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Borouge 2 Project

BOROUGE PHILOSOPHY DOCUMENT


CONTROL & OPERATION PHILOSOPHY
08-PP-561-80001
Revision: H
Page: 2 of 7

DSN: 887 08-PP-561-80001Rev H.doc

CONTENTS


1.0 PURPOSE................................................................................................................................. 3
2.0 DEFINITIONS AND ABBREVIATIONS............................................................................. 3
2.1 DEFINITIONS..................................................................................................................................3
2.2 ABBREVIATIONS...........................................................................................................................4
3.0 REFERENCE DOCUMENTS................................................................................................ 4
4.0 PROCESS CONTROL SYSTEM OVERVIEW................................................................... 4
5.0 OPERATING PHILOSOPHY................................................................................................ 5
6.0 PLANT AUTOMATION, CONTROL AND OPTIMISATION SYSTEMS ..................... 5
6.1 OBJECTIVE.....................................................................................................................................5
6.2 LEVELS OF AUTOMATION ........................................................................................................5
6.3 INSTRUMENTATION, CONTROL, AND MONITORING SYSTEMS...................................5
6.4 ADVANCED PROCESS CONTROL SYSTEMS.........................................................................5
6.5 ALARM PHILOSOPHY .................................................................................................................6
7.0 PROTECTION SYSTEMS..................................................................................................... 6
8.0 PACKAGED EQUIPMENT CONTROL.............................................................................. 6
9.0 COMPRESSOR CONTROL.................................................................................................. 7
10.0 STANDARD CONTROL IMPLEMENTATIONS............................................................... 7








Borouge 2 Project

BOROUGE PHILOSOPHY DOCUMENT
CONTROL & OPERATION PHILOSOPHY
08-PP-561-80001
Revision: H
Page: 3 of 7

DSN: 887 08-PP-561-80001Rev H.doc
1.0 PURPOSE
The purpose of this document is to define the technical requirements for the Process
Control Design on the Borouge 2 Project Utilities and Offsites FEED. The scope is
restricted to those systems which are depicted on the P&IDs. It is provided to the
CONTRACTOR for the specification and definition of the COMPANYS minimum
requirements for the WORKS. The document is restricted to extensions to, or
qualifications of, the Project Control & Operation Philosophy Document BDP-PP-03-
003.
Any references to VENDOR define the requirements to be imposed on the VENDOR by
the CONTRACTOR.
2.0 DEFINITIONS AND ABBREVIATIONS
2.1 DEFINITIONS
For the purposes of this specification, the following definitions shall apply:
COMPANY means Abu Dhabi Polymers Company Limited (Borouge) and its
successors in interest.
CONCESSION REQUEST refers to a technical or other deviation requested by the
CONTRACTOR or VENDOR to COMPANY. Its submission is often linked to an
authorization to modify the design, to use, repair, recondition, reclaim, or release
materials, components or equipment already in progress or completely manufactured but
which does not meet or comply with COMPANY requirements. A CONCESSION
REQUEST is subject to COMPANY approval.
CONTRACTOR means a party contracted to COMPANY to carry out work or services
to the Project.
GOODS means any and all things, including but not limited to materials and equipment
(including spare parts) required to be incorporated in the WORK.
PROJ ECT means the Borouge 2 Project at Ruwais, Abu Dhabi, UAE.
VENDOR means any and all persons, firms, partnerships, companies, bodies, entities
or a combination thereof including sub-vendors and suppliers, who are providing
GOODS, and the successors and assigns of such persons, firms, partnerships, companies,
bodies, entities or a combination thereof.
Shall and Must indicate a mandatory requirement.
In addition, supplementary definitions are contained in Article 1 of the AGREEMENT.
Borouge 2 Project

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CONTROL & OPERATION PHILOSOPHY
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2.2 ABBREVIATIONS
2oo3 Two out of Three voting
APC Advanced Process Control
CCR Central Control Room
CCS Compressor Control System
DCS Distributed Control System
EPC Engineering, Procurement and Construction
ESD Emergency Shutdown
ICS Integrated Control System
MMI Man Machine Interface
MOS Maintenance Override Switch
POS Process Override Switch
PV Process Variable
SIS Satellite Instrument Shelter
3.0 REFERENCE DOCUMENTS
The following Reference Documents form a part of this Specification:
BGS-PP-03-001 Process Engineering Philosophies
BDP-PP-03-002 Emergency Shutdown and Emergency Block-in Philosophy
BDP-PP-03-003 Control & Operation Philosophy
BDP-PP-03-004 Compressor Control Philosophy
83-IS-563-80001 Plant Safeguarding (U&O)
82-IS-563-80001 Plant Control Philosophy

The edition or revision of the Reference Documents shall be the edition current at the
EFFECTIVE DATE of the AGREEMENT.
CONTRACTOR shall advise COMPANY of any changes to Reference Documents after
the EFFECTIVE DATE. CONTRACTOR shall comply with COMPANY instruction to
comply with any changed Referenced Documents.
CONTRACTOR shall advise of conflict among any Reference Documents and any
technical specification, and COMPANY will determine which shall govern.

4.0 PROCESS CONTROL SYSTEM OVERVIEW
Borouge 2 Project will be provided with a new Integrated Control System (ICS) for
control, operation and protection. This will comprise dedicated equipment residing in
the existing plant Central Control Room (CCR), a number of new Satellite Instrument
Shelters (SISs) and some new local control rooms of Product Handling Areas. The CCR
will be extended as necessary to accommodate the Human Machine Interface (MMI) to
the new ICS. The new system will cover the majority of the equipment installed as part
of the Borouge 2 Project. Some items will, however, be controlled by extensions to the
Borouge 2 Project

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existing control and protection systems. These include:
New Hydrogen Storage and Compressor Packages;
New Ethylene Vaporiser.
Additional Service Water Pump
Additional Potable Water Pump
The majority of the equipment is wired to the U&O SISs and controlled from the U&O
consoles. Other items installed within the U&O battery limits are controlled from the
Process units. These include:
Ethylene rundown from EU2
Propylene rundown from OCU & EU2.
Propylene export from storage.
Ethane export from storage.
An overview of the configuration of the ICS including all associated systems is given in
the Plant Control and Safety Systems Philosophy Document BGS-IU-024.
5.0 OPERATING PHILOSOPHY
Refer to Project Control & Operation Philosophy Document BDP-PP-03-003 Section 9.
6.0 PLANT AUTOMATION, CONTROL AND OPTIMISATION SYSTEMS
6.1 OBJECTIVE
The main requirement of the Integrated Control System is to provide safe, stable and
consistent plant operating conditions to support the operational, business and design
objectives (production rate, product quality and safety) of the main production plants.
The objective is to control the plant within the permissible operating envelope during
start-up and changes in operating parameters, thereby avoiding ESD System protective
action.
6.2 LEVELS OF AUTOMATION
This is based on the Project Philosophy with the exception that on-line optimisation is
not foreseen in the U&O control requirements. Refer to Project Control & Operation
Philosophy Document BDP-PP-03-003 Section 10.2.
6.3 INSTRUMENTATION, CONTROL, AND MONITORING SYSTEMS
Refer to Project Control & Operation Philosophy Document BDP-PP-03-003 Section
10.3.
6.4 ADVANCED PROCESS CONTROL SYSTEMS
No requirement for APC is foreseen.
Borouge 2 Project

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6.5 ALARM PHILOSOPHY
Refer to Project Control & Operation Philosophy Document BDP-PP-03-003 Section
10.5.
7.0 PROTECTION SYSTEMS
This is based on the Project Control & Operation Philosophy Document BDP-PP-03-003
Section 11 with the following exceptions:
Level 2 ESD push-buttons are only foreseen for the following systems:
Propylene Storage and Vaporisation.
Butene-1 Storage and Pumps.
Mixed Butenes Storage and Pumps.
Mixed Fuels Storage and Pumps.
Gasoline Storage and Metering;
Butane Storage and Pumps.
Ethane Storage and Vaporisation.
Acid and Caustic Storage.
Additional Level 2 ESD push-buttons may be required for Wastewater Treatment.
Requirement shall be evaluated by U&O EPC CONTRACTOR when details of all
packages are available.
The following items are included in existing Step 1 ESD Groups:
Ethylene Vaporiser 40-XA-102 in Ethylene Storage and Vaporisation Level 2
ESD Group;
Hydrogen Storage Package 40-XA-403 and Hydrogen Compressor Package 40-
XK-502 in Hydrogen Storage and Compression Level 2 ESD Group.
Only these systems are included in the respective Plant Level 3 shutdowns. The
objective for all other items is to keep all equipment in service unless local protective
action is required to protect an item.
An overview of the requirements is given in the Plant Safeguarding (U&O) Document
83-IS-563-80001.
8.0 PACKAGED EQUIPMENT CONTROL
This is based on the Project Control & Operation Philosophy Document BDP-PP-03-003
Section 12.
It is foreseen that the following items will have control functions implemented in
package PLCs:
Steam Turbines.
Effluent Treatment packages.
Borouge 2 Project

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Flare Ignition Systems.
9.0 COMPRESSOR CONTROL
This is based on the Project Compressor Control Philosophy Document BDP-PP-03-004.
It applies specifically to the Air and Propylene Boil-off Compressor Packages. It is
foreseen that compressor control and protection will be implemented in the DCS on the
basis of specifications developed between Package Vendor and Contractor. The
following functions are foreseen:
Performance Control
Start-up Sequencing.
Shut-down Sequencing.
Anti-surge Control.
Anti-surge Protection.
Machine Protection.
10.0 STANDARD CONTROL IMPLEMENTATIONS
Refer to the Project Control & Operation Philosophy Document BDP-PP-03-003 Section
13.