CONTROL NARATIVE FOR:

AQUEOUS AMMONIA TRUCK UNLOADING,

TANK STORAGE, FORWARDING, VAPORIZER,
DILUTION AIR PACKAGES

for the
Black & Veatch
Sandy Creek Project
B&V Purchase Order Number 149060.65.0221

Document Number: CN-24729-01-3

n: :
0 ed For Construction
1 Per Customer Comments
2 Per Customer Comments
3 Per Customer Comments

TRUCK UNLOADING STATION:

Truck Unloading Control Panel [CPL-604](Located Off Skid-Outside Of The Hazardous

Location):
- available to fill amber pilot light per tank (DO)
- tank start filling illuminated-push button per tank (DO/DI)
- tank stop filling illuminated-push button per tank (DO/DI)
- unloading skid open/closed pilot lights (DO)
- six (6) channel ammonia detector-truck unloading station and tank farm monitoring (DI)
- limit switch (DI)
- pneumatic actuated valve-ABV (DO)
- tank liquid level (AI)
- tank pressure (AI)

Operation:
1. Visually inspect that the vapor return and liquid fill lines are properly connected to the truck.
2. The DCS operator selects the tank TNK-005A/B to be filled. The tanks that are available for
filling can be identified with an amber pilot light located on the front of the truck unloading
station control panel [CPL-604]. When the tank TNK-005A/B is available for filling, the
amber pilot light will be illuminated.
3. In order to begin filling a tank TNK-005A/B the liquid level of the tank (LT-509 or LT-514)
must be < 85%, the pressure inside of the tank (PT-505 or PT-510) must be < 50 psig, and no
ammonia should be detected at the truck unloading station or inside of the tank farm, and no
Ammonia Controller Fault should exist and Tank Discharge Valve (ABV-139 or ABV-141)
must be closed. If any of the above conditions are not met during operation, the
station/package will automatically shutdown.
4. Select the tank TNK-005A/B to receive ammonia by pressing the respective tank start filling
push button located on the front of the truck unloading station control panel CPL-604.
4a. The operator should first manually open the vapor return line (BV-101) at the truck unloading
station. Then the liquid fill line (BV-102) should be manually opened by the operator.
4b. When it has been determined that both the manual vapor return (BV-101)and liquid fill (BV-
102) lines have been opened at the truck unloading station (via the indication lights on the
local panel CPL-604), the operator shall press the selected tank’s fill push button. The
selected tank vapor return (ABV-118/120) will be commanded to open and verified (via limit
switch).
4c. Verification that the tank vapor return (ABV-118/120) has opened (via limit switch) will
initiate the command to open the selected tank liquid fill (ABV-114/116) and verified (via
limit switch). At this point the selected tank (TNK-005A/B) can be filled and associated tank
filling amber pilot light flashes.
4d. The operator can begin pumping liquid from the truck to the tank (TNK-005A/B).
5. In order to stop filling a tank (TNK-005A/B), the operator should stop pumping liquid from the
truck (TNK-005A/B).
5a. After the truck pump has stopped pumping liquid to the selected tank (TNK-005A/B), the
operator should press the respective tank stop filling push button located on the front of the
truck unloading station control panel (CPL-604).
5b. When the stop filling push button has been pressed, the selected tank liquid fill ABV (ABV-
114 or ABV-116) will be commanded to close.
5c. Verification that the tank liquid fill ABV (ABV-114/116) has closed (via limit switch) will
initiate the command to close the tank vapor return ABV (ABV-118 or ABV-120).
5d. Verification that the tank vapor return ABV (ABV-118 or ABV-120)has closed (via limit
switch) will illuminate the tank stop filling pilot light, turn off the tank start filling pilot light,
and the tank filling amber pilot light stops flashing.
6. The operator should manually close the liquid fill line (BV-102) at the truck unloading station.
Then the vapor return line (BV-101) should be manually closed by the operator. Verification
that both valves are closed can be seen with the valve closed pilot light on the control panel.
7. The operator can disconnect liquid fill and vapor return lines from the truck unloading station.

Automatic Shutdowns:
1. Selected tank level (LT-509/514) is > or = 85% (This condition will turn off the selected tank
available to fill pilot light and will not allow this tank to be filled until the level is again <
85% and the alarm has been reset.)
2. Selected tank pressure (PT-505/510)is > or = 50 psig (This condition will not allow this tank to
be filled until the pressure is again < 50 psig and the alarm has been reset.)
3. Ammonia detection at the truck unloading station or the tank area (This condition will not allow
any tank to be filled until there is no more ammonia detected and the alarm has been reset.)

FORWARDING PACKAGE:

Forwarding Junction Box [JBX-601](Located On Skid-Outside Of The Hazardous Location):

- forwarding pump outlet pressure (AI)

Operation:
1. In order to begin pumping from a tank, the liquid level of the tank (LT-509 or LT-514) must be
> or = 5%, the pressure inside of the tank (PT-505 or PT-510) must be less than negative 3
psig, the vaporizer level (LT-528) should be < 95 % and there should be no ammonia
detected at the tank area or at the vaporizer package area. If any of the above conditions are
not met during operation, the station/package will automatically shutdown.
2. The operator must verify that the manual valves (BV-138, BV-140, BV-150, and BV-151) for
the pump train intended for operation are open.
3. Select (via the DCS) the tank (TNK-005A/B) to pump ammonia from.
4. With conditions normal and the tank (TNK-005A/B) selected to pump from, the recirculation
ABV (ABV-161 or ABV-201) of the selected tank is commanded to open and verified (via
limit switch).
5. When the recirculation ABV of the selected tank has been opened (via limit switch), the pump
suction ABV (ABV-139 or ABV-141) of the selected tank is commanded to open and
verified (via limit switch).
6. After the recirculation and pump suction ABVs have been opened, a pump start command is
sent to the forwarding package control panel.
7. The operator must select one of the two pumps (P-012A/B) for forwarding ammonia via the
DCS graphic.
8. In order to stop forwarding ammonia to the vaporizer (VPR-013), the operator will stop the
pump (P-012A/B) via the DCS graphic.
9. The vaporizer ABV (ABV-165) is commanded to close and verified (via limit switch).
10. The pump suction ABV (ABV-139 or ABV-141) at the selected tank (TNK-005A/B) is
commanded to close and verified (via limit switch).
11. The recirculation ABV (ABV-161 or ABV-201) at the selected tank (TNK-005A/B) is
commanded to close and verified (via limit switch).
Automatic Shutdowns:
1. The liquid level of the selected tank (TNK-005A/B) is < 5%.
2. The pressure inside of the tank is less than or equal to negative 3 psig.
3. The nitrogen purging pressure is not satisfied (low)
4. The vaporizer level is > 95%, which is indicated by LT-528
5. Ammonia detection at the tank farm.

VAPORIZER PACKAGE:

Vaporizer Junction Box [JBX-602] (Located On Skid):

- vaporizer liquid level (AI)
- limit switch (DI)
- pneumatic actuated valve-ABV (DO)
- control valve (AO)
- line pressure (AI)
- line flow (AI)

Operation:
1. In order for the vaporizer package to operate, there must be an appropriate level (> or = to 55%)
of liquid inside of the vaporizer (VPR-013), and the pressure must be at an operable pressure
(< 135 psig).
2. When the vaporizer ABV (ABV-165) has been opened and verified (via limit switch), the
ammonia level control valve (ACV-168) will maintain the level inside of the vaporizer
(VPR-013) using the vaporizer level transmitter (LT-528) as the process variable. The level
will be maintained based on a fixed set point. When a higher liquid level is required inside
of the vaporizer (VPR-013), the level control valve (ACV-168) will open more, allowing
more liquid to flow. When the desired level is reached, the level control valve (ACV-168)
will close.
3. The pressure control loop will be based on an operator set point. For this loop, the pressure
inside of the line (PT-526) is the process variable and will be controlled by the steam control
valve (ACV-180). When the pressure needs to be increased, the steam control valve
(ACV-180) will open more, allowing more steam to flow. As the pressure reaches the
desired pressure, the pressure control valve (ACV-180) will actuate accordingly to maintain
the appropriate pressure.
4. The ammonia flow control loop will be based on a DCS demand. As more flow is required, the
ammonia flow control valve (ACV-177 or ACV-221) actuates to maintain the appropriate
flow. As more ammonia is generated, the steam pressure loop and liquid level loop will
adjust accordingly.

Automatic Shutdowns:
1. Liquid level (LT-528) inside of the vaporizer reaches a shutdown level.
2. Pressure (PT-526) inside of the line reaches a shutdown level.
3. Low low vapor temperature (TE-524) going to the dilution air package.
4. Dilution Air Fan Trips
5. Low Dilution Air Flow (FT-525/523)
6. Ammonia Leak
7. Aux Steam Pressure Low (PI-520/522)
8. Aux Steam Pressure High (PI-520/522)
9. Aux Steam Temperature High (TI-521)

DILUTION AIR PACKAGE:

Dilution Air Heater Control Panel [cpl-605] (Located On Skid-Outside Of The Hazardous
Location):
- emergency shutdown push button
- run permissive (DO)
- heater status (DI)
- heater temperature control (AO)
- pressure switch (DI)
- air flow rate (AI)
- heater vessel temperature (AI)
- heater outlet temperature (AI)
- limit switch (DI)
- pneumatic actuated valve-ABV (DO)

Operation:
1. In order for the dilution air package to operate, there must be a minimum air flow through the
heater vessel, measured with the fan discharge flow transmitters (the sum of FT-537 and FT-
538). This means that the fan outlet valve (Fan 21A = ABV-197; Fan 21B = ABV-198) must
be open before starting the fan in the same line. There must not be a high heater bundle
temperature (internal to CPL), high heater outlet temperature (TE-536), or high vessel
temperature (TE-535).
2. There must first be a run permissive from the DCS.
3. After the run permissive is received at the heater control panel (CPL-605), the heater will start
if the local high temperature output in not active.
4. An analog signal is sent to the heater control panel (CPL-605)from the main control system in
order to fire the heater controllers.
5. In order to stop the heater, the run permissive is removed or the local emergency stop is
pressed.

Automatic Shutdowns:
1. No air flow through the heater vessel (FT-537/538).
2. High heater bundle temperature/Internal to control panel (CPL-605)
3. High heater outlet temperature (TE-536)
4. Low Heater outlet temperature (TE-536)
5. High Vessel (HT-025) temperature (TE-535)