VOC System Control Philosophy Process Description PDF

VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION AODOCS # P0-SHW-39-P2-001 Project Title VOC Area-Veolia Central Utilities And Waste Valorization Plant Rev....

VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION AODOCS # P0-SHW-39-P2-001 Project Title VOC Area-Veolia Central Utilities And Waste Valorization Plant Rev. 04 Contractor Power Energy Gulf for Environmental Services Company Date 21-Jul-2024 VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION Revision Date Prepared by Reviewed & Approved by Remarks 04 21-Jul-24 Anirudh AN Page 1 of 9  VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION AODOCS # P0-SHW-39-P2-001 Project Title VOC Area-Veolia Central Utilities And Waste Valorization Plant Rev. 04 Contractor Power Energy Gulf for Environmental Services Company Date 21-Jul-2024 1) SCOPE: It covers all the VOC system control philosophy process description. 2) PURPOSE: The activities to be performed in order to make sure the safe Control of the unit. 3) REFERENCE DRAWING: P0-SHW-39-P6-400-01 - PIPING & INSTRUMENTATION DRAWING FOR VOC SYSTEM 4) TERMINOLOGIES: Project: VOC Area-Veolia Central Utilities and Waste Valorization Plant Contractor: PE- Power Energy company Owner/Company: Veolia Middle East Company. VOC: Volatile Organic Components 5) OPERATION AND CONTROL PHILOSOPHY: VOC system is used to treat the VOC from the building and tank farm area in the project. There are two separate streams in this process package. 1. Building Area VOC 2. Tank Farm Area VOC 1. Building Area VOC: 1.1. Process Description: There are two carbon polisher tanks (39-HAA-005 & 006) of 60 m3 volume available in the building area VOC treatment stream, and the VOC enters to the Polishers through common duct from building area to Inlet Butterfly Valves (VM-057, 058, 063 and 064) and passes through the activated carbon bed for treatment and clean On Spec Air will exit from the vent ducts VM-059, 060, 061 and 062 and VM-065, 066, 067 and 068 on the top of the two carbon polisher tanks respectively. The purpose of having four ducts in each polisher tank is to regulate the flow. The drain valves VM-69 to VM-80 and VM-106 to VM-110 are provided to drain off any condensate coming into the building area VOC treatment unit. The drain valves are closed under normal operation and are opened manually in case of a high pressure drop alarm (~25 mbar) 1.2. Control Philosophy: The following instrumentation equipment are used in the control & instrumentation system (CIS) for Building area VOC system. Page 2 of 9  VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION AODOCS # P0-SHW-39-P2-001 Project Title VOC Area-Veolia Central Utilities And Waste Valorization Plant Rev. 04 Contractor Power Energy Gulf for Environmental Services Company Date 21-Jul-2024 Equipment ID location 39-PDIT-001 39-HAA-005 Pressure differential indicator transmitter 39-PDIT-002 39-HAA-006 Temperature Gauge (localized) 39-TG-001 39-HAA-006 Temperature Gauge (localized) 39-TG-002 39-HAA-005 VOC Analyzer 39-AT-001 39-HAA-006 The control philosophy is divided into two levels: 1.2.1 Normal process control system: The pressure drop across the activated carbon polisher tanks is monitored and transmitted by the differential pressure indicator transmitters (39-PDIT-001 & 39-PDIT-002) on each tank respectively. These are connected to the VOC package control system which is installed in the portable cabin provided in the package unit. During normal operation, the pressure drop value should be less than 10 inches of WC (~25 mbar) which is set as the high DP alarm set point in the HMI integrated with the PLC. The localized temperature gauge is provided to monitor the temperature on the inside of the carbon polisher tanks. 1.2.2 Emergency process control system: a) High pressure drop alarm: If the pressure drop across the activated carbon polisher tanks is greater than or equal to 10 inches of WC (~25 mbar), an alarm alerts the operator which would require the operator to:  Open the drain valves VM-75 to VM-80 and VM-110, and VM-111 to drain off any condensate (if present) and check if pressure drop reduces and the alarm goes off. If not, then:  isolate the tank and change the activated carbon and replace it with fresh activated carbon. b) High temperature monitoring system: If the temperature inside the carbon polisher tanks exceeds 100 o C, the system is shut down until the temperature is reduced to less than 100 o C. The temperature inside the carbon polisher tanks 39-HAA- 005 & 006 are measured through localized temperature gauges in the carbon polisher tanks. Note: 160oC is the auto ignition temperature of carbon black. c) High VOC monitoring system: If the VOC concentration from the outlet of the carbon polisher tanks is greater than 0.24 ppm, it is advisable to replace the carbon bed with fresh activated carbon. The VOC concentration from the outlet of the carbon polisher tanks can be measure by the analyzer provided at the outlet of the carbon polisher tanks. Page 3 of 9  VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION AODOCS # P0-SHW-39-P2-001 Project Title VOC Area-Veolia Central Utilities And Waste Valorization Plant Rev. 04 Contractor Power Energy Gulf for Environmental Services Company Date 21-Jul-2024 2. TANK FARM AREA VOC: 2.1. Process Description: In tank farm area, the gas (VOC laden air) passes through flame arrestor (39-SPF-201) and then it passes through inline Gas Pipe Cooler (39-EL-201) and then it passes through the knock out tank (39-RD-201) to remove any condensate from the bottom of tank. From the knock out tank, the Gas passes through the blowers (39-BC-001 / 39-BC-002) and then discharges to the VOC Solvent Scrubber (39-WBA-001), where the gas undergoes treatment with biodiesel. There is Flame arrestor (39-SPF-002) installed at Gas outlet of Scrubber and gas will pass through it before entering 1st stage of Carbon Polishers (39-HAA-001 & 39-HA-002) which are installed in parallel and then the outlet of 1st stage carbon polisher will be the inlet of 2nd stage carbon polishers (39-HAA-003 & 39-HA-004). The final Treated gas from outlet of 2nd stage polisher will pass through flame arrestor (39-SPF-003) before going to Atmospheric vent. Air operated Blowdown pump (39-PVP-001) which is blowdown pump is connected to the common drain of all the equipment. VOC Scrubber Solvent pump (39-PVP-002), is an air operated pump. The pump discharge is connected to the VOC Solvent Scrubber (39-WBA-001) through the inline scrubber solvent cooler (39-EL-202) to cool down the surfactant temperature to the required range, the purpose of the solvent pump is to recirculate the solvent in the scrubber tank. 2.2. Control Philosophy: The control philosophy is divided into each equipment which are integrated together as a whole providing a safe, reliable and continuous operation with minimal intervention. 2.2.1. Blower and Condensate Knockout drum: Blowers 39-BC-001/002 are designed to operate in manual mode as one duty and one stand-by, in automatic operation of the blower, it runs on the timer control from the PLC system, and the time interval can be set from the HMI. The following instrumentation equipment are used in the control and instrumentation system for Condensate knockout drum unit in the Tank farm VOC area. Equipment ID location Level Indicator transmitter 39-LIT-001 39-RD-201 Pneumatic operated Control valve 39-VC-001 39-BC-001/002 - Blower air inlet line Pneumatic operated ON/OFF Valve 39-VA-001 39-BC-001/002 - Blower Common Discharge line 39-PIT-008 39-RD-201 Pressure indicator transmitter 39-PIT-009 39-BC-001/002 - Blower Suction line 39-PIT-010 39-BC-001/002 - Blower Common Discharge line Temperature indicator transmitter 39-TIT-001 39-BC-001/002 - Blower Common Discharge line Page 4 of 9  VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION AODOCS # P0-SHW-39-P2-001 Project Title VOC Area-Veolia Central Utilities And Waste Valorization Plant Rev. 04 Contractor Power Energy Gulf for Environmental Services Company Date 21-Jul-2024 The control philosophy is divided into the following: 2.2.1.1. Normal process control system: A. Level: The level of condensate in the condensate knockout drum is measured using the level indicator transmitter 39-LIT-001. During normal operation, 30% level in the condensate knockout drum which is therefore set as high-level alarm point in the HMI integrated with the PLC. B. Pneumatic control valve: During normal operation, the pneumatic control valve 39-VA- 001 is kept open (ON) (VEOLIA Incinerator not under operation) to line up the VOC to the scrubber. The pneumatic valve 39-VC-001 is controlled based on the suction pressure of the blower which is given as set point to the HMI which is integrated with the PLC. 10 inches of WC is given as set point for the control valve 39-VC-001. C. Pressure Indicator Transmitter: Pressure across the blower suction and discharge line is monitored using the pressure indicator transmitter 39-PIT-009 and 39-PIT-010 respectively. During normal operation, the pressure drop across the whole tank farm area VOC system is 40 - 50 inches of WC (~100 - 125 mbar). 60 inches of WC (~150 mbar) is set as high pressure drop alarm in the HMI integrated with the PLC. D. Temperature indicator transmitter: The temperature of the air at the blower discharge line is monitored using the temperature indicator transmitter 39-TIT-001. This is given as signal to the inline air cooler 39-EL-201. During normal operation, the temperature of air at the blower discharge is less than 60oC which is given as high temperature alarm set point (signal) in the HMI integrated with the PLC. 2.2.1.2. Emergency / shutdown process control system: A. Level: If the level of condensate in the condensate knockout drum is greater than 30 %, the blow down pump 39-PVP-001 is switched on. This is done by giving the level as the signal for the solenoid valve VE-001 in which 30 % level is given as set point from the HMI which is integrated with the PLC. This indicates the operator to manually open the drain valve of the condensate knockout drum 39-RD-201. B. Pneumatic control valve: Low or no flow from tank farm: (VEOLIA – Incinerator – under operation): In the event of low or no flow from the tank farm, the suction pressure across the blower goes below 25 inches of WC (~62.5 mbar), this is increased by controlling the pneumatic Operated Control valve 39-VC-001 which increases the flow and satisfies the volumetric capacity of the blower by intake of Atmospheric Air. The pneumatic operated control valve is a fail to open valve whose positioner is adjusted based on the set point of the pressure at the suction side of the blower (10 inches of WC (~25 mbar)). Page 5 of 9  VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION AODOCS # P0-SHW-39-P2-001 Project Title VOC Area-Veolia Central Utilities And Waste Valorization Plant Rev. 04 Contractor Power Energy Gulf for Environmental Services Company Date 21-Jul-2024 The valve 39-VA-001 is ON/OFF Type Pneumatic operated to open 3 minutes per hour of operation which is given as set point in the timer at the HMI which is integrated with the PLC. Below will be Logic for ON/OFF Valve.  WHEN INCINERATION ON (DCS SIGNAL TO PLC) o 39-VA-001 CLOSE. OPEN 3 MIN PER HOUR o 80-VA-001 OPEN o 80-VA-002 OPEN  WHEN INCINERATION OFF (DCS SIGNAL TO PLC) o 39-VA-001 OPEN o 80-VA-001 CLOSE o 80-VA-002 CLOSE C. Pressure Indicator Transmitter: If the pressure drop across the entire tank farm area VOC treatment system reached 60 inches of WC due to increase in the Scrubber solution level or carbon exhaustion, it gives an alarm to the operator after which carbon media should be replaced or the scrubber solution level has to be reduced for normal operation. D. Temperature monitoring: If the temperature of air at the blower discharge is greater than 55oC, the inline air cooler 39-EL-201 starts automatically in order to reduce the temperature up to 50oC after which the inline gas cooler 39-EL-201 is stopped automatically. If the temperature of air at the blower discharge is greater than 60oC due to the malfunction of the inline air cooler 39-EL-201, an alarm is raised after which the blower trips automatically. 2.2.2. VOC Solvent Scrubber and Carbon polisher vessel: The following instrumentation equipment was used for the control and instrumentation system of the VOC solvent scrubber and carbon polisher vessel system in the tank farm area. Equipment ID location LS-002 39-WBA-001 Level switch LS-003 39-WBA-001 PDIT-003 39-HAA-001 PDIT-004 39-HAA-002 Pressure differential indicator transmitter PDIT-005 39-HAA-003 PDIT-006 39-HAA-004 TIT-002 39-PVP-002 - Pump discharge line Temperature indicator transmitter TIT-003 39-PVP-002 - Pump discharge line Page 6 of 9  VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION AODOCS # P0-SHW-39-P2-001 Project Title VOC Area-Veolia Central Utilities And Waste Valorization Plant Rev. 04 Contractor Power Energy Gulf for Environmental Services Company Date 21-Jul-2024 The control philosophy is divided into the following: 2.2.2.1. Normal process control system: A. Level: The level of the scrubber solvent inside the VOC solvent scrubber is monitored using the level switch LS-001 (high) and LS-002 (low). During the normal operation, the solvent level inside the VOC solvent scrubber is maintained at 15 - 20 %. The level can also be observed physically using the level hose provided in the VOC solvent scrubber. B. Solvent Recirculation System: The average flow rate of the recirculation pump for the scrubber solvent is 0.2m3/min. Therefore, the average time it takes to fill the scrubber 1. 0 – 15 %: 16.2 minutes 2. 15 – 20 %: (Normal operational level): 5.4 minutes Therefore, the total time required to fill the solvent initially is about 22 minutes and replenishment from the lower level (15 %) takes about 6 minutes. The recirculation pump 39-PVP-002 will be automatically switched OFF if both blower(s) 39-BC-001 & 002 is OFF. C. Pressure Drop monitoring (Carbon Polisher Vessel): The pressure drop across the carbon polisher vessels 39-HAA-001/002/003/004 is monitored using the pressure differential indicator transmitter PDIT-003/004/005/006 respectively. During normal operation, the pressure drop across the carbon polisher vessels is maintained at 10 – 25 inches of WC. 25 inches of WC is set as high pressure drop alarm point to the HMI integrated with the PLC. D. Temperature Monitoring: The temperature of scrubber solvent is monitored using the temperature indicator transmitter TIT-002 and TIT-003. This is given as signal to the inline scrubber solvent cooler 39-EL-202. During normal operation, the temperature of scrubber solvent must be less than 60oC. 60oC is given as high temperature set point alarm to the HMI integrated with the PLC. The inline scrubber solvent cooler 39-EL-202 would be OFF under normal operation. (if the temperature is less than 60oC). 2.2.2.2. Emergency / shutdown process control system: A. Level: If the level of the scrubber solvent is greater than 25 %, a high-level alarm alerts the operator to drain the scrubber solvent (manually) and reduce the level back to 15 – 20%. The solenoid valve (VE-001) will be open till the level is 25 % after which the solenoid valve has to be manually bypassed by opening the valve VM-048 to reduce the solvent level further down from 25 % to maintain the level between 15 – 20 %. If the level of the scrubber solvent is less than 15%, a low-level alarm alerts the operator to increase the level by filling the scrubber with fresh scrubber solvent. This is done by opening the valve VM-043 and closing the valve VM-029. The operator has to ensure that surfactant tank IBC HDPE tote is filled with scrubber solvent before lining up of the valve. B. High pressure drop alarm: If the pressure drop across the carbon polisher vessels is greater than 25 inches of WC (~62.5 mbar), a high pressure drop alarm is raised alerting the operator to replace the carbon bed with fresh carbon. Page 7 of 9  VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION AODOCS # P0-SHW-39-P2-001 Project Title VOC Area-Veolia Central Utilities And Waste Valorization Plant Rev. 04 Contractor Power Energy Gulf for Environmental Services Company Date 21-Jul-2024 C. Temperature monitoring: If the temperature of the scrubber solvent is greater than 55oC, this automatically switches on the inline scrubber solvent cooler 39-EL-202 based on the signal from the temperature indicator transmitter TIT-002. This reduces the temperature of the solvent up to 50oC after which the inline cooler 39-EL-202 is switched off automatically and the temperature can be measured from the temperature indicator transmitter TIT-003. Page 8 of 9  VOC SYSTEM CONTROL PHILOSOPHY PROCESS DESCRIPTION AODOCS # P0-SHW-39-P2-001 Project Title VOC Area-Veolia Central Utilities And Waste Valorization Plant Rev. 00 Contractor Power Energy Gulf for Environmental Services Company Date 12-10-2022 PIPING & INSTRUMENTATION DIAGRAM Page 9 of 9