Project Name: FAB10A
PN: S86165
HEAT RECOVERY WATER SYSTEM (PHASE A1)
SOO
MICRON Fab 10A Project
Sequence of Operations
For
Heat Recovery Water System (Phase A1)
Document Reference: 86165 2 ENG 8608 SOO 005
Engineer Responsible for System
Vynus
Engineer Responsible for SOO & P&ID
Vynus / Palani
Rev.
0
Comment
Initial Release for Review
By
Vynus
Document: 86165 2 ENG 8608 SOO 005 – Heat Recovery Water System
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Create Date: 24 Sep 2018
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Date
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Project Name: FAB10A
PN: S86165
HEAT RECOVERY WATER SYSTEM (PHASE A1)
SOO
CONTENTS
1
REFERENCE DOCUMENTS.................................................................................................................. 4
1.1
1.2
1.3
1.4
2
GENERAL INFORMATION .......................................................................................................................... 4
SYSTEM PROCESS AND INSTRUMENTATION DRAWINGS (P&ID’S) .............................................................. 4
OTHER RELEVANT DOCUMENTS................................................................................................................ 4
GENERAL................................................................................................................................................ 4
KEY EQUIPMENT AND INSTRUMENTS ............................................................................................ 5
2.1 KEY EQUIPMENT ITEMS............................................................................................................................ 5
2.1.1
Heat Exchangers .......................................................................................................................... 5
2.1.2
Pumps ........................................................................................................................................... 5
2.1.3
Valves (ON/OFF) .......................................................................................................................... 5
2.1.4
Valves (Modulating)...................................................................................................................... 5
2.1.5
Other key equipment items ............................................................................................................ 6
2.2 KEY INSTRUMENTS.................................................................................................................................. 6
2.2.1
Pressure instruments ..................................................................................................................... 6
2.2.2
Flow instruments........................................................................................................................... 6
2.2.3
Temperature instruments .............................................................................................................. 6
2.2.4
Analytical instruments .................................................................................................................. 7
2.2.5
Miscellaneous other instruments ................................................................................................... 7
3
OVERALL SYSTEM DESCRIPTION .................................................................................................... 8
3.1
3.2
4
SYSTEM OVERVIEW ................................................................................................................................. 8
SUB-SYSTEMS ......................................................................................................................................... 8
SUB-SYSTEM FUNCTIONAL DESCRIPTIONS ................................................................................ 10
4.1 SUB-SYSTEM 1 – HRW DISTRIBUTION PUMPS......................................................................................... 10
4.1.1
General description .................................................................................................................... 10
4.1.2
Key equipment items ................................................................................................................... 10
4.1.3
Key instruments .......................................................................................................................... 10
4.1.4
Start-Up...................................................................................................................................... 10
4.1.5
Normal operation (“Auto”)......................................................................................................... 11
4.1.6
Shut-Down .................................................................................................................................. 12
4.1.7
Interlocks.................................................................................................................................... 12
4.1.8
Interfaces with other systems ...................................................................................................... 12
4.1.9
FMCS parameter displays........................................................................................................... 12
4.1.10
Switching between “Manual” and “Auto” .............................................................................. 13
4.1.11
“Local” control ..................................................................................................................... 13
4.1.12
Set-points / Warnings / Alarms ............................................................................................... 13
4.2 SUB-SYSTEM 2 – HRW HEAT EXCHANGERS ........................................................................................... 14
4.2.1
General description .................................................................................................................... 14
4.2.2
Key equipment items ................................................................................................................... 14
4.2.3
Key instruments .......................................................................................................................... 15
4.2.4
Start-Up...................................................................................................................................... 15
4.2.5
Normal operation (“Auto”)......................................................................................................... 15
4.2.6
Shut-Down .................................................................................................................................. 16
4.2.7
Interlocks.................................................................................................................................... 16
4.2.8
Interfaces with other systems ...................................................................................................... 16
4.2.9
FMCS parameter displays........................................................................................................... 16
4.2.10
Switching between “Manual” and “Auto” .............................................................................. 17
4.2.11
“Local” control ..................................................................................................................... 17
4.2.12
Set-points / Warnings / Alarms ............................................................................................... 17
4.3 SUB-SYSTEM 3 – MINIMUM FLOW .......................................................................................................... 18
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Project Name: FAB10A
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
SOO
4.3.1
General description .................................................................................................................... 18
4.3.2
Key equipment items ................................................................................................................... 18
4.3.3
Key instruments .......................................................................................................................... 18
4.3.4
Start-Up...................................................................................................................................... 18
4.3.5
Normal operation (“Auto”)......................................................................................................... 18
4.3.6
Shut-Down .................................................................................................................................. 19
4.3.7
Interlocks.................................................................................................................................... 19
4.3.8
Interfaces with other systems ...................................................................................................... 19
4.3.9
FMCS parameter displays........................................................................................................... 19
4.3.10
Switching between “Manual” and “Auto” .............................................................................. 20
4.3.11
“Local” control ..................................................................................................................... 20
4.3.12
Set-points / Warnings / Alarms ............................................................................................... 20
4.4 SUB-SYSTEM 4 – HRW HEAT-LOAD CALCULATIONS .............................................................................. 21
4.4.1
General description .................................................................................................................... 21
4.4.2
Key equipment items ................................................................................................................... 21
4.4.3
Key instruments .......................................................................................................................... 22
4.4.4
Start-Up...................................................................................................................................... 23
4.4.5
Normal operation (“Auto”)......................................................................................................... 23
4.4.6
Shut-Down .................................................................................................................................. 23
4.4.7
Interlocks.................................................................................................................................... 23
4.4.8
Interfaces with other systems ...................................................................................................... 23
4.4.9
FMCS parameter displays........................................................................................................... 23
4.4.10
Switching between “Manual” and “Auto” .............................................................................. 24
4.4.11
“Local” control ..................................................................................................................... 24
4.4.12
Set-points / Warnings / Alarms ............................................................................................... 24
Appendix 1
Set-points / Warnings / Alarms
Appendix 2
P&ID’s
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
SOO
1
Reference Documents
1.1
General Information
Document F10A-SOO-000 – “General Information” contains generic information and
guidelines that relate to all SOO’s for this project.
If there is any contradiction between this document and F10A-SOO-000 – “General
Information”, this document shall take precedence.
1.2
System Process and Instrumentation Drawings (P&ID’s)
The following P&ID’s describe the Process Cooling Water system.
Drawing Number
Sht Rev.
F10A-SCH-C1-01-MCHWT-003
1
2
F10A-SCH-C1-00-MCHWT-001
F10A-SCH-F0-00-MCHWT-003
1
1
3
2
1.3
Description
CUP A1 Building Level 1 Chiller Plant Room
Heat Recovery Water Schematic
CUP A1 Building Chilled Water Schematic
FAB1 Building Heat Recovery System Schematic
Other relevant documents
The following documents are related to the distribution of services from this system
but do not contain any controls directly affecting this system. As such are not included
in this systems boundary.
Document Number
Rev. Description
N/A
N/A
1.4
N/A
General
The sequence of operation and logic provided in this document is a general summary
of the sequence and logic requirements. Preparation and updating of the detailed
logic sequence for proper and efficient functioning of the respective systems and subsystems is within the full turnkey scope of the system integrator.
If the intent of any part of the document is not clear, it is the responsibility of the
system integrator to obtain clarification before commencing work.
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
SOO
2
Key equipment and instruments
The specific equipment items and instruments applicable to this system are tabulated
below.
2.1
Key equipment items
2.1.1 Heat Exchangers
Tag Descriptor
C10A1-01-C161D-HRW-HX-01 (Future)
C10A1-01-C161D-HRW-HX-02 (Phase 2)
C10A1-01-C161D-HRW-HX-03 (Phase 1)
C10A1-01-C171D-HRW-HX-04 (Phase 1)
Function / Description
Heat Recovery System Heat Exchangers
2.1.2 Pumps
Tag Descriptor
C10A1-01-C171D-HRW-PMP-01 (Future)
C10A1-01-C171D-HRW-PMP-02
C10A1-01-C171D-HRW-PMP-03
C10A1-01-C181D-HRW-PMP-04
Function / Description
Heat Recovery Water Pumps
2.1.3 Valves (ON/OFF)
Tag Descriptor
Function / Description
C10A1-1-Cxxx-HRW-HX-01-FCV01 (Future)
Cup Level 1 Heat Recovery Heat Exchanger 1
On/Off Valve
Cup Level 1 Heat Recovery Heat Exchanger 2
On/Off Valve
Cup Level 1 Heat Recovery Heat Exchanger 3
On/Off Valve
Cup Level 1 Heat Recovery Heat Exchanger 4
On/Off Valve
C10A1-1-Cxxx-HRW-HX-02-FCV01
C10A1-1-Cxxx-HRW-HX-03-FCV01
C10A1-1-Cxxx-HRW-HX-04-FCV01
2.1.4 Valves (Modulating)
Tag Descriptor
Function / Description
C10A1-1-Cxxx-HRW-HX-01-TCV-01
(Future)
C10A1-1-Cxxx-HRW-HX-02-TCV-01
Cup Level 1 Heat Recovery Heat Exchanger 1
Temperature Control Valve
Cup Level 1 Heat Recovery Heat Exchanger 2
Temperature Control Valve
Cup Level 1 Heat Recovery Heat Exchanger 3
Temperature Control Valve
Cup Level 1 Heat Recovery Heat Exchanger 4
Temperature Control Valve
C10A1-1-Cxxx-HRW-HX-03-TCV-01
C10A1-1-Cxxx-HRW-HX-04-TCV-01
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
SOO
C10A1-1-Cxxx-HRW-HDR-PCV-01
Cup Level 1 Heat Recovery By-pass Safety Relief
Pressure Control Valve
2.1.5 Other key equipment items
Tag Descriptor
Function / Description
None
2.2
Key instruments
2.2.1 Pressure instruments
Tag Descriptor
Function / Description
C10A1-1-Cxxxx-HRW-HDR01-PIT-01
C10A1-1-Cxxxx-HRW-HDR02-PIT-01
F10A1-x-Fxxx-HRW-HDR-PDIT-01
F10A1-x-Fxxx-HRW-HDR-PDIT-02
F10A2-x-Fxxx-HRW-HDR-PDIT-01
F10A2-x-Fxxx-HRW-HDR-PDIT-02
C10A2-x-Fxxx-HRW-HDR-PDIT-01
C10A2-x-Fxxx-HRW-HDR-PDIT-01
CUPA1-L-1 HRW SUPPLY HDR. PR.- Monitoring
CUPA1-L-1 HRW RETURN HDR. PR.- Monitoring
FABA1-L-x HRW Diff. PR. 01 - Pump Control
FABA1-L-x HRW Diff. PR. 02 - Pump Control
FABA2-L-x HRW Diff. PR. 01 - Pump Control
FABA2-L-x HRW Diff. PR. 02 - Pump Control
CUPA2-L-x HRW Diff. PR. 01 - Pump Control
CUPA2-L-x HRW Diff. PR. 02 - Pump Control
2.2.2 Flow instruments
Tag Descriptor
Function / Description
C10A1-1-Cxxx-CW-HDR-02-FIT-01
CUPA1-LEVEL 1 Condenser water return flowmeter from HRW
CUPA1-LEVEL 1 HRW Supply header flow-meter
to FabA1
FABA2-LEVEL x HRW Supply header flow-meter
to FabA2 Level x
CUPA2-LEVEL x HRW Supply header flow-meter
to CupA2 Level x
CUPA2-LEVEL x Condenser water return flowmeter from HRW
C10A1-1-Cxxx-HRW-HDR-01-FIT-01
F10A2-x-Fxxx-HRW-HDR-01-FIT-01
C10A2-x-Cxxx-HRW-HDR-01-FIT-01
C10A2-x-Cxxx-CW-HDR-02-FIT-01
2.2.3 Temperature instruments
Tag Descriptor
C10A1-1-Cxxx-CW-HDR-01-TIT-01
C10A1-1-Cxxx-CW-HDR-02-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-02
Function / Description
CUPA1 LEVEL 1 Condenser water supply header
temperature from HRW
CUPA1 LEVEL 1 Condenser water return header
temperature to HRW
CUPA1 LEVEL 1 HRW Supply header
temperature to CUPA1-Control
CUPA1 LEVEL 1 HRW Supply header
temperature to CUPA1-Control
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
SOO
C10A1-1-Cxxx-HRW-HDR-02-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-02
C10A1-1-Cxxx-HRW-HDR-02-TIT-01
C10A2-x-Cxxx-CW-HDR-01-TIT-01
C10A2-x-Cxxx-CW-HDR-02-TIT-01
C10A2-x-Cxxx-HRW-HDR-01-TIT-01
C10A2-x-Cxxx-HRW-HDR-02-TIT-01
C10A2-x-Cxxx-HRW-HDR-01-TIT-01
C10A2-x-Cxxx-HRW-HDR-02-TIT-01
CUPA1 LEVEL 1 HRW Return header
temperature from CUPA1
CUPA1 LEVEL 1 HRW Supply header
temperature to FABA1-Control
CUPA1 LEVEL 1 HRW Supply header
temperature from FABA1-Control
CUPA1 LEVEL 1 HRW Return header
temperature from FABA1
CUPA2 LEVEL x Condenser water supply header
temperature from HRW
CUPA2 LEVEL x Condenser water return header
temperature to HRW
CUPA2 LEVEL x HRW Supply header
temperature to CUPA1-Control
CUPA2 LEVEL x HRW Return header
temperature from CUPA1
CUPA2 LEVEL x HRW Supply header
temperature to FABA2-Control
CUPA2 LEVEL x HRW Return header
temperature from FABA2
2.2.4 Analytical instruments
Tag Descriptor
Function / Description
None
2.2.5 Miscellaneous other instruments
Tag Descriptor
Function / Description
None
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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3
Overall System Description
3.1
System Overview
Four (4) heat exchangers are employed in parallel to transfer heat from the
Condenser Water and into the Heat Recovery Water. The heat exchangers are sized
to be 4 x 33.3% capacities.
Design conditions are:
Condenser water entering HEX
Condenser water leaving HEX
Heat Recovery water entering HEX
Heat Recovery water leaving HEX
: 35.0 oC  2.0 oC
: 25.0 oC  2.0 oC
: 20.0 oC  2.0 oC
: 30.0 oC  2.0 oC
The control system objective is to maintain the Heat Recovery Water discharged from
the circulation pumps at 30.0 oC at all times. The Heat Recovery Water system is a
closed system.
A minimum flow is maintained through the heat exchangers via a Pressure control
valve located between the Heat Recovery Water circulation pump discharge and
return headers.
The Heat Recovery water circulation pumps are VFD controlled with the pump
frequency set using differential pressure between the supply and return pipes at endof-line, FAB level 1.
Equipment
Heat Recovery Heat
Exchangers
Heat Recovery Water
Pumps
3.2
3
Equipment Quantity
Standby Phase
1
3
1
2
4
3
Total
Duty
1
Phase
2
1
Future
1
1
2
1
Sub-Systems
The following Table identifies the sub-systems that the Overall system can be broken
down into. Each sub-system will then be described in detail in Section 4.0 of this SOO
document.
No.
1
2
3
Sub-System Name
Sub-System 1 – HRW Distribution
Pumps
Sub-System 2 – HRW Heat
Exchangers
Sub-System 3 – Minimum flow
Functional Description
Distribution of HRW to facilities
Transfer condenser water heat to heat recovery
fluid
Provides minimum flow condition to pumps
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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4
Sub-System 4 – HRW Heat-Load
Calculations
HRW heat load calculation
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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4
Sub-system Functional Descriptions
4.1
Sub-System 1 – HRW Distribution Pumps
4.1.1 General description
The Heat Recovery Water system is a closed loop circulated through 3 VFD driven
pumps. The pump frequency is controlled by one of following options.



End of line pressure transmitters located at FABA1 Level 1.
End of line pressure transmitters located at FABA2 Level x.
End of line pressure transmitters located at CUPA2 Level x.
The above said options can be selected from FMCS SCADA.
4.1.2 Key equipment items
4.1.2.1 Pumps
Tag Descriptor
C10A1-01-C171D-HRW-PMP-01 (Future)
C10A1-01-C171D-HRW-PMP-02
C10A1-01-C171D-HRW-PMP-03
C10A1-01-C181D-HRW-PMP-04
Function / Description
Heat Recovery Water Pumps
4.1.3 Key instruments
4.1.3.1 Pressure instruments
Tag Descriptor
C10A1-1-Cxxxx-HRW-HDR01-PIT-01
C10A1-1-Cxxxx-HRW-HDR02-PIT-01
F10A1-x-Fxxx-HRW-HDR-PDIT-01
F10A1-x-Fxxx-HRW-HDR-PDIT-02
F10A2-x-Fxxx-HRW-HDR-PDIT-01
F10A2-x-Fxxx-HRW-HDR-PDIT-02
C10A2-x-Fxxx-HRW-HDR-PDIT-01
C10A2-x-Fxxx-HRW-HDR-PDIT-01
4.1.4
Function / Description
CUPA1-L-1 HRW SUPPLY HDR. PR.- Monitoring
CUPA1-L-1 HRW RETURN HDR. PR.- Monitoring
FABA1-L-x HRW Diff. PR. 01 - Pump Control
FABA1-L-x HRW Diff. PR. 02 - Pump Control
FABA2-L-x HRW Diff. PR. 01 - Pump Control
FABA2-L-x HRW Diff. PR. 02 - Pump Control
CUPA2-L-x HRW Diff. PR. 01 - Pump Control
CUPA2-L-x HRW Diff. PR. 02 - Pump Control
Start-Up
With no pumps running, the FMCS operator will normally initiate a HRW system start-up by
clicking on a “HRW START BUTTON” on the HRW system graphic display. The FMCS will
then execute the following start-up sequence:
i)
Heat Exchanger On/Off valves would be opened automatically.
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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ii) Once valve open status confirmed, temperature control PID loop will be active
and controlled by HRW supply temperature.
iii) Pump Starts at minimum frequency. Pump would be controlled by end-of-line
differential pressure transmitter. Ref above point no.4.1.1
4.1.5 Normal operation (“Auto”)
4.1.5.1 PID control
In “Auto” mode, the frequency output of the VFD Driven Pumps maintains the
end-of-line differential pressure.
Two pressure differential transmitters located at FAB Level 1 between the
Heat Recovery Water supply and return pipes is the primary instrument that
controls the Heat Recovery Water pumps. Options also provided at FMCS
SCADA for selecting the end-of-line differential pressure transmitter located at A2
area. Refer above point no. 4.1.1
4.1.5.2 Control logic
The automatic control algorithm shall determine the number of pumps that
need to run to satisfy the demand using the header pressure as the criteria for
controlling pump speeds and starting / stopping additional pumps. However,
the operator selected “minimum number of pumps running” shall take
precedence over the automatic control algorithm.
Demand control shall be based on the following description:
i)
The FMCS uses the pressure value as PV to a PID loop, the output
of which is used to regulate the VFD speeds.
ii)
The speed of all the operating pumps is raised and lowered in
unison.
iii)
If the pressure is not maintained as per the required PID set point
then operator shall decide to increase to the number of pumps by
increasing the minimum demand value in the Duty standby
faceplate. Then the FMCS will start the next available pump that is
in “Auto” mode and with the lowest accumulated run hours.
iv)
The new pump will be started at minimum speed, and slowly
ramped up until its speed matches that of the other running pumps.
v)
The FMCS then includes the new pump under the control of the
pressure PID loop, adjusting the speed to maintain the pressure
set-point.
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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vi)
Similarly, if the speed of the operating pumps falls below a set
level, then the FMCS will automatically slowly ramp down the
speed of the pump and will continue to run at PID low clamp output
value. If required operator shall decide to decrease the number of
pumps by decreasing the minimum demand value in the Duty
standby faceplate. Then the FMCS will stop the pump that is in
“Auto” mode, which is having the highest accumulated run hours.
In “Local” mode, the operator at the field shall be able to operate the pumps
from the VFD panels and the end of line differential pressure transmitter at
FAB level 1 will have no control over the frequency.
In case of analogue signal failure to the VFD’s, the Variable Frequency Drive
shall be programmed to fail at Last Operational Frequency configuration.
4.1.6 Shut-Down
4.1.6.1
Normal Shut-Down
Shutdown of the system will be manual. An automatic shutdown sequence is
not required.
4.1.6.2
Emergency Shut-Down
No emergency shutdown procedure is required.
4.1.7 Interlocks
If all four Heat Exchanger On/Off valves are closed or encounter FTO alarm then
pump will be stopped, if pump already running and temperature control valve will be
fully closed.
4.1.8 Interfaces with other systems
This system does not interface with any other systems.
4.1.9 FMCS parameter displays
4.1.9.1
Operator Interface
The FMCS screen shall display the status of each pump, and the pump
frequency in Hertz. Another screen accessible from the main Heat Recovery
Water screen shall display run hours for each of the pumps.
The end-of-line pressure differential value shall be displayed continuously
along with the PID loop set-point value.
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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The PID loop set-point values shall be operator adjustable.
4.1.9.2
Logging / Trending
Trending available for instruments mentioned in table 4.1.3.
4.1.10 Switching between “Manual” and “Auto”
The FMCS operator can, at any time, manually start and stop a pump by firstly
clicking on the “Auto” / “Manual” icon on the FMCS monitor, to place the device into
“Manual” mode. The “Start” / “Stop” icon can then be chosen.
In “Manual” mode, frequency shall be able to be adjusted on the FMCS screen. The
minimum and maximum frequency shall correspond to the programmed VFD minimum
and maximum frequency. The motor frequency shall be shown in Hertz.
Switching a running piece of equipment from “Auto” to “Manual” and vice-versa will be
feasible without disruption to this piece of equipment or the overall control scheme.
The system will continue to control in “Auto” (Taking the benefit of the equipment
running in “Manual”)
4.1.11 “Local” control
All motors [including VFD controlled motors] can be switched into local control mode
at the MCC.
If the pump is selected to “Local” at the MCC / VFD, then the FMCS no longer has any
control over the device, which will come under the control of the electrical MCC.
When selected to “Local”, the device can be started and stopped only from “Start” /
“Stop” buttons on the MCC / VFD. Similarly, frequency adjustment can be done only
manually from raise / lower buttons on the VFD unit, the HRW end-of-line pressure
PID loop having no control over this frequency.
During this period FMCS shall be tracking the actual frequency of the locally operated
pump and adjusting the frequency reference such that once the drive is put to “Auto”
mode, the transfer is “bumpless” and VFD will not be subjected to a sudden increase
/decrease of frequency.
4.1.12 Set-points / Warnings / Alarms
A table of set points, warnings and alarms for all equipment and instruments is
included in Appendix 1.
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4.2
Sub-System 2 – HRW Heat Exchangers
4.2.1 General description
The Heat Recovery Water system utilizes four (4) plate heat exchangers to raise the
temperature of the Heat Recovery Water using waste heat from the chiller condenser
water system. The heat exchangers are piped in parallel with the flow being split
between them. The flow of condenser water through the plate heat exchangers is
controlled by a modulating valve fitted to each unit. Each of the modulating valve on
the heat exchangers is controlled using a single PID loop where the average
temperature of the heat recovery water supply temperature is calculated from the two
temperature transmitters on the two outgoing supply pipes.
4.2.2 Key equipment items
4.2.2.1 Heat Exchangers
Tag Descriptor
C10A1-01-C161D-HRW-HX-01 (Future)
C10A1-01-C161D-HRW-HX-02
C10A1-01-C161D-HRW-HX-03
C10A1-01-C171D-HRW-HX-04
4.2.2.2 Valves (ON/OFF)
Tag Descriptor
Function / Description
Heat Recovery System Heat Exchangers
Function / Description
C10A1-1-Cxxx-HRW-HX-01-FCV-01(Future) Cup Level 1 Heat Recovery Heat Exchanger 1
On/Off Valve
C10A1-1-Cxxx-HRW-HX-02-FCV-01
Cup Level 1 Heat Recovery Heat Exchanger 2
On/Off Valve
C10A1-1-Cxxx-HRW-HX-03-FCV-01
Cup Level 1 Heat Recovery Heat Exchanger 3
On/Off Valve
C10A1-1-Cxxx-HRW-HX-04-FCV-01
Cup Level 1 Heat Recovery Heat Exchanger 4
On/Off Valve
4.2.2.3 Valves (Modulating)
Tag Descriptor
C10A1-1-Cxxx-HRW-HX-01-TCV-01(Future)
C10A1-1-Cxxx-HRW-HX-02-TCV-01
C10A1-1-Cxxx-HRW-HX-03-TCV-01
C10A1-1-Cxxx-HRW-HX-04-TCV-01
C10A1-1-Cxxx-HRW-HDR-PCV-01
Function / Description
Cup Level 1 Heat Recovery Heat Exchanger 1
Temperature Control Valve
Cup Level 1 Heat Recovery Heat Exchanger 2
Temperature Control Valve
Cup Level 1 Heat Recovery Heat Exchanger 3
Temperature Control Valve
Cup Level 1 Heat Recovery Heat Exchanger 4
Temperature Control Valve
Cup Level 1 Heat Recovery By-pass Safety
Relief Pressure Control Valve
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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4.2.3 Key instruments
4.2.3.1 Temperature instruments
Tag Descriptor
C10A1-1-Cxxx-CW-HDR-01-TIT-01
C10A1-1-Cxxx-CW-HDR-02-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-02
C10A1-1-Cxxx-HRW-HDR-02-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-02
C10A1-1-Cxxx-HRW-HDR-02-TIT-01
C10A2-x-Cxxx-CW-HDR-01-TIT-01
C10A2-x-Cxxx-CW-HDR-02-TIT-01
C10A2-x-Cxxx-HRW-HDR-01-TIT-01
C10A2-x-Cxxx-HRW-HDR-02-TIT-01
C10A2-x-Cxxx-HRW-HDR-01-TIT-01
C10A2-x-Cxxx-HRW-HDR-02-TIT-01
Function / Description
CUPA1 LEVEL 1 Condenser water supply header
temperature from HRW
CUPA1 LEVEL 1 Condenser water return header
temperature to HRW
CUPA1 LEVEL 1 HRW Supply header
temperature to CUPA1-Control
CUPA1 LEVEL 1 HRW Supply header
temperature to CUPA1-Control
CUPA1 LEVEL 1 HRW Return header
temperature from CUPA1
CUPA1 LEVEL 1 HRW Supply header
temperature to FABA1-Control
CUPA1 LEVEL 1 HRW Supply header
temperature from FABA1-Control
CUPA1 LEVEL 1 HRW Return header
temperature from FABA1
CUPA2 LEVEL x Condenser water supply header
temperature from HRW
CUPA2 LEVEL x Condenser water return header
temperature to HRW
CUPA2 LEVEL x HRW Supply header
temperature to CUPA1-Control
CUPA2 LEVEL x HRW Return header
temperature from CUPA1
CUPA2 LEVEL x HRW Supply header
temperature to FABA2-Control
CUPA2 LEVEL x HRW Return header
temperature from FABA2
4.2.4 Start-Up
There is no start-up procedure for this sub-system.
4.2.5 Normal operation (“Auto”)
4.2.5.1 PID control
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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In “Auto” mode, the temperature control valves for both heat exchangers will
modulate to maintain temperature at the discharge header at set-point
(operator adjustable between 20.0 oC and 32.0 oC).
In the case of an analogue card failure, the Temperature Control Valves shall
“Fail at Last Operational Position”
In case of failure of the pneumatic supply, the Temperature Control Valves
shall stay last position.
4.2.5.2 Control logic
It shall be possible to isolate each Heat Recovery Heat Exchanger using the
solenoid operated Flow Control Valves. These valves shall be able to be
selected from the FMCS screen and manually set to “Open” or “Closed”.
4.2.6 Shut-Down
4.2.6.1
Normal Shut-Down
There is no shut-down procedure for this system.
4.2.6.2
Emergency Shut-Down
There is no Emergency shut-down procedure for this system.
4.2.7 Interlocks
There are no interlocks associated with this sub-system.
4.2.8 Interfaces with other systems
This system does not interface with any other systems.
4.2.9 FMCS parameter displays
4.2.9.1
Operator Interface
The Heat Recovery Heat Exchanger temperature control valve opening (0100%) shall be continuously displayed on the FMCS screen along with the
discharge header Temperature Set-Point and Present Value.
4.2.9.2
Logging / Trending
The Heat Recovery Water supply and return discharge header temperature
values shall be logged with date and time stamp. These values shall be
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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displayed on a historical trend graphs along with the respective set-point
value and valve-opening signal.
4.2.10 Switching between “Manual” and “Auto”
Selecting “Manual” mode in the FMCS, the operator shall be able to “stroke” the full
range (0-100%) of the Temperature Control Valve.
Switching a running piece of equipment from “Auto” to “Manual” and vice-versa will be
feasible without disruption to this piece of equipment or the overall control scheme.
The system will continue to control in “Auto” (Taking the benefit of the equipment
running in “Manual”)
4.2.11 “Local” control
There is no “Local” control of the Temperature Control Valves.
4.2.12 Set-points / Warnings / Alarms
A table of set-points, warnings and alarms for all equipment and instruments is
included in Appendix 1.
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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4.3
Sub-System 3 – Minimum Flow
4.3.1 General description
The Heat Recovery Water pump system has a Pressure Control Valve that operates
to provide a minimum flow at times of low demand.
4.3.2 Key equipment items
4.3.2.1 Valves (Modulating)
Tag Descriptor
C10A1-1-Cxxx-HRW-HDR-PCV-01
Function / Description
Cup Level 1 Heat Recovery By-pass Safety Relief
Pressure Control Valve
4.3.3 Key instruments
4.3.3.1 Pressure instruments
Tag Descriptor
Function / Description
F10A1-x-Fxxx-HRW-HDR-PDIT-01
FABA1-L-x HRW Diff. PR. 01 - By-pass Safety
Relief Pressure Control Valve
FABA1-L-x HRW Diff. PR. 02 - By-pass Safety
Relief Pressure Control Valve
FABA2-L-x HRW Diff. PR. 01 - By-pass Safety
Relief Pressure Control Valve
FABA2-L-x HRW Diff. PR. 02 - By-pass Safety
Relief Pressure Control Valve
CUPA2-L-x HRW Diff. PR. 01 - By-pass Safety
Relief Pressure Control Valve
CUPA2-L-x HRW Diff. PR. 02 - By-pass Safety
Relief Pressure Control Valve
F10A1-x-Fxxx-HRW-HDR-PDIT-02
F10A2-x-Fxxx-HRW-HDR-PDIT-01
F10A2-x-Fxxx-HRW-HDR-PDIT-02
C10A2-x-Fxxx-HRW-HDR-PDIT-01
C10A2-x-Fxxx-HRW-HDR-PDIT-01
4.3.4 Start-Up
There is no start-up procedure for this sub-system.
4.3.5 Normal operation (“Auto”)
4.3.5.1 PID control
The Heat Recovery Water Pressure Control Valve (PCV) is used to maintain
the end-of line differential pressure set point while maintaining a minimum
flow condition when there is low demand for Heat Recovery Water.
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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At times of low demand there will only be one Heat Recovery Water pump
operating at the minimum frequency (operator set on the FMCS) and the endof-line pressure differential is above the set-point, then the Heat Recovery
Pressure Control Valve shall open to bleed water from the discharge manifold
into the return pipe to achieve the end-of-line pressure differential and
maintain a minimum flow through the pump and heat exchangers.
The Pressure Control Valve shall only open when the pump is at minimum
frequency. The FMCS uses the end of line differential pressure value as PV to
a PID loop, the output of which is used to regulate the Pressure Control Valve
opening.
If demand for Heat Recovery Water increases, the Pressure Control Valve
shall progressively closed off until it is fully shut. When the valve is fully shut,
the Heat Recovery pump frequency can be increased to provide the required
end-of-line differential pressure.
4.3.5.2 Control logic
Refer to PID control above.
4.3.6 Shut-Down
4.3.6.1
Normal Shut-Down
There is no shut-down procedure for this system.
4.3.6.2
Emergency Shut-Down
There is no Emergency shut-down procedure for this system.
4.3.7 Interlocks
The Pressure Control Valve PID control shall be interlocked so that the Heat
Recovery pump shall not be able to be sped up until the Pressure Control Valve is
fully shut.
4.3.8 Interfaces with other systems
This system does not interface with any other systems.
4.3.9 FMCS parameter displays
4.3.9.1
Operator Interface
The FMCS screen shall continuously display the Pressure Control valve
percentage open.
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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4.3.9.2
Logging / Trending
No logging or trending is required.
4.3.10 Switching between “Manual” and “Auto”
In “Manual” mode, the operator shall be able to manually open the Pressure Control
Valve irrespective of the end-of-line pressure differential value.
4.3.11 “Local” control
There is no “Local” control of the Pressure Control Valve.
4.3.12 Set-points / Warnings / Alarms
A table of set-points, warnings and alarms for all equipment and instruments is
included in Appendix 1.
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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4.4
Sub-System 4 – HRW Heat-Load Calculations
4.4.1 General description
The heat-load on each side of the Heat Recovery heat exchangers (Condenser Water
and Heat Recovery Water) will be calculated and displayed on the FMCS.
The FMCS will calculate heat load demand for both sides of the Heat Recovery Water
heat exchangers using temperature transmitters in the Condenser and Heat Recovery
Water supply and return headers, together with the flow transmitters in the supply
pipes, in accordance with the formula
CW Heat-Load (kW) =
[(Q1 x  x CP x (T2-T1)] / 3,600
Where:
Q1

CP
T1
T2
is the HRW flow rate (header 1) in m3/hour
is the density of water (1,000 kg/m3)
is the constant where the value is 4.184 KJ/kgK
is the HRW return header temperature (header 1) (oC)
is the HRW discharge header temperature (header 2) (oC)
Overall HRW Heat-Load (kW) =
[(Q1 x  x CP x (T2-T1)) +
(Q2 x  x CP x (T4-T3))] /
3,600
Where:
Q1
Q2

CP
T1
T2
T3
T4
is the HRW flow rate (header 1) in m3/hour
is the HRW flow rate (header 2) in m3/hour
is the density of water (1,000 kg/m3)
is the constant where the value is 4.184 KJ/kgK
is the HRW return header temperature (header 2) (oC)
is the HRW supply header temperature (header 1) (oC)
is the HRW return header temperature (header 2) (oC)
is the HRW supply header temperature (header 1) (oC)
The flow meter is used for monitoring only and will be displayed on the FMCS
screens.
4.4.2 Key equipment items
Tag Descriptor
Function / Description
None
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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4.4.3 Key instruments
4.4.3.1 Flow instruments
Tag Descriptor
Function / Description
C10A1-1-Cxxx-CW-HDR-02-FIT-01
CUPA1-LEVEL 1 Condenser water return flowmeter from HRW
CUPA1-LEVEL 1 HRW Supply header flow-meter
to FabA1
FABA2-LEVEL x HRW Supply header flow-meter
to FabA2 Level x
CUPA2-LEVEL x HRW Supply header flow-meter
to CupA2 Level x
CUPA2-LEVEL x Condenser water return flowmeter from HRW
C10A1-1-Cxxx-HRW-HDR-01-FIT-01
F10A2-x-Fxxx-HRW-HDR-01-FIT-01
C10A2-x-Cxxx-HRW-HDR-01-FIT-01
C10A2-x-Cxxx-CW-HDR-02-FIT-01
4.4.3.2 Temperature instruments
Tag Descriptor
C10A1-1-Cxxx-CW-HDR-01-TIT-01
C10A1-1-Cxxx-CW-HDR-02-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-02
C10A1-1-Cxxx-HRW-HDR-02-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-02
C10A1-1-Cxxx-HRW-HDR-02-TIT-01
C10A2-x-Cxxx-CW-HDR-01-TIT-01
C10A2-x-Cxxx-CW-HDR-02-TIT-01
C10A2-x-Cxxx-HRW-HDR-01-TIT-01
C10A2-x-Cxxx-HRW-HDR-02-TIT-01
C10A2-x-Cxxx-HRW-HDR-01-TIT-01
C10A2-x-Cxxx-HRW-HDR-02-TIT-01
Function / Description
CUPA1 LEVEL 1 Condenser water supply header
temperature from HRW
CUPA1 LEVEL 1 Condenser water return header
temperature to HRW
CUPA1 LEVEL 1 HRW Supply header
temperature to CUPA1-Control
CUPA1 LEVEL 1 HRW Supply header
temperature to CUPA1-Control
CUPA1 LEVEL 1 HRW Return header
temperature from CUPA1
CUPA1 LEVEL 1 HRW Supply header
temperature to FABA1-Control
CUPA1 LEVEL 1 HRW Supply header
temperature from FABA1-Control
CUPA1 LEVEL 1 HRW Return header
temperature from FABA1
CUPA2 LEVEL x Condenser water supply header
temperature from HRW
CUPA2 LEVEL x Condenser water return header
temperature to HRW
CUPA2 LEVEL x HRW Supply header
temperature to CUPA1-Control
CUPA2 LEVEL x HRW Return header
temperature from CUPA1
CUPA2 LEVEL x HRW Supply header
temperature to FABA2-Control
CUPA2 LEVEL x HRW Return header
temperature from FABA2
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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4.4.4 Start-Up
There is no start-up procedure for this sub-system.
4.4.5 Normal operation (“Auto”)
4.4.5.1 PID control
There is no PID control for this system.
4.4.5.2 Control logic
There is no control logic for this system.
4.4.6 Shut-Down
4.4.6.1
Normal Shut-Down
There is no shut-down procedure for this system.
4.4.6.2
Emergency Shut-Down
There is no Emergency shut-down procedure for this system.
4.4.7 Interlocks
There are no interlocks associated with the various analogue signals and equipment
for this system.
4.4.8 Interfaces with other systems
This system does not interface with any other systems.
4.4.9 FMCS parameter displays
4.4.9.1
Operator Interface
The temperature values at both Condenser Water and Heat Recovery Water
supply and return headers shall be continuously displayed on the FMCS
screen.
The calculated instantaneous Heat-Load for each side of the heat exchangers
shall also be continuously displayed on the FMCS screen.
4.4.9.2
Logging / Trending
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HEAT RECOVERY WATER SYSTEM (PHASE A1)
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The Condenser Water heat load calculation and Heat Recovery water flowrates and Supply/Return temperatures shall be logged with date and time
stamp. The Condenser Water heat load calculation and Heat Recovery water
flow-rates and Supply/Return temperatures values shall be displayed on a
historical trend graph.
4.4.10 Switching between “Manual” and “Auto”
There is no “Manual” or “Auto” option available.
4.4.11 “Local” control
There is no “Local” control.
4.4.12 Set-points / Warnings / Alarms
Not applicable.
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HEAT RECOVERY WATER SYSTEM - SOO
APPENDIX 1: Set points / Warnings / Alarms
Pressure Instruments
Tag Number
Description
C10A1-1-Cxxxx-HRW-HDR01-PIT-01
CUPA1-L-1 HRW SUPPLY HDR.
PR.- Monitoring
CUPA1-L-1 HRW RETURN
HDR. PR.- Monitoring
FABA1-L-x HRW Diff. PR. 01 Pump Control
FABA1-L-x HRW Diff. PR. 02 Pump Control
FABA2-L-x HRW Diff. PR. 01 Pump Control
FABA2-L-x HRW Diff. PR. 02 Pump Control
CUPA2-L-x HRW Diff. PR. 01 Pump Control
CUPA2-L-x HRW Diff. PR. 02 Pump Control
C10A1-1-Cxxxx-HRW-HDR02-PIT-01
F10A1-x-Fxxx-HRW-HDR-PDIT-01
F10A1-x-Fxxx-HRW-HDR-PDIT-02
F10A2-x-Fxxx-HRW-HDR-PDIT-01
F10A2-x-Fxxx-HRW-HDR-PDIT-02
C10A2-x-Fxxx-HRW-HDR-PDIT-01
C10A2-x-Fxxx-HRW-HDR-PDIT-01
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Units
Set-point
Set-point
(NOTE 1)
Low-Low
Value
Action
Warning and Alarm switching points
Low
High
Value
Action
Value
Action
High-High
Value
Action
Note 2
N/A
Note 2
Alarm
Note 2
Warning
Note 2
Warning
Note 2
Alarm
Note 2
N/A
Note 2
Alarm
Note 2
Warning
Note 2
Warning
Note 2
Alarm
Note 2
N/A
Note 2
Alarm
Note 2
Warning
Note 2
Warning
Note 2
Alarm
Note 2
N/A
Note 2
Alarm
Note 2
Warning
Note 2
Warning
Note 2
Alarm
Note 2
N/A
Note 2
Alarm
Note 2
Warning
Note 2
Warning
Note 2
Alarm
Note 2
N/A
Note 2
Alarm
Note 2
Warning
Note 2
Warning
Note 2
Alarm
Note 2
N/A
Note 2
Alarm
Note 2
Warning
Note 2
Warning
Note 2
Alarm
Note 2
N/A
Note 2
Alarm
Note 2
Warning
Note 2
Warning
Note 2
Alarm
Bar
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HEAT RECOVERY WATER SYSTEM - SOO
Temperature Instruments
Tag Number
C10A1-1-Cxxx-CW-HDR-01-TIT-01
C10A1-1-Cxxx-CW-HDR-02-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-02
C10A1-1-Cxxx-HRW-HDR-02-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-01
C10A1-1-Cxxx-HRW-HDR-01-TIT-02
C10A1-1-Cxxx-HRW-HDR-02-TIT-01
C10A2-x-Cxxx-CW-HDR-01-TIT-01
C10A2-x-Cxxx-CW-HDR-02-TIT-01
C10A2-x-Cxxx-HRW-HDR-01-TIT-01
Description
CUPA1 LEVEL 1 Condenser
water supply header temperature
from HRW
CUPA1 LEVEL 1 Condenser
water return header temperature
to HRW
CUPA1 LEVEL 1 HRW Supply
header temperature to CUPA1Control
CUPA1 LEVEL 1 HRW Supply
header temperature to CUPA1Control
CUPA1 LEVEL 1 HRW Return
header temperature from CUPA1
CUPA1 LEVEL 1 HRW Supply
header temperature to FABA1Control
CUPA1 LEVEL 1 HRW Supply
header temperature from
FABA1-Control
CUPA1 LEVEL 1 HRW Return
header temperature from FABA1
CUPA2 LEVEL x Condenser
water supply header temperature
from HRW
CUPA2 LEVEL x Condenser
water return header temperature
to HRW
CUPA2 LEVEL x HRW Supply
header temperature to CUPA1Control
Units
°C
Set-point
Set-point
(NOTE 1)
Low-Low
Value
Action
Warning and Alarm switching points
Low
High
Value
Action
Value
Action
High-High
Value
Action
35
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
20
N/A
N/A
Alarm
19
Warning
N/A
Warning
N/A
Alarm
35
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
35
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
20
N/A
N/A
Alarm
19
Warning
N/A
Warning
N/A
Alarm
35
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
35
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
20
N/A
N/A
Alarm
19
Warning
N/A
Warning
N/A
Alarm
35
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
20
N/A
N/A
Alarm
19
Warning
N/A
Warning
N/A
Alarm
35
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
General Note: Set-points and values are nominal and may be altered either during commissioning or alternatively by operator adjustment via FMCS (see notes below). Set points value to be discussed
and determined during SAT.
Note1: Set-point 2 is only required where a dead-band is used.
Note2: Value to be determined during commissioning.
Note3: Value to be operator adjustable via FMCS.
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HEAT RECOVERY WATER SYSTEM - SOO
APPENDIX 2: P&ID’s
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