Functional

Description
Package Boiler #2 PLC
Functional Description
 Functional Description – Package Boiler#2 PLC

REVISION LOG

Revision Author / Approved Date Issued To Comments

Editor
0 IM 27 April Thermal Operations, For Reviewed
2010 Maintenance,
Engineering

54750921.doc Page 2 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

TABLE OF CONTENTS

REVISION LOG 2
1. INTRODUCTION..........................................................................................................................5
1.1. Project Overview................................................................................................................5
1.2. Scope.................................................................................................................................5
1.3. Purpose of Functional Specification...................................................................................5
1.4. Abbreviations and Acronyms..............................................................................................6
1.5. Glossary and Definitions.....................................................................................................6
2. PROJECT INFORMATION..........................................................................................................6
3. PURPOSE OF SYSTEM..............................................................................................................7
3.1. General...............................................................................................................................7
3.2. Objectives...........................................................................................................................7
4. PB2 SYSTEM PLC LOGIC.........................................................................................................8
4.1. User-Defined Tags.............................................................................................................8
4.1.1. Analogue_Alarm............................................................................................................8
4.1.2. Digital_Alarm.................................................................................................................8
4.2. MainTask............................................................................................................................9
4.3. Logics Description..............................................................................................................9
4.3.1. Burner System...............................................................................................................9
4.3.1.1. _01_Communication............................................................................................9
4.3.1.2. _02_Signals.........................................................................................................9
4.3.1.3. _03_AirOilParameter............................................................................................9
4.3.1.4. _04_PIC510A7G1_SteamPress........................................................................10
4.3.1.5. _05_FIC510A7G2_AirFlow................................................................................10
4.3.1.6. _06_FIC510A13F_OilFlow.................................................................................10
4.3.1.7. _07_LIC510W2_WaterLvl..................................................................................10
4.3.1.8. _08_PIC510A9G2_AtomSteam.........................................................................10
4.3.1.9. _09_SIC510A5G1_Salinity................................................................................11
4.3.1.10. _10_AIC510K1_0xygenTrim..............................................................................11
4.3.1.11. _11_Sequence & _12_SequenceCtrl.................................................................11
4.3.1.12. _13_Start............................................................................................................13
4.3.1.13. _14_Alarms........................................................................................................13
4.3.1.14. _15_BoilerOut....................................................................................................13
4.3.1.15. _16_OilTotalizer & _17_SteamTotalizer............................................................13
4.3.2. Program : Analogue.....................................................................................................14
4.3.3. Program: BOP (Balance Of Plant)...............................................................................14
4.3.3.1. Communication..................................................................................................14
4.3.3.2. Oil Valves...........................................................................................................15
4.3.3.3. FW Pumps:........................................................................................................15
4.3.3.4. Fuel Oil Pump....................................................................................................15
4.3.3.5. Combustion Air Fan...........................................................................................15
4.3.3.6. _06_PIC_510A5G2_FOPress............................................................................15
4.3.3.7. _07_TIC_510G28_FOTemp..............................................................................16
4.3.3.8. _08_LIC_510M137_DeaLvl...............................................................................16
4.3.3.9. _11_Alarms........................................................................................................17
4.3.4. PID LOOP Program Folder..........................................................................................17
5. APPENDIX.................................................................................................................................18
5.1. Functional Block Diagram.................................................................................................18
5.2. Steam Pressure PID Block Diagram................................................................................18
5.2.1. Air Flow PID Block Diagram........................................................................................19
54750921.doc Page 3 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

5.2.2. Oil Flow Control PID....................................................................................................20

5.2.3. Steam Drum Water Level PID.....................................................................................21
5.2.4. Atomizing Steam Pressure PID..................................................................................22
5.2.5. Salinity / Blow Down PID.............................................................................................23
5.2.6. Oxygen Trim PID.........................................................................................................23
6. SEQUENCE FLOW CHART......................................................................................................24
6.1. Start Sequence:................................................................................................................24
6.2. Stop Sequence.................................................................................................................25

54750921.doc Page 4 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

1. INTRODUCTION

1.1. Project Overview

The PLC of PB#2 was built with SLC controller and running since 2002 to produce saturated steam with
capacity 30 T/Hr. To standardized all the controller at Utilities to be Logix family based then project PLC
replacement initiated.
The old PLC using SLC 5/04 with 2 Processors. 1 Processor to control the burner and one Processor to
control the Auxiliary system.

This system using platform Logix Family with Control Logix PLC and RsView Se.

1.2. Scope
This Functional Specification describes the functional requirements for the project. It includes the following
supplementary documents that define requirements applicable to system components;

Document Ref. Title

NA NA

1.3. Purpose of Functional Specification

This functional specification is intended to provide a ‘plain English’ description of the system and the
functions performed. It should be easily understood by people more familiar with the plant than with the
details of a modern control system.

54750921.doc Page 5 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

1.4. Abbreviations and Acronyms

Abbreviations and acronyms used in this document are noted below.

CV Control Variable
SP Set Point
PV Process Variable
HMI Human Machine Interface. Also known as operator interface.
I/O Inputs and Outputs
PC Computer
PLC Programmable Logic Controller
RA Rockwell Automation
OIT Operator Interface Terminal. Also known as operator interface.
PB2 Package Boiler #2
FWP Feed Water Pump
FOP Fuel oil Pump
HFO High Sulphur Fuel Oil
LDO Light Diesel Oil

1.5. Glossary and Definitions

Alarm: Advice to the operator of a critical system or process fault. The control system may
take remedial action.
Warning: Advice to the operator of a system or process fault or incomplete operator input.

2. PROJECT INFORMATION
Control systems cannot be developed in isolation from the other plant and equipment on the site. The
control system design should be based on the same information as used by other engineering disciplines
when designing their contribution to the project. This information for this project is as follows;

Document Reference Description

54750921.doc Page 6 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

3. PURPOSE OF SYSTEM

3.1. General
The Package Boiler #2 PLC system purpose is to control the Boiler system include the burner and the
auxiliary system such as Boiler Feed Pump, Boiler Fuel Oil Pump. Also to Get Status and Alarm of Boiler.

3.2. Objectives

 Control Steam Pressure PID

 Control Air Flow for Burner
 Control Oil Flow for Burner
 Control Steam Drum Water Level
 Control Atomizing Steam for Burning Process
 Control Water Salinity
 Control Oxygen Trim
 Control Fuel Oil Pressure
 Control Fuel Oil Temperature
 Control Daearator Level
 Control Flash Tank Level
 Monitor Alarm and trip signal for Boiler
 Control Start Sequence of Burner
 Control Air and Oil Parameter for Burner
 Control Oil Valve system
 Control Feed water Pumps
 Control Fuel Oil Pumps
 Control Combustion Air fan

54750921.doc Page 7 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

4. PB2 SYSTEM PLC LOGIC

The following sections detail the PLC logic and configuration.

4.1. User-Defined Tags

Several custom User-Defined tags have been created to standardize data management. The follow
sections will describe these tags.

4.1.1. Analogue_Alarm
This tag is used to monitor analogue alarm points, it provides an easy interface with the HMI.

Name Data Type Style Description

L_SV REAL Float Low Alarm value in engineering units
H_SV REAL Float High Alarm value in engineering units
LL_SV REAL Float Low-Low Alarm value in engineering units
HH_SV REAL Float High-High Alarm value in engineering units
HH Digital_Alarm Tag used to monitor High-High Alarm conditions
H Digital_Alarm Tag used to monitor High Alarm conditions
L Digital_Alarm Tag used to monitor Low Alarm conditions
LL Digital_Alarm Tag used to monitor Low-Low Alarm conditions
BAD Boolean Decimal Tag used to monitor the status of the analogue value,
this bit is set when the value is out of range or
communication is disrupted with the input module

4.1.2. Digital_Alarm
This tag is used to monitor digital alarm points, it provides an easy interface with the HMI.

Name Data Type Style Description

Alm Boolean Decimal Alarm Latch Bit – active to indicate an alarm condition
Als Boolean Decimal Alarm Handshake Bit – used by the HMI to indicate that
the alarm condition has been received.
Ack Boolean Decimal Acknowledge Bit – used to indicate that the alarm has
been acknowledged by the Operator on the HMI
Tmr TIMER Timer - used to delay alarm activation
This tag is used to communicate upset conditions to the HMI.

54750921.doc Page 8 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

4.2. MainTask

The Main Task is a Continuous Task that calls all the other programs in sequence. Each program
has a main routine which calls a series of other routines. The following lists the scheduling of the
programs:

Continuous Task
- Main Task
 Burner
 Analogue
 BOP
Periodic Task:
PID_LOOP
 PID_FBD

4.3. Logics Description

4.3.1. Burner System

In this program folder, the controller will control the burner for some of Loop Controller like:
- Steam Pressure
- Combustion Air Flow
- Fuel Oil Flow
- Steam Drum Water Level
- Atomizing Steam
- Salinity and
- Oxygen Content

4.3.1.1. _01_Communication
this ladder system, the burner will exchange the data with BOP (balance of Plant). As in the original logic
the data exchange using MSG instruction. But right now the system is only using one processor together.
This rung also give indication to MMI regarding status of some signals such as Oil Valves, Steam Purge
Valve.

4.3.1.2. _02_Signals
In this ladder, the controller will arrange signals to be indicated in MMI

4.3.1.3. _03_AirOilParameter
In this part as the core control for Air and Oil, this part is very important. This rung will define the Set
Point of Air and Oil based on operation condition. Scaling Air PV and Oil PV.
The Set Point relation can be seen in the Step diagram.

54750921.doc Page 9 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

4.3.1.4. _04_PIC510A7G1_SteamPress

Steam Pressure PID is the master Demand Controller that have function to give master demand value
to be using as Air and Oil Set point in Mod Free Position.
This Rung will set parameter for Steam Pressure PID. Steam Pressure PID have to Set Point based on
Pressure Mode operation :
 High Pressure Set Point (6 s/d 10 Bar) and
 Low Pressure Set Point (11.5 s/d 15 Bar)
In Auto Mode the Steam Pressure PID will Continuously Set the Output CV to drive Air and Oil Set Point
based on the Set Point on which Pressure Mode Operation
In Manual Mode the Operator can Increase the CV by pressing Increase or Decrease Push Button

4.3.1.5. _05_FIC510A7G2_AirFlow
This Rung will set parameter for Air Flow PID. The Process Variable is taken From Calculation from
Air/Oil Parameter Program. For detail, please to see PID Diagram for Air Flow on attachment
The Set Point also come from calculation of Air/Oil parameter based on the Step Condition.
The Control Variable (CV) then connected to Analogue Output Slot 7.Ch 2 (Air Damper)
In Auto Mode Set Point will take from calculation, in manual mode, operator can set the opening damper
by Increase or Decrease the Output.

4.3.1.6. _06_FIC510A13F_OilFlow
This Rung will set parameter for Oil Flow PID. The Process Variable is taken From Calculation from
Air/Oil Parameter Program. For detail, please to see PID Diagram for Oil Flow on attachment
The Set Point also come from calculation of Air/Oil parameter based on the Step Condition.
The Control Variable (CV) via tag N100[46]. In the purge and Ignition the CV will force to value 600.
In Auto Mode Set Point will take from calculation, in manual mode, operator can set the opening Valve
by Increase or Decrease the Output.

4.3.1.7. _07_LIC510W2_WaterLvl
This Rung will set parameter for Steam Drum Water Level PID. The Process Variable is taken From
Analogue Input LT_510_W16. For detail, please to see PID Diagram for Water Level on attachment
This Controller have two mode Set Point is Low Mode Set point and High Mode Set Point its depend on
the status of Oil Valve
The CV connected to Analogue Output Slot 7.Ch 1 (Water Level C.V)

In Auto Mode Set Point will take from operator input Set Point, in manual mode, operator can set the
opening Vale by Increase or Decrease the Output.

4.3.1.8. _08_PIC510A9G2_AtomSteam
This Rung will set parameter for Atomizing Steam Pressure PID.
The Process Variable is taken From Analogue Input PT_510_A9G2. For detail, please to see PID Diagram
for Atom Steam Pressure on attachment
The Set Point taken from calculation, that depending on Air Flow Value.
The CV from PID then connected to Split range Time Proportional. It is using for Motorized valve that the
change of PV is slow such as temperature control.
The motorized valve will get pulse from this controller to open and close the valve.

In Auto Mode Set Point will take from calculation, in manual mode, operator can set the opening Vale by
Increase or Decrease the Output.

54750921.doc Page 10 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

4.3.1.9. _09_SIC510A5G1_Salinity
This routine will set parameter for Salinity Content PID at Mud Drum .
The Process Variable is taken From Analogue Input ST_510_A5G1. For detail, please to see PID Diagram
for Salinity on attachment
The set point Set to fix value 3500. This PID using reverse action.
The CV from PID then calculate to create pulse with the frequency of pulse proportional with the value of
CV and actuate the Blow Down Solenoid Valve
In Auto Mode Set Point will take from fix number, in manual mode, operator can set the Solenoid valve
open or close to change the salinity value

4.3.1.10. _10_AIC510K1_0xygenTrim
This routine will set parameter for Oxygen Trip PID . This Oxygen trim will indicate to the Operator how
much of Oxygen Contents on gas flue. If the oxygen too low, it means the combustion not efficient or too
much oil, and if too high it mean too much air in the combustion. .
The Process Variable is taken From Analogue Input AT_510_K1. For detail, please to see PID Diagram
for Salinity on attachment
This PID have function to add value to Air PV around -/+ 5 %, if the Oxygen Trim set to ON then the Set
Point will entered to PID and the value will set to Air Flow PV in Mod Free Step.
The set point is input by operator.
The CV from PID then calculate to create value to be add to Air PV.

The Operation will always in auto. In Manual operator can enter th Output of PID that can influence the
value of Air Flow PV.

4.3.1.11. _11_Sequence & _12_SequenceCtrl

This Routine have function as Sequence Function Chart (SFC). Start from Step 0 to 9 for starting and 11
to 14 for Normal Off.

Step Number Description

Step 0 = Burner Tripped If any trip happen to the Boiler then automatically
will set to Step 0, it only change to step 1 if all the
trip interlocks are clear. The Set Point of Air will set
to -20% and Oil SP = 20% initiated by Bit No
initiating Step (No Step Active)
Start Sequence
Step 1 =Ready This step will stop all start condition and get ready
for next step, it will change to step 2 after boiler start
command initiated in 5 seconds The Set Point of Air
will set to -20% and Oil SP = 20% initiated by Bit
Closed signal to Air/Oil Position.
Step 2 = Starting This step will starting the burner. Start The
Combustion Air Fan and Atomizing Valve, the
atomizing valve will remain opened until unit tripped
or step to step 1. The Set Point of Air will set to
-20% and Oil SP = 20% initiated by Bit Closed signal
to Air/Oil Position.
Step 3 = Purging In this step the Air will Flow to the Wind box in high
flow rate to purge the burner system. The Set Point
of Air will set to 70% and Oil SP = 15% initiated by
Bit set purge position to Air /Oil Control
Step 4 = Ignition Position In this step, the air and oil will controlled to reach the
right value before ignition activated. The Set Point of
Air will set to 18% and Oil SP = 15% initiated by Bit
set Ignition position to Air /Oil Control
54750921.doc Page 11 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

Step 5 = Ignition At this step, the Ignition Valve will inserted and
ignition process starting, the step will be change to
step 6 if the igniter inserted for 10 Secs. The Set
Point of Air will set to 18% and Oil SP = 15%
initiated by Bit set Ignition position to Air /Oil Control
Step 6 = Safety In this step, during Ignition valve opened, the Oil
Valve then Open to start combustion in the burner.
The Set Point of Air will set to 18% and Oil SP =
15% initiated by Bit set Ignition position to Air /Oil
Control
Step 7 = Stabilize IN this step the condition will remain same with the
previous step, and wait until 10 Sec to move to the
next step. The Set Point of Air will set to 18% and Oil
SP = 15% initiated by Bit set Ignition position to
Air /Oil Control
Step 8 = Transition In this step, there is no delay and it’s only activated
for future used, while this step will set minimum
position in air/oil control if the Boiler slave is running.
Step 9 = Mod Free In this step, the Set Point will set auto from Steam
Load, based on the calculation on Air/Oil Parameter
routine. The Mod free signal will allow the demand
index from steam CV used as the Air and Oil Set
Point.
Stop Sequence
Step 11 = Steam Purge to Shut Down This Step will activated if the combustion process
already happen (start from Step 6 to 9) and burner
stopped by Operator. The Air and Oil Set point will
set to 25%, initiated by Steam purge pos. signal to air/oil control
signal

Step 12 = Steam Purge to Shut Down
Step 13 = Steam Purge to Shut Down
Step 14= Stop to Step 1
This Step will activated After Step 11 for 15 seconds.
The Air and Oil Set point will set to 25%, initiated by
Steam purge pos. signal to air/oil control signal
This Step will activated After Step 12 for 2 seconds
Steam Purge Valve then Opened, the combustion
process then stopped by close the Oil Solenoid
valve. The Air and Oil Set point will set to 25%,
initiated by Steam purge pos. signal to air/oil control signal
This Step will activated After Step 13 steady for 50
seconds Steam Purge Valve reamain Opened, the
atomizing valve then closed . The Set Point of Air
will set to -20% and Oil SP = 20% initiated by Bit
Closed signal to Air/Oil Position.

Please to see the step Flowchart for details in the attachment .

54750921.doc Page 12 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

4.3.1.12. _13_Start
In this routine, the start signal to initiate burner start will set. There is 2 mode of Starting:
1. Auto
2. Manual

In Auto, the burner will start depend on Pressure Set point of Low Start and High Presure Start set
point.
In Low Press Mode, the boiler will automatically start if pressure less than 6 Bar and automatically
stop if the pressure reach the Set Point to stop
In high Pressure mode, the burner will start if the pressure less than 11.5 bar and stop if reach the
high set point of burner.

In manual mode, the burner will start depend on the operator demand. It will not use parameter of
Steam Pressure.

4.3.1.13. _14_Alarms
In this routine will set the alarms for critical signal at PB2. The important thing is the Boiler trip signal.
The following alarm will caused tripping to the PB2:

Alarms Description
steam pressure too High (transmitter) Threshold = 15.5 Bar
Combustion Air Fan Off
Alarm High Steam Pressure (Pressure Switch)
Steam Drum Too Low Level Threshold = -200 mm
Threshold = 2 Bar
Lance Not In Position off
Oil Valve not in Closed Position
Flame Failure IF scanner 1 & 2 Fail in step 7 to 9
Combustion Air Fan Overload
Misfiring If the step 2 to 7 stuck more than 5 minutes
Fuel Oil Temperature too High Threshold = 155 deg C
Igniters Inserted Locked
Fire In Wind box
High Temperature Uptake
External Shutdown
Steam Drum Level Too High Threshold = 380 mm
Low Fuel Oil Pressure Threshold = 12 Bar
Air Damper Close
Fuel Oil Temperature Too Low Threshold = 50 deg C, this trip disable if using LDO
Remote IO Communication Fault

4.3.1.14. _15_BoilerOut
This routine will control the step action. Each step will have action to be done and will be handled by this
logic.

4.3.1.15. _16_OilTotalizer & _17_SteamTotalizer

This Routine will counting Steam and Oil Totaliser

54750921.doc Page 13 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

4.3.2. Program : Analogue.

This Logic consist of 25 subroutine for all analogue input and will control the alarm set point and status.

4.3.3. Program: BOP (Balance Of Plant)

In this Programs is control for auxiliary system of Package Boiler such as Feed water Fuel Oil Pressure,
Combustion air Fan and Oil Valves.
This program consist of 11 Routines:

The routine explanation can read below:

4.3.3.1. Communication
This program arrange transfer data from Burner to BOP

54750921.doc Page 14 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

4.3.3.2. Oil Valves

This logic function to indicated to MMI the status of DO fuel is selected or not (HFO selected).

4.3.3.3. FW Pumps:
Control Feed water Pump to fill the steam Drum. The function is to select which is the master or slave,
this selection fw motor one must be in auto mode. Check Overload status, if one motor is overload then
start slave.
If the level dearator is too low (below -420 mm) and pump in auto then shut down the Pump 1 & 2.

In this Folder, for chemical pump will manually set by operator by pressing start/stop button.

4.3.3.4. Fuel Oil Pump.

The system are same with Feed Water Pump. In this rungs will select the master or slave pump, When
Pump Master overload then the slave Pump will started and when the Master back to normal then
automatically the slave pump will be stopped.
If the Fuel Pressure less than 5 bar, then the slave pump will automatically started to change the master
pump and the master will be off.

4.3.3.5. Combustion Air Fan

This Logic function is to start Combustion Air Fan/ FD fan to supplying air for combustion process. This
Fan will be get signal start from Burner when in Starting Step (Step No=2). And will be stopped by Ready
Step (Step No = 1).
In this rung also counting the Run Hours of Combustion Air.

4.3.3.6. _06_PIC_510A5G2_FOPress

This routine function is to control and add parameters of Fuel Oil Pump PID. When Fuel Oil Pressure
High then close the valve by pulse and when it going low then start to send open pulse to control valve.
When Pressure reach less than 5 bar then start Fuel Oil Pump Slave.
The Set Point entered by operator via MMI. The PV taken from pressure sensor in the field. The CV then
calculated to create pulse open or close the valve to increase or decrease the Fuel Oil Pressure.
In the auto mode, the fuel oil pressure will follow the Set Point in the manual mode the output will
controlled by operator by push the increase or decrease button.

54750921.doc Page 15 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

4.3.3.7. _07_TIC_510G28_FOTemp
This routine have function to control and add parameters for fuel oil temperature PID. The burner have
two mode of fuel usage:
1. HFO or
2. LDO

In HFO mode the Fuel Oil temperature will using Set Point from operator that entered via HMI. In the
LDO mode the Set Point will set to zero.
The controller Set Point entered by operator via HMI. The PV taken from temperature sensor in the fuel
pipe and the CV then calculated to produce Pulse proportionally by the CV Output of PID.
In auto mode, the fuel temperature will follow Set Point and in the manual mode the output will
controlled by operator by push the increase or decrease button.

4.3.3.8. _08_LIC_510M137_DeaLvl
This routine have function to control and add parameters for Dearator Level PID. When level dearator
is higher then Set Point the valve feed water will closing, if the level dearator is lower than Set Point, the
feed water control valve will opening.
The Set Point entered by operator via MMI. The PV taken from sensor level at dearator. The CV then
connected to Control valve directly to close or open the feed water control valve.
In the auto mode, the fuel dearator level will follow the Set Point in the manual mode the output will
controlled by operator by push the increase or decrease button.
_09_LIC_510E28_FTankLvl
This routine have function to control and add parameters for Flash Tank Level PID. When level of
flash tank is higher then Set Point the Flash Tank Level Control valve will closing, if the level flash tank
is lower than Set Point, the valve will opening.
The Set Point entered by operator via MMI. The PV taken from sensor level at Flash tank. The CV then
connected to Control valve directly to close or open the feed water control valve.
In the auto mode, the flash tank level will follow the Set Point in the manual mode the output will
controlled by operator by push the increase or decrease button.

_10_MasterSelect
54750921.doc Page 16 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

This routine have function to select the mode of operation of burner (high steam or low steam mode).
This rung also will select the master / slave selection of boiler. Actually this function is the future usage
when two package boiler run in parallel.

4.3.3.9. _11_Alarms
This routine have function to generate alarms for BOP also to counting run hours of Feed water pump
and Fuel Oil Pump.

4.3.4. PID LOOP Program Folder

This program folder using periodic task which have task period 10 ms. This PID correspondence with
PID in the Burner and in the BOP program.
The Logic write in FBD (functional Block Diagram) to make the viewer more familiar and easy to
maintain.

Please to see at attachment for Function Block Diagram Of PID Loop

54750921.doc Page 17 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

5. APPENDIX

5.1. Functional Block Diagram

5.2. Steam Pressure PID Block Diagram

Low Press Mode

B13[0].6
& PIC510A7G1_SP_HP
Auto

SP = + CV
PID Steam
N10[152] N100[19] N100[18]
Pressure
Low Press Mode -
B13[0].6
& PIC510A7G1_SP_LP
Auto B

PT_510_A7G1a.Eng To Set Point Air Flow

(Steam Pressure) Controller

54750921.doc Page 18 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

5.2.1. Air Flow PID Block Diagram

N101[4] =
180
Ignition pos. to
FIC510A7G2_CV_O
air/oil controller + CV
PID Air O.7:2
B67[0].3 N100[3] N10[2] FIC510A7G2_SP Flow
-
N100[2] C From PID Oxygen Trim
N101[2]= E
N100[65]
-200 N100[10]
N101[3]= To Oil N100[14] + 1000
N100[1] Flow PID
OR 700

Purge pos. to N100[11]

air/oil controller / 10 x / 10 /
N101[21] N100[13] 10
B67[0].2
Step 4 Step 5 Step 6 Step 7
Ign Pos Ignition Safety Stabilize Closed Sig. to
air/oil controller
Step 1 B67[0].0
Ready OR / 100 N101[22]+
& Scaled CV N101[37] +
OR S24
Initial Step N101[6]= Steam
Step 2 100
B47[0].15 Control
Starting
N100[17]

D N100[61] > N101[23]+ - N101[22]+ x

S24 S24
To Oil Flow >
SP
N101[20] - N101[36] - 100 Index
Scaled Oil N100[22] N100[20] (S24)
Flow From Oil
F
N100[31] Flow PV
Create Index untill
N100[21] Min Pos. > N101[20]<N101[36] or
Signal to Air Flow N101[36]>1300
N100[26] air/oil Ctrl Scaled
N101[7]=
N100[60] Mod Free Pos 0 B14[2].12 (0 – 1000)
250
2 B67[0].5 N12[43]
N100[71]
> Step 8
N100[24]
1 Transiti
Steam Purge to B14[4].11
on
Control N100[25]
B67[0].4
Step 9
N100[26] Purge OR
N100[29]
Pos
OR
N101[1]=
B14[5].5 600
Step 11 Step 12 Step 13 7 Bar Sel. (Low Inert Gas
> Press Mode) Position
Steam Steam Steam
Purge Purge Purge B14[0].6 B14[0].7

EN B14[0].1 OR
& ONS
N100[101] + 10 100
TT=10s
B14[5].9
T14[173.DN &
T=3secs B14[5].7

54750921.doc Page 19 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

5.2.2. Oil Flow Control PID

N101[15] N101[10] Scaled Output to
=200 =100 0-1000
>
SP + CV
N100[33] N100[35] PID Oil /
N10[32] N100[44] 16.384
Flow
-
PV

N100[32] N100[45]
Closed Sig. to Purge or N12[71] G N100[49] FC_510_OILFLW
OR <
air/oil controller Ignition Step (AO 7.0.3)
To Atom Steam N101[11]
B67[0].0 Active
N101[9]= PID =600
B14[2].0
150
Initial Step
B47[0].15 & Scaled Oil Flow N101[8]=
(0-1000) N12[44] x x 0.01
From Air Flow 120
< N100[61] D N100[31]
PID SP

N100[10] From Air Flow

E
PID PV
F FT_510_A13Fa.Eng
(AI 1.6.4)
To Oil Flow
SP

To O2 Trim
PID SP

54750921.doc Page 20 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

5.2.3. Steam Drum Water Level PID

N10[58]
Oil Valve Status + CV
N10[62] SP PID Steam LIC510W2_CV_O
ZV_510_OIL Drum Level AO 7.0.1
-
N10[59]

LT_510_W16a.Eng
Steam Drum Level

54750921.doc Page 21 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

5.2.4. Atomizing Steam Pressure PID

N101[70] Pulse
=600 > CV Open
N101[59] / 10 SP + PID Atomizing Split Range Time
N10[92]
Steam Press. Proportional
- Pulse
N101[60] <
=280 PV Close

PT_510_A9G2a.Eng
Atom Steam Press
N101[60]
N101[74] / 100 +
+S24

N101[61] N101[60]
+ x N101[20] - N101[73] - 100 / 10
From Oil Flow +S24 +S24
PV

G N12[72] >
Process
Calculation and S24
1000 > Create Index S24

Air Flow PV Scale

(0-1000)
N12[43]

54750921.doc Page 22 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

5.2.5. Salinity / Blow Down PID

Pulse
Position Open
N10[182] - PID Salinity/ Proportional
=3500 Blow Down Control
+ Pulse
Close

ST_510_A5G1a.Eng

5.2.6. Oxygen Trim PID

Enter When Low Low SP O2 Trim
Oil Flow SP From HMI

0 N101[46] N100[30] + N101[54] N10[232] SP + PID Oxygen CV Scale from 50

Trim N100[34]
to -50
-
& & PV

AT_510_K1a.Eng N100[37]
Oxygen Content
O2 Trim ON
B67[0].6
B14[1].2

To Air Flow PV
<

N101[35]
H =500

Oil Flow Scaled Load to Low

PV From Oil O2 Trim SP
Flow PID From HMI

54750921.doc Page 23 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

6. SEQUENCE FLOW CHART

6.1. Start Sequence:

STEP 0 = TRIPPED

TRIP INT. Clear?

Yes
Burner Step 1 = Ready
Trip Reset All Step Sequence Timer
STEP 1 = READY Stop Combustion Air Fan
Close Atomizing Steam Valve
Close Signal to Air/Oil Control
Disable Trip Alarm Low Atomizing Pressure Low
Burner Start?
Burner Stop
Delay = 5 Secs
Step 2 = Starting
Burner Start Combustion Air Fan
Trip STEP 2 = STARTING Open Steam Atomizing Valve
Set Closed signal to Air/Oil Control
Disable Trip Alarm Low Atomizing Pressure Low
Combustion Air Fan Run?
Delay = 30 Secs

Burner Step 3 = Purging

Trip STEP 3 = PURGING Set Purge Position to Air/Oil Control
Disable Trip Alarm Low Atomizing Pressure Low
Air PV > 65%?
Delay = 60 Secs

Burner
Trip STEP 4 = IGN. POSITION
Step 4 = Ignition Position
Set Ignition Position to Air/Oil Control

Ignition Position From Air/Oil Control

(Air PV = 16.5 – 19.5% and Oil PV = 13.5 - 16.5 %)

Step 5 = Ignition
Burner Set Ignition Position to Air/Oil Control
Trip STEP 5 = IGNITION Open Ignition Valve

Igniter Inserted
Delay = 10 Secs
Step 6 = Safety
Set Ignition Position to Air/Oil Control
Burner Open Ignition Valve
STEP 6 = SAFETY
Trip Open Oil Solenoid Valve

Delay = 15 Secs
Burner Stop
Step 7 = Stabilize
Set Ignition Position to Air/Oil Control
Burner STEP 7 = STABILIZE Open Oil Solenoid Valve
Trip

Delay = 10 Secs

Step 8 = Transition
Burner STEP 8 = TRANSITION Open Oil Solenoid Valve
Trip Disable Set minimum Position to Air/Oil Control

Lance In Position & Not manual Start &

Not Boiler Slave Start
Step 8 = Transition
Open Oil Solenoid Valve
Set Mod. Free Signal to Air/Oil Control
Burner STEP 9 = MOD FREE A
Trip

Go TO Step 11

54750921.doc Page 24 of 25
Printed: 2021-12-08 6:22:53 PM
 Functional Description – Package Boiler#2 PLC

6.2. Stop Sequence

To Tip Step From Starting
Sequence
B A

Step 11 = Steam Purge to S/D

STEP 11 = Steam Purge to Open Oil Solenoid Valve
Trip Burner
S/D Set Steam purge pos. signal to air/oil control

Delay = 15 Secs

Step 12 = Steam Purge to S/D

STEP 12 = Steam Purge to Open Oil Solenoid Valve
Trip burner
S/D Set Steam purge pos. signal to air/oil control

Delay = 2 Sec
Step 13 = Steam Purge to S/D
Open Steam Purge Valve
Trip Burner STEP 13 = Steam Purge to Set Steam purge pos. signal to air/oil control
S/D

Delay = 50 Secs
Step 14 = Stopping to Step 1
Close Atomizing steam Valve
Trip burner STEP 14 = Stopping to Open Steam Purge Valve
Step 1 Set Closed Signal to Air/Oil Control

54750921.doc Page 25 of 25
Printed: 2021-12-08 6:22:53 PM