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Level Calculation

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EGD PHASE-2 ECR REVIEW
CHANDRA ASRI
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
DETAIL DESIGN
PS-2 has experienced Un-Planned Shutdown due to Spurious Trip Signal from Transmitter that
lead to SM production loss. To prevent the spurious trip/ false trip, SMI has road map to increase
plant reliability of PS-1 and PS-2 by implement 2 out of 3 (2oo3) interlock configuration. From P1
study, there are 11 instrument tag no will be install during TAM PS2. From 11 tag no, 9 tag no is
flow transmitter and the 2 another tag no is level transmitter.
For flow transmitter, Differential pressure transmitter (DPT) is proposed. While for level
transmitter, Remote diaphragm seal differential pressure transmitter will be used due to material
properties that easily polymerize.
The following are detail designs for each transmitter:
a. 2FT-2051B ~ 2FT-2058B
New transmitter will be installed using existing orifice. Existing orifice is flange tap orifice. New
tapping point will be provided in existing nipple, so from one nipple will be separate to two
transmitter tapping point follow drawing below. Red line is new tapping point.
Figure 1 Illustration of 2FT-2051B ~ 2FT-2058B
Differential range for new transmitter will follow existing range (0 – 2500 mmH2O) with meter
range 0 – 100000 Kg/h.
b. 2FT-3001B
New transmitter will be installed using existing orifice. Existing orifice is D-D/2 tap orifice. New
tapping point will be installed in D-D/2 tap of orifice, but with opposite direction from the existing
tapping point location follow drawing below. Red line is new tapping point.
Page 1 of 5
ECR No
: 513-19-030
Equipment : 2FB-503/507/508
Plant / Area : SMI
Prepared by : Ardinda
Checked by : F.A Gunawan
Approved by : Arief Dharmawan
Signed:
Signed:
Signed:
EGD PHASE-2 ECR REVIEW
CHANDRA ASRI
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
Figure 2 Illustration of 2FT-3001B
Differential range for new transmitter will follow existing range (0 – 2500 mmH2O) with meter
range 0 – 50000 Kg/h.
c.
2LT-3638B & 2LT-3638C
Base on phase 1 study, in 2FA-308 will be installed additional 1 level transmitter and
replacement existing level switch to be level transmitter.
Figure 3 Illustration 2FA-308
Page 2 of 5
ECR No
: 513-19-030
Equipment : 2FB-503/507/508
Plant / Area : SMI
Prepared by : Ardinda
Checked by : F.A Gunawan
Approved by : Arief Dharmawan
Signed:
Signed:
Signed:
EGD PHASE-2 ECR REVIEW
CHANDRA ASRI
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
Drawing above, is GA drawing of 2FA-308. New level transmitter will be installed with c-c length
800 mm, while existing level switch that will be replaced with new level transmitter has 340 mm
c-c length.
C.1 Replacement Existing Level Switch
For replacement existing level switch, calculation for new level transmitter follow drawing below:
Figure 4 Illustration Replacement Existing Level Switch
π‘ˆπ‘…π‘‰ = 𝐻𝑠 − 𝐿𝑠
= {(𝑆𝐺𝑓 π‘₯ (𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž)) + π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯(π‘‡π‘π‘Žπ‘π‘–π‘™π‘™π‘Žπ‘Ÿπ‘¦)}
− {π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯((𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž) + π‘‡π‘π‘Žπ‘π‘–π‘™π‘™π‘Žπ‘Ÿπ‘¦}
= {(𝑆𝐺𝑓 π‘₯ (𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž)) − (π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯(𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž))}
= {(0.82π‘₯340) − (0.934π‘₯340)} π‘šπ‘šπ»2 𝑂
= 278.8 − 317.56 π‘šπ‘šπ»2 𝑂
= −38.76 π‘šπ‘šπ»2 𝑂
𝐿𝑅𝑉 = 𝐻𝑠 − 𝐿𝑠
= {(π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯(π‘‡π‘π‘Žπ‘π‘–π‘™π‘™π‘Žπ‘Ÿπ‘¦)} − {π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯((𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž) + π‘‡π‘π‘Žπ‘π‘–π‘™π‘™π‘Žπ‘Ÿπ‘¦)}
= {−π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯(𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž)}
= {−0.934 π‘₯ 340}
= −317.56 π‘šπ‘šπ»2 𝑂
With
π‘‡πΆπ‘Žπ‘π‘–π‘™π‘™π‘Žπ‘Ÿπ‘¦
𝑆𝐺𝑓
π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘›
= height of capillary
= specific gravity of fluid inside the tank
= specific gravity of silicon oil
C.2 New Level Transmitter
Page 3 of 5
ECR No
: 513-19-030
Equipment : 2FB-503/507/508
Plant / Area : SMI
Prepared by : Ardinda
Checked by : F.A Gunawan
Approved by : Arief Dharmawan
Signed:
Signed:
Signed:
EGD PHASE-2 ECR REVIEW
CHANDRA ASRI
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
Calculation for new level transmitter follow drawing below:
Figure 5 Illustration New Level Transmitter
π‘ˆπ‘…π‘‰ = 𝐻𝑠 − 𝐿𝑠
= {(𝑆𝐺𝑓 π‘₯ (𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž)) + π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯(π‘‡π‘π‘Žπ‘π‘–π‘™π‘™π‘Žπ‘Ÿπ‘¦)}
− {π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯((𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž) + π‘‡π‘π‘Žπ‘π‘–π‘™π‘™π‘Žπ‘Ÿπ‘¦}
= {(𝑆𝐺𝑓 π‘₯ (𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž)) − (π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯(𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž))}
= {(0.82π‘₯800) − (0.934π‘₯800)} π‘šπ‘šπ»2 𝑂
= 656 − 747.2 π‘šπ‘šπ»2 𝑂
= −91.2 π‘šπ‘šπ»2 𝑂
𝐿𝑅𝑉 = 𝐻𝑠 − 𝐿𝑠
= {(π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯(π‘‡π‘π‘Žπ‘π‘–π‘™π‘™π‘Žπ‘Ÿπ‘¦)} − {π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯((𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž) + π‘‡π‘π‘Žπ‘π‘–π‘™π‘™π‘Žπ‘Ÿπ‘¦)}
= {−π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘› π‘₯(𝑐 − 𝑐 π‘™π‘’π‘›π‘”π‘‘β„Ž)}
= {−0.934 π‘₯ 800}
= −747.2 π‘šπ‘šπ»2 𝑂
With
π‘‡πΆπ‘Žπ‘π‘–π‘™π‘™π‘Žπ‘Ÿπ‘¦
𝑆𝐺𝑓
π‘†πΊπ‘ π‘–π‘™π‘–π‘π‘œπ‘›
= height of capillary
= specific gravity of fluid inside the tank
= specific gravity of silicon oil
From Figure 3 Illustration 2FA-308, new level transmitter and existing tapping point of level switch
have different elevation for 0% level and 100% level. To accommodate this situation, need range
modification of level transmitter that replace existing level switch in DCS.
Page 4 of 5
ECR No
: 513-19-030
Equipment : 2FB-503/507/508
Plant / Area : SMI
Prepared by : Ardinda
Checked by : F.A Gunawan
Approved by : Arief Dharmawan
Signed:
Signed:
Signed:
EGD PHASE-2 ECR REVIEW
CHANDRA ASRI
Jl. Raya Anyer Km. 123 Ciwandan , Cilegon.
Banten 42447, Indonesia
Figure 6 Illustration Elevation New Level Transmitter
From drawing above,
205
0% of level transmitter that replace existing level switch = 800 x 100%
= 25.625% (range of level transmitter with c-c 800 mm)
100% of level transmitter that replace existing level switch =
=
205+340
x
800
545
800
100%
x 100%
= 68.125% (range of level transmitter with c-c 800 mm)
So, DCS range of level transmitter that replace existing level switch will be set from 25.625% to
68.125%. If level below 25.625%, two another transmitter will appear actual level value, while level
transmitter that replace existing level switch will always show 25.625%. While if level more than
68.125%, two another transmitter will appear actual level value, while level transmitter that replace
existing level switch will always show 68.125%.
Page 5 of 5
ECR No
: 513-19-030
Equipment : 2FB-503/507/508
Plant / Area : SMI
Prepared by : Ardinda
Checked by : F.A Gunawan
Approved by : Arief Dharmawan
Signed:
Signed:
Signed:
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