motor indicating motor running will be sent back to the PLC and the
motor symbol will turn GREEN. This will occur within 3 seconds.

g. If the read back motor running signal is not received within the time set of 3 seconds, a package
trip signal is generated and start-up sequence aborted.
h. The lube oil pressure differential PDI-01A/B/C should be greater than 1.5 kg/cm.
i. After passing all the conditions described above, a start signal to start the compressor motor
32-MC-801-A/B/C is generated from the PLC to the MCC after 10 seconds delay. Then
compressor motor running signal MSRB is received in the PLC from MCC. If no feedback
signal is received within 3 seconds, the compressor-starting sequence is aborted and a trip
signal is generated.

j. Compressor main driver runs with compressor capacity (slide valve) loaded to min loading
position (adjustable setpoint) and left to run for 30 seconds (idling mode).

k. After the 30 sec idling mode,

i. Compressor slide valve control will be based on Tank Pressure PY-864. This is
accomplished by the pressure controller PIC-01A/B/C located in the control panel,
and by setting the adjustable PID calculations for the suction pressure PID. The controls
of the compressor capacity are via the slide valve ZT-01A/B/C load and unload.

ii. During normal operation if the main motor current IT-01A/B/C is detected to be higher
than the set point (adjustable setpoint) at the HMI, the slide valve position will be
limited to load or will be forced to unload.

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Normal Compressor Stop Sequence

The following explains the normal stopping sequence for 1 compressor package. The stop sequence
is standard for all 3 compressors regardless of the Startup Mode.
a. Slide valve ZT-01A/B/C is forced to unload to 0% within 60 seconds.

b. If the slide valve is not able to unload to 0% within 60 sec, the compressor will still stop.
c. Compressor motor 32-MC-801-A/B/C stop. [Slide valves at 0% or 60 seconds, whichever
comes first]

d. XV-073 will be energized to equalize the discharge and suction pressure.

e. After the compressor motor had stop for 5 sec (adjustable setpoint), the running oil pump 32MP-802-A/B/C will stop.

Tag

Description

Position

XV-201A/B/C

Economizer On/Off Valve

Close

XV-071

Suction Drum Liquid Level On/Off Valve

Close

XV-072A/B/C

Oil Return Valve

Close

XV-073A/B/C

Blowdown Valve

Close

PCV-101A/B/C

Oil Pressure Control Valve

Close

LCV-1501

Liquid Receiver Level Control Valve

Close

LCV-101

Economizer Level Control Valve

Close

Note: the Common valves XV-071, LCV-1501 and LCV-101 are enabled if at (open or close ) if at
least one compressor is running. Will keep closed only if 3 compressors are stopped.

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Compressor / System Emergency Shutdown & Trips:

Emergency shutdown is activated either:

1) By trip signal generated from the PLC of the local control panel, which will shut off all
equipment within the package immediately. If the trip signal is caused by common instruments,
entire system will be forced to shut down. If the trip signal is generated by specific compressor
package, only the specific compressor package will be forced to shut down. Remaining package
will still be allowed to operate.
2) By pushing the Emergency shutdown pushbutton ESD-02, physically located on the local
control panel or ESD-01 located at the Local Operator panel, all the motors will stop, all
solenoid valves will be de-energized and the all compressors slide valve will be at current
position. If ESD-01A/B/C is pushed, only the specific compressor package will shut down. All
common instruments will not be affected.

3) Power failure to compressor motors 32-MC-801-A/B/C or oil pump motors 32-MP-802-A/B/C

indicated through readback signals.

CAPACITY CONTROL SLIDE VALVE ZT-01A/B/C

The slide valve ZT-01A/B/C is operated in two modes, AUTO and MANUAL. Any mode can
be selected by setting the slide valve soft selector switch the HMI menu.

AUTO Mode
In this mode, the compressor capacity is controlled automatically in accordance with system load
requirements by means of slide valve ZT-01A/B/C load and unload, which is controlled by the PID
loop calculation described earlier.

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MANUAL Mode
In this mode, the compressor slide valve can be loaded and unloaded via the LOAD & UNLOAD
soft key buttons from the HMI MANUAL MODE of the local control panel. This is accomplished by
the generated signal from the PLC to activate the solenoid valves of the compressor slide valve
selected. Oil pump must be running before the slide valve can Load or Unload.
LIQUID LEVEL CONTROL

Liquid Level control of this system consist of a solenoid valve SV-1501 and a Level control valve
LCV-1501, where the PLC logic will control the opening and closing of the valve base on the PID
calculation.
The solenoid valve has three modes of operation, HAND, OFF, and AUTO mode. Either one of
the three modes is selected by setting the soft selector switch from the HMI of the local control panel.

HAND Mode
In this mode, the Liquid Level Control solenoid valve SV-1501 is energized and de-energized
locally by the HAND and OFF soft key buttons from the HMI. This mode is usually used to perform
stroke test on the valve before starting the system.

OFF Mode
In this mode, the Liquid Level Control solenoid valve SV-1501 is electrically isolated and is deenergized. Usually this mode is incorporated for maintenance purposes.

AUTO Mode
In this mode, the Liquid Level Control solenoid valve SV-1501 is energized and de-energized
automatically by a signal generated by the PLC program built in the local control panel installed.
The level controller LIC-01 built in the PLC of the local control panel is used to control the Liquid
Receiver Level.

The Liquid Level Control Valve LCV-1501 will vary its opening to maintain liquid NH3 level in the
receiver.

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ECONOMIZER LEVEL CONTROL

Economizer Level control of this system consist of a solenoid valve SV-101 and an Economizer Level
control valve LCV-101, where the PLC logic will control the opening and closing of the valve base on
the PID calculation.
The solenoid valve has three modes of operation, HAND, OFF, and AUTO mode. Either one of
the three modes is selected by setting the soft selector switch from the HMI of the local control panel.

HAND Mode
In this mode, the Economizer Level Control solenoid valve SV-101 is energized and de-energized
locally by the HAND and OFF soft key buttons from the HMI. This mode is usually used to perform
stroke test on the valve before starting the system.

OFF Mode
In this mode, the Liquid Level Control solenoid valve SV-101 is electrically isolated and is deenergized. Usually this mode is incorporated for maintenance purposes.

AUTO Mode
In this mode, the Liquid Level Control solenoid valve SV-101 is energized and de-energized
automatically by a signal generated by the PLC program built in the local control panel installed.
The level controller LIC-02 built in the PLC of the local control panel is used to control the
Economizer Level.

The Economizer Level Control Valve LCV-101 will vary its opening to maintain liquid NH3 level in
the economizer.

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SOLENOID VALVES CONTROL

All the solenoid valves have three modes of operation, HAND, OFF, and AUTO mode. Either
one of the three modes is selected by setting the soft selector switch from the HMI of the local control
panel.

HAND Mode
In this mode, the solenoid valve is energized and de-energized locally by the HAND and OFF soft
key buttons from the HMI. This mode is usually used to perform stroke test on the valve before
starting the system.

OFF Mode
In this mode, the solenoid valve is electrically isolated and is de-energized. Usually this mode is
incorporated for maintenance purposes.

AUTO Mode
In this mode, the solenoid valve is energized and de-energized automatically by a signal generated by
the PLC program built in the local control panel installed.

The AUTO Mode function of each solenoid valve is described as follows;-

a. Economizer XV-201A/B/C
The Economizer vapor line to the compresor is controlled by a solenoid valve (SV201A/B/C) and it is activated based on the slide valve position of the compresor in operation
(adjustable setpoints)
Cut In .

80% (valve opens)

Cut Out.

60% (valve closes)

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b. Oil Return XV-072A/B/C

When the specific compressor package is in operation, the solenoid valve (SV-072A/B/C)
will be energized and de-energized when the package stops.

c. Blow-down XV-073A/B/C
When the specific compressor package is starting and the discharge pressure PT-03A/B/C is
greater than 5 kg/cm, the solenoid valve (SV-073A/B/C) will be energized and de-energized
when the pressure drops below 5 kg/cm (adjustable setpoint).

d. Liquid Receiver Level Control LCV-1501

This Solenoid Valve is energized when either one of the compressor packages is started and
de-energized when all compressor packages are stopped.

e. Economizer Liquid Level Control LCV-101

The economizer liquid level is controlled by a level transmitter LT-02, that energizes SV-101
when at least one compressor is in operation.

f. Suction Drum Liquid Level Control SV-071 (XV-071)

The liquid level in the Suction Drum will be controlled by XV-071.
If at least one compressors is ruuning and the LT-03 is less than 30 % (adjustable set point )
the SV-071 will energize, to OPEN XV-071. The SV-071 will be de enerzized if the Level
LT-03 is Bigger than 70% (adjustable setpoint) to close XV-071

OIL PUMP MOTOR 32-MP-802A/B/C

Oil pump motor 32-MP-802A/B/C has three modes of operation, HAND, OFF, and AUTO
mode. Either one of the three modes is selected by setting the soft selector switch from the HMI of the
local control panel.

HAND Mode
In this mode, the oil pump motor 32-MP-802A/B/C will start running manually and can be stopped
with the soft key OFF from the HMI of the local operator.
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OFF Mode
In this mode, the oil pump motor 32-MP-802A/B/C is electrically isolated and cannot be started or
stopped. Usually this mode is incorporated for maintenance purposes.

AUTO Mode
In this mode, the oil pump motor 32-MP-802A/B/C is started and stopped automatically by a
signal generated by the PLC program built in the local control panel installed.

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