CONTROL VALVES IN SPLIT RANGES

For certain control strategies some valve need to be operated in split range ,
i.e, from 0 to 100 % signal two valves operate to maintain the parameter. In
these cases valves may operate in either of following manner
CASE A

VALVE 2

VALVE 1

50

25

100

% SIGNAL

The above figure shows opening of both valves as signal varies from 0 to 100 %
SIGNAL
%
0
25
50
75
100

OPEN. OF VALVES
VALVE 1 VALVE 2
100
0
50
0
0
0
0
50
0
100

Example LV - 5 A & B :
LV - 5A is the condensate import valve of the carbamate condenser shell side
LV - 5B is the condensate export valve of the carbamate condenser shell side
At 50 % output both valves are closed
At 0 % output LV - 5A valve is full open & LV - 5B full closed
At 100 % output LV - 5A valve is full closed & LV - 5B full open

CASE B

VALVE 1

VALVE 2

25

50

% SIGNAL

100

The above figure shows opening of both valves as signal varies from 0 to 100 %
SIGNAL
%
0
25
50
75
100

Example

OPEN. OF VALVES
VALVE 1 VALVE 2
0
0
50
0
100
0
100
50
100
100

PV - 7 A & B .

PV - 5A is the condensate import valve of the carbamate condenser shell side

& LV - 5B is the condensate export valve of the carbamate condenser shell
side
At 50 % output both valves are closed
At 0 % output LV - 5A valve is full open & LV - 5B full closed
At 100 % output LV - 5A valve is full closed & LV - 5B full open

TRIP LOGICS FOR UREA PLANT

The plant operates on fail safe principle which means that in case of an emergency or
any undesirable event the plant should move to safe conditions.For this to happen all
critical equipments have been provided with tripping logics so that a particular
equipment would be stopped automatically in case of an emergency

IS - 01

TRIP LOGIC FOR TK - 01 / K - 01

IS - 02

TRIP LOGIC FOR H.P SYNTHESIS LOOP

IS - 03

TRIP LOGIC FOR H.P AMMONIA PUMP , P - 01

IS - 04

TRIP LOGIC FOR H.P CARBAMATE PUMP , P - 02

IS - 05

TRIP LOGIC FOR UREA MELT

IS - 06

TRIP LOGIC FOR INSTRUMENT AIR FAILURE

IS - 08

TRIP LOGIC FOR DRAIN RECOVERY PUMPS P-12A/B

IS - 09

TRIP LOGIC FOR HYDROLYZER TRIP CIRCUIT

IS - 10

TRIP LOGIC FOR HYDROLYZER FEED PUMP

IS - 11

TRIP LOGIC FOR COND. EXTACTION PUMP TRIP

IS - 12
IS - 16

TRIP LOGIC FOR PURIFIED WASTE WATER

TRIP LOGIC FOR DEMISTER FLUSHING

TERMS ASSOCIATED WITH TRIP LOGICS

1

DELAY: Minimum time for which a switch has to remain actuated to cause tripping

READY TO RESET: Condition indicating fullfilment of certain requirements

for starting the M/C
VOTING LOGIC: Provision of more than one usually three switches for a
particular tripping cause so that actual tripping occurs only
when atleast 2 out of 3 switches for a particular reason actuate
simultaneously
ACTIVE / INACTIVE: Indicates the state of switches. An active switch if
actuated will cause tripping whereas inactive switch will not
cause tripping even on actuation of the switch
FIRST OUT: First reason (switch) on which a m/c trips on actuation of more
than one tripping switches

BYPASS: Physical condition of a trip cause which will not lead to

tripping even in case of actual actuation of switch

HARDWARE SWITCH : Switches provided on DCS consoles in form of

knobs to bypass the trip switches

SOFTWARE SWITCH : Switches which can be bypassed from LM only

DESCRIPTION OF TRIP LOGICS

IS - 1
This trip logic relates to TK - 1/K - 1. All the trip reasons are listed below
PSXL 601 CO2 Compressor low suction pressure
PSXL 02 CO2 Compressor low discharge pressure
PSXH 01 CO2 Compressor high discharge pressure
LSXH 641 High level in surface condenser E - 28
PSXH645 High extraction steam pressure

PSXH 648 Turbine exhaust pressure very high

LSXH62 High level CO2 knock out drum MV -9
ZSXH 650 Compressor,Turbine, Gear box high axial displacement
XSXH 650 Compressor, Turbine, Gear box high vibration
SH 650
Turbine high speed
PSXL677 Lube oil header pressure low
PSXL690 Lube control oil pressure
PSXL 691 Low trip oil pressure
LSXH606 High level in 1st interstage separator MV - 16
LSXH 609 High level in 2nd interstage separator MV - 17
LSXH 612 High level in 3rd interstage separator MV - 18
IS 06
Emergency trip: instrument air failure.
On the trip , following actions will be taken by the system automatically.
- ESV closes
- passivation air flow control valve FV 61 closes
- anti surge valve FV 602 opens
- Interstage vent valve opens
- HV 01 closes
Barring device gets permissive to start only after the following
- Normal lube oil pressure
- Turbine zero speed achieved
- Trip oil pressure switch actuated (PXL 691)
IS 01 restting is permitted only after following :
- All the trips switches are in healthy condition
- Trip oil switch (PSXL 691) bypassed
- Barring device disengaged
- Interstage vent valve open indication switch bypassed
- FV 602 open
- HV 601 open
- Overhead tank normal level
IS - 2
This trip logic relates to HP Loop. All the trip reasons are listed below
Trip actuation is on the following
- PSXH 06
Reactor high pressure
- IS 03
P 1 trip
- IS 06
Emergency trip actuation
On the trip , following actions will be taken by the system automatically.
- HV 02 closes
- FV 34 opens
- HV 06 closes
- P 1 tripping

IS 02 restting is permitted only after following :

All the trips switches are in healthy condition
P 1 running
IS -3
This trip logic relates to HP AMMONIA PUMP P-1. All the trip reasons are listed below
-

PLL 98
PLL 97
PLL 96
PSXH 31
WSXH 51
IS 02

Low lube oil pressure in torque convertor

Low lube oil pressure in Gear box
Low lube oil pressure in Crank case
High dicharge pressure
Crank case overload protection
On the actuation of IS 02

On actuation of pump overspeed switch (SXH 51) , the pump return to minimum
speed. It can be restted only with the help of local hardware push button switch
provided.
IS - 4
This trip logic relates to HP CARBAMATE PUMP P-2. All the trip reasons are listed below
IXL 02
ZXH 501
XXH 501
TH 509
TH 510
TH 512
TH 516
TH 518
TH 515
PLL 522
PLL 527
PLL 508

Low current consumption

High axial displacement
High vibration
High 1st stage thrust bearing temperature
High first stage journal bearing temp
High first stage journal bearing temp
High second stage journal bearing temp
High second stage journal bearing temp
High second stage thrust bearing temp
Low lube oil pressure
Low seal flush suction pressure
Low seal flush flow

IS 04 restting is permitted only after following :

PLL 508
PH521
TL 503
LL 504

All the trips switches are in healthy condition

Noramal seal flush flow
Normal lube oil pressure
Normal lube oil temp
Normal level in lube oil console

IS - 5
This trip is actuated only when for following reasons

- Belt conveyors not running

- Scrapper not running
- Bucket not running
On the trip , following actions will be taken by the system automatically.
- 11 HS 132
- 21 HS 132
- HS 137

11 Unit prilling diversion to V5

21 Unit prilling diversion to V5
Flushing steam to bucket side will open

IS - 6
In case of instrument air failure PSXL 301 will actuate, the IS 06 will activate, and this will
result in the tripping of CO2 compressor (IS 01) and IS 02
IS - 8
The actuation of this trip will give start / off command to P 12 A/B.
IS - 9
This trip will be actuated only when hydrolyser temp goes very high (TXH 160 )
And this will result in closing HS inlet to R 02 (FV 165)
IS - 10
This trip will be actuated on following:
IXL 14
FXL 158 / 159

Low current consumption

Low seal flush flow

This will result in the tripping of P 14.

IS - 11
The actuation of this trip will give start / off command to P 23 A/B.
IS - 12
This trip will actuate only when 11AH 161 A (high conc of urea in treated waste
water) actuate.
The actuation of this trip will close HV 163 (condensate to DM plant) and open HV 162
(recycle to V 6).
IS - 16
This opens the demister pad flushing water valve HV 173 after every 15 mins for a
duration of 15 sec