BASIC SHUTDOWN SYSTEMS & INTERLOCKS

PT Chandra Asri Petrochemical Company

Ciwandan, Cilegon, Indonesia
July 2007
CAUTIONARY NOTICE
This document contains information which is proprietary to Kellogg Brown & Root, Inc. This information is to be held in confidence. No disclosure,
reproduction or other use of this document is to be made without the prior written consent of the Kellogg Brown & Root, Inc.

Shutdown System / Permissives

Low Fire Trip
Complete Trip
Permissives for Hydrocarbon Cracking
Permissives for Decoking
Permissives for Burner Lightoff
Burner Lightoff Procedure
Permissives for MOV Switching

CONFIDENTIAL

Furnace Shutdown Systems

Low Fire Trip
Not a complete shutdown
Furnace remains hot (so-called hot standby condition)
Rarely results in mechanical work

Complete trip
No firing
Furnace cold
May require mechanical work if furnace has been cracking more
than ~10 days

CONFIDENTIAL

Furnace Shutdown Systems

LOW FIRE TRIP ACTIONS 6376-IC3522-01 Sheet 1 of 9

Isolates HC Feed
Trips Main Burners Leaving Decoke Burners On
Resets Fuel Gas Control Valve Set Point
Dilution Steam Flow Set Same As SAD
Purge Steam To FPHT I Coil Initiated
Firing Rate Reduced To LFT Setpoint
Isolates Decoke Air (If In SAD Prior To LFT)
Isolates Decoke Water (If In SWD Prior To LFT)
Isolates Cracked Gas Analyzer
Disables Total Feed Controllers
Isolates DMDS

CONFIDENTIAL

Low Fire Trip

Avoids a complete trip!

Furnace sent to safe condition (similar to decoke)
Thermal swing reduced
Furnace remains hot (no shut down)
Possibility of mechanical work reduced

Hydrocarbon operation resumed after decoking

CONFIDENTIAL

Furnace Shutdown Systems

COMPLETE TRIP ACTIONS 6376-IC3522-01 Sheet 1 of 9

Close Decoke Burners Pilots Remain On

Open Main Burner XV-10850
Isolates HC Feed
Isolates Decoke Air (If In SAD Prior To CT)
Isolates Decoke Water (If In SWD Prior To CT)
Dilution Steam Flow Reset To Complete Trip Rate
Isolate Quench Oil Purge Quench Oil Nozzles
Isolates Cracked Gas Analyzer
Isolates DMDS

Pilots Typically Stay Lit Exception If CT Initiated By Operator or HighHigh-High Furnace Arch Pressure

CONFIDENTIAL

Complete Trip

Furnace is shut down

Furnace is cold (pilots typically firing)
Mechanical work probably required.

CONFIDENTIAL

Low Fire Trip

Initiators for Low Fire Trip:

Low-Low hydrocarbon feed pass flow (any pass)
Low-Low dilution steam pass flow (any pass)
Low-Low SHP steam drum level
High-High SHP steam temperature
High-High arch pressure (Hot Furnace Only)
High-High transfer line temperature (either side of furnace)
Manual trip

CONFIDENTIAL

Low HC Feed Flow Trip

LOW HC FEED
FLOW

IF IN SWD, ADD HC
FEED, DS, DECOKE
STEAM & DECOKE
BFW FLOW RATES

CONFIDENTIAL

LOW
FIRE
TRIP

Low Dilution Steam Flow Trip

LOW DILUTION
STEAM FLOW

IF IN SWD,
RESET

LOW
IF IN SAD,
ADD DIL STEAM
& PURGE STEAM
FLOW RATES

CONFIDENTIAL

IF FURNACE
COLD, DISABLE

FIRE
TRIP

Low Steam Drum Level Trip

LOW STEAM
DRUM LEVEL

LOW
FIRE
TRIP

60 SEC
DELAY

REQUIRED TO PROTECT PQES

CONFIDENTIAL

COMPLETE
FURNACE
TRIP

High SHP Steam Temperature Trip

HIGH STEAM
TEMP

LOW
FIRE
TRIP

8 MIN
DELAY
COMPLETE
FURNACE
TRIP

HIGH-HIGH
STEAM
TEMP

CONFIDENTIAL

High Arch Pressure Trip

HIGH ARCH
PRESSURE
(PTs)

ARCH
PRESSURE
HIGH?
(TTS)

HIGH ARCH
PRESSURE
(TTs)

30 SEC
DELAY

TRIP OPEN
ID FAN
DAMPER

NO

FIREBOX
COLD?

30 SEC
DELAY

CONFIDENTIAL

YES

LOW
FIRE
TRIP

COMPLETE
FURNACE
TRIP

30 SEC
DELAY

High Transfer Line Temperature Trip

HIGH TRANSFER
LINE TEMPERATURE
(EITHER SIDE)

LOW
FIRE
TRIP

CONFIDENTIAL

5 MIN.
DELAY

COMPLETE
FURNACE
TRIP

Manual Low Fire Trip

MANUAL LOW
FIRE TRIP
CONTROL ROOM

LOW
FIRE

MANUAL LOW
FIRE TRIP
BURNER PANEL

TRIP

CONFIDENTIAL

Checks After Low Fire Trip

LOW
FIRE
TRIP

LOW TOTAL
DILUTION
STEAM FLOW

30 SEC
DELAY

HIGH FLUE
GAS TEMP

5 MIN
DELAY

CONFIDENTIAL

COMPLETE
FURNACE
TRIP

Complete Trip

Initiators for Complete Trip:

High-High / Low-Low fuel gas pressure
High-High-High SHP steam temperature
High-High-High Firebox Pressure
ID Fan Failure
Manual trip
CONFIDENTIAL

Fuel Gas Complete Trips

HIGH ARCH
PRESSURE (COLD)

HIGH-HIGH-HIGH
ARCH PRESSURE

LOW FUEL
GAS PRESSURE
COMPLETE
FURNACE
TRIP

HIGH FUEL
GAS PRESSURE
MANUAL
COMPLETE TRIP
CONTROL ROOM
MANUAL
COMPLETE TRIP
BURNER PANEL
CONFIDENTIAL

Pilot Trips
HIGH-HIGH-HIGH
ARCH PRESSURE
LOW PILOT
GAS PRESSURE
HIGH PILOT
GAS PRESSURE

PILOT
TRIP

MANUAL
COMPLETE TRIP
CONTROL ROOM
MANUAL
COMPLETE TRIP
BURNER PANEL
CONFIDENTIAL

Interlocks for MOV Switching

Permissives for MOV Switching

Analyzer sample valves closed

HC feed isolated

Quench oil isolated

Decoke air isolated

In Decoke mode

DMDS isolated

Steam flow rates above minimum (Administrative)

Permissive failure after decoking commences causes alarm

CONFIDENTIAL

MOV Switching - From Transfer Line to Decoke Line

Control room operator activates local panel

Field operator begins transfer line valve (TLV) closure

High Transfer line pressure alarm active

Operator stops TLV movement based on furnace pressure and/or TLV P

Field operator begins opening of decoke line valve (DLV).

Low Transfer line pressure alarm active

Operator stops DLV movement based on transfer line pressure and/or TLV
P

If Transfer Line Low DP or High Pressure Occurs valve movement stops

until corrected

Close TLV - Low TLV P alarm disabled

Open DLV - High transfer line pressure alarm disabled.
CONFIDENTIAL

MOV Switching Sequence - From Decoke Line to Transfer Line

Control room operator activates local panel

Field operator begins DLV closure

High Transfer line pressure alarm active

Operator stops DLV movement based on transfer line pressure

and/or TLV P

Field operator begins opening of TLV

Low Transfer line pressure alarm active

If Transfer Line Low DP or High Pressure Occurs valve movement stops

until corrected

Close DLV - Low TLV P alarm disabled

Open TLV - High transfer line pressure alarm disabled.
CONFIDENTIAL

Interlocks for Hydrocarbon Service

Decoke line MOV 100% closed
Decoke air isolated
Transfer line MOV 100% open
Decoke/Cracking Mode Switch in Cracking position
Steam flow rates above minimum (Administrative)
Permissive failure after cracking commences causes an alarm

CONFIDENTIAL

Interlocks to Open Decoke Air (SAD)

Transfer line MOV 100% closed

Decoke line MOV 100% open

HC feed isolated

Quench oil isolated

Decoke/Cracking Mode Switch in Decoke position

Chromatograph isolated

Steam flow rates above minimum (Administrative)

Permissive failure after decoking commences causes an alarm

CONFIDENTIAL

Burner Lightoff System

Checks permissives
Purges firebox
Checks for burner fuel gas cock closure
Includes temporary bypasses for:
High fuel gas pressure
Low fuel gas pressure

Firebox purge & fuel gas cock closure tests run in

parallel to save time
Includes bypass switch for pilots usage
CONFIDENTIAL

Interlocks / Procedure for Burner Light-off

Burner Purge Panels:

ESD Console Panel

Outside Burner Panel
DCS Switches, Lights

CONFIDENTIAL

Fuel Gas Control

QIC

ATM @ SAFE
LOCATION

AI

PIC

Burner Header

FO

CONFIDENTIAL

Burner Light-Off Sequences

There are four separate burner light-off sequences
1.

2.

3.

4.

Pilot, Main, and Decoke Burner Light-Off

1.

Furnace is cold or Complete Trip with Pilot Trip

2.

Pilots lit first then Main and Decoke burners can be tested and lit

Main & Decoke Burner Light-Off

1.

Furnace has had Complete Trip but Pilots remain lit

2.

Main and Decoke burners tested together and enabled

Main Burner Light-Off

1.

Furnace has had Low Fire Trip but Pilots and Decoke burners remain lit

2.

Main burners are tested and enabled

Main & Decoke Burner Light-Off Pilots Bypassed

1.

Furnace has had Complete Trip or is Cold

2.

Main and Decoke burners tested together and enabled

All three sequences follow a similar pattern

CONFIDENTIAL

Burner Light-Off Sequence Firebox Purge

If furnace is hot and permissives satisfied, firebox purge
starts automatically.
If furnace is cold, operator must initiate firebox purge.
Must satisfy all permissives for 15 minutes.
Purge complete light illuminates.

CONFIDENTIAL

Burner Light-Off Sequence Cock Closure Test

Field operator closes all burner fuel gas cocks
Check that burner fuel gas header pressure is low
Operator starts 5 minute timer:
Fuel gas commissioned to spring loaded valve
Open isolation valve upstream of spring loaded valve
Operator holds spring loaded valve open
Fuel gas flows through RO into burner fuel gas header
Fuel gas header pressure rises to set point?
Close isolation valve upstream of spring loaded valve

CONFIDENTIAL

Burner Light-Off Sequence Light Burners

Firebox purge & cock closure tests successful

5 minute timer starts automatically
Low & High fuel gas pressure trips bypassed for 5 minutes
Fuel gas commissioned to fuel gas header
Operator adjusts fuel gas vent to stabilize pressure between Low
& High fuel gas pressure trip set points (PCV-1082
recommended setpoint ~ 0.4 kg/cm2g)
Light burners as required
Close vent valve when sufficient burners are lit to allow CV to
control
CONFIDENTIAL