1_General description.

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TEXON AUTOMATION BOILER CONTROLS

Texon ref. no. O-9114, O-9115, O-9116, O-9117

Vessels: LNG/C ”Al Khaznah”, LNG/C ”Shahamah”, LNG/C ”Ish”, LNG/C Ghasha”

Description and operating manual.

About the manual

The manual is divided into 10 sections:
1. General description
2. Control panels, brief description of the different functions
3. Operation
4. Graphic display, operation and calibration data inputs
5. Detailed description of Combustion controls (steam pressure, fuel oil, gas, air, level and steam
temperature)
6. Detailed description of Burner management for fuel oil (purge sequence, boiler safety)
7. Detailed description of Gas firing
8. Flame scanners
9. Trouble shooting

1. General description

Texon-Kockums Boiler Control Systems are well known and highly respected.
More than 35 years of experience and development has led to a fully integrated system.
The control concept is dedicated for marine main boilers and auxiliary systems.
Implemented in Siemens ”Simatic S7” PLC hardware, it is flexible to meet customer and project
requirements.
External equipment is specified and supplied by Texon.

Basic design features

Rugged basic design, based on development, design, installation, commissioning and operation of more than
250 marine boilers, of which 20 are dual fired onboard LNG-carriers, over a period of more than 35 years.
The system has extensive functionality and operators support for start up and any abnormal condition
operations.

 Brief description
See section 3-7 for more details.
Functions
 The MASTER controller is measuring the superheated steam outlet pressure (two transmitters each
boiler, the highest is used for the control).
 Depending on the steam pressure, high or low, increasing or decreasing, the master controller
output (POWER DEMAND) is varying from 0-100%.
 The power demand signal is multiplied 1x, 1.5x or 3x depending on the number of burners in
operation. The result is called BURNER DEMAND.
 The burner demand is the set-point for fuel oil controller and fuel gas controller
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 The set-point for the air controller is the sum of air required for each of the fuels. However, there is
a cross limiter which does not allow the fuel to increase until air supply is sufficient.
 The drum level controller uses three level transmitters. The two transmitters that are closest in the
level reading are selected and the average of these two is used as process value for the drum level
controller. The output from this controller is connected to the positioner of each of the two drum
level control valves (a small and a large valve). The two positioners are connected in series.
 The steam temperature controller uses three temperature transmitters at the superheater outlet
and one at the de-superheater outlet. The two superheater outlet transmitters that are closest in
the temperature reading are selected and the average of these two is used as process value for the
steam temperature controller.
 The F.O. pump pressure is controlled. A pressure transmitter is fitted at the heater outlet and an
output signal to an I/P-transducer is controlling the pump by-pass valve. The pressure set-point can
be either fixed or floating, following the burner rail oil pressure control valve opening.
 Atomizing steam pressure is controlled on both boilers. The pressure is following the graph supplied
by the burner maker.

 Construction
 The boiler controls is strictly technically speaking, one (1) system with full redundancy for CPU, HMI
and I/O-rack communication (ProfiBus).
 Physically, it is divided in PORT and STBD systems.
 The power supply is 24V DC from ship´s battery and 110V AC. An AC/DC converter (24V DC/20A) is
fitted in each of the PLC-cabinets.
 Controls available in ECR: All
 Controls available from local panel: Start and stop of burners. Control of fuel oil, fuel gas,
combustion air, drum level and steam temperature
 Controls are available in ECR as well as in local panel at all times.

 Power supply (Drawings 441.41.027_1 / 441.41.027_2 / 441.41.027_3)

24V DC supply (24V I)
Each of the PLC cabinets (PORT and STBD) has a 24V supply from ship´s battery system (”BATTERY
SWITCHBOARD FOR INSTRUM & ALARM SYS SERVICE”) in El. equipment room on F-deck.

110V AC supply to AC/DC converter (for 24V II)

Each of the PLC cabinets (PORT and STBD) has a 110V AC supply from ”UPS POWER DIST BOARD” in El.
equipment room on F-deck:
 PORT: Circuit UPS 10
 STBD: Circuit UPS 11

110V AC supply to Boiler Local Panel

The local panel has one (1) common 110V AC supply from circuit EL25 in ”AC 110V INST SERV SECT BD” in
El. equipment room on F-deck
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Transient protection
The 24V supply is protected by a transient suppressor (Blitzductor BVT AD 24). This is required for the
Siemens type approval from DNV.

Voltage divider
The 2.8kΩ and 2.0 kΩ resistors are used to produce a 10.0V reference for check of the battery supply
voltage (2.0/2.0+2.8) x 24V = 10V

Rectifier diodes (V103 etc)

The purpose of the diodes is to make sure there is 24V DC even if one of the supplies fail
(24V I or 24V II)

 Loop Guard
 Each sensor (transmitter, push button etc) is supplied 24V DC from a "Loop Guard".
 The loop guard is limiting the current to a safe value, determined by the bulb.
 The bulb is 24V/4W, thus giving a maximum current of approx. 170mA.

1) Short circuit across a 4-20mA transmitter: Current is limited to 70mA by the bulb and 250Ω resistor.
2) Short circuit across i.e. a limit switch: Current is limited to 170mA by the bulb.

1 2 3 4 5 6 7 8 9 The loop guard is mounted on a terminal rail and has eight pcs of bulbs.
The bulbs are numbered 1-9 as per the sketch.

1 4 7 The terminals on top are connected all together. This can be done in two different
ways depending on the type of loop guard:
3 6 9 1. Top terminals 1-9 are linked together on the printed circuit board in groups of
three: 1-2-3, 4-5-6, 7-8-9. In this case 3-4 and 6-7 are connected together with
2 5 8 an external jumper
2. Top terminals 1-9 are all linked together on the printed circuit board. In this
To corresp. no. of bulb
case external jumpers are not required
1 2 3 4 5 6 7 8 9 The terminals in the bottom correspond to a bulb as per the sketch.
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 PLC
 The PLC is divided into separate "racks" (see drwg 461.41.014):
 CPU-racks are numbered #0 (Port PLC cabinet) and #1 (Stbd PLC-cabinet)
 I/O racks 11-12-13-14 are fitted in Port PLC-cabinet in ECR
 I/O racks 21-22-23-24 are fitted in Stbd PLC-cabinet in ECR
 I/O rack 16 (Port) and 26 (Stbd) are fitted in Engine Control Console, under the control panel
 I/O rack 17 (Port), 27 (Stbd) and 31 (Common mimic) are fitted in Boiler Local Panel (BLP)

Control
 The boilers are normally controlled by one of the CPU:s. This CPU is the "Master". A yellow LED "MSTR"
indicates which one is the master CPU

Communication
The CPU:s communicate with the I/O-racks via the ProfiBus cables (purple color)
The CPU:s communicate with the HMI via the "ProfiNet" network cables (green color)
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Layout of CPU:s, I/O-racks, HMI, PC and network ring

Port side ECC Stbd side ECC

SCADA #0 SCADA #1

T20A
24V DC from 24V I
ships battery
Industrial Ethernet / Profinet

Port side boiler Stbd side boiler

control cabinet control cabinet

T6A AC
110V AC from 24V II
main switch board
DC
AC/DC converter

CPU #0 CPU #1

2x sync
cables

ProfiBus ProfiBus
DP#0 DP#1

Rack #11 Rack #12 Rack #13 Rack #14 Rack #16 Rack #17 Rack #21 Rack #22 Rack #23 Rack #24 Rack #26 Rack #27 Rack #31

Digital inputs, Analog outputs, Analog intputs, Digital inputs, Digital inputs, Digital inputs, Digital inputs, Analog outputs, Analog intputs Digital inputs, Digital inputs, Digital inputs, Digital outputs
UV-scanner Digital outputs IR-scanner Digital outputs Digital outputs Digital outputs UV-scanner Digital outputs Digital outputs Digital outputs Digital outputs

Port side boiler Port side Port side boiler Stbd side boiler Stbd side Stbd side boiler Common boiler
control cabinet ECC local panel control cabinet ECC local panel local panel
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 PSU for CPU-racks

The PSU is supplied with 24V DC.

For further information on this module, see "Siemens S7-400 modules.pdf"
In case of battery backed up memory, there are two batteries:
 BATT 1
 BATT 2
In case of battery failure, the alarm "At least one of the batteries is faulty" will
show on the alarm screen.
 Check the battery voltage. Do not remove batteries unless you are sure
to have a correct 24V supply. Each battery should be 3.6V.
 If both correct, try to turn the batteries in the holder to get rid of oxide
or similar
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 CPU
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 The CPU is fitted with a number of diagnostic LED:s

Cables connected to CPU (see drwg 441.41.004_1):

 2 sets of synchronization cables (orange fiber optics)
 One “ProfiBus” for connection to the I/O-system (purple cable)
 One network cable for connection to network switch

For further information on this module, see "Siemens S7-400 redundant system.pdf"

 I/O modules
 Each I/O module is fitted in a “slot”.
 There are five types of I/O modules:
1. Analog input 8 channel (Transmitters, IR flame scanners)
2. Analog output 8 channel (I/P-transducers, E-positioners)
3. Digital input 32 channel (Push buttons, limit switches)
4. Digital outputs 32 channel (Lamps, solenoids, relays)
5. Counter 8 channel (UV flame scanners)
 Each I/O is identified by
 Rack 11, 12, 13, 14, 16, 17………
 Slot Beginning on 4 in each rack
 Channel Analog modules: 0-7
Digital modules: 0.0-0.7, 1.0-1.7, 2.0-2.7, 3.0-3.7
 Terminal 1-40 on all modules
 Slots are numbered from 4 and upwards
 Each I/O module is connected with a removable 40-pole connector with wires. Terminal number is
normally printed on the blue wire in all modules for easy identification.
 Analog modules have a red LED "SF". This will be lit in case of a "Wire break"
 Digital inputs have a green LED status indicator for each channel. LED "ON" =24V in
 Digital outputs have a green LED status indicator for each channel. LED "ON" =24V out
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 Communication modules
 Each I/O-rack is fitted with two IM153-2 communication modules
 The left module is always connected to ProfiBus DP #0
 The right module is always connected to ProfiBus DP #1
 IM153-2 module is fitted with five diagnostic LED:s
1. SF System failure Normally OFF
2. BF1 Backup failure Normally OFF
3. BF2 Backup failure Normally OFF
4. ACT "Active" Normally ON or OFF (one IM153-2 is always "Active")
5. ON Normally ON

Relays
PORT STBD Function
K101-138 K201-238 Burner actuators, OPEN order
K139 K239 Steam dump piston valve, OPEN order
K140-141 K240-241 F.D. fan Low-High order
K142 K242 Main condenser dump spray valve, OPEN order
K143-144 K243-244 Boiler tripped, signal to M/E control system an Diesel generator
K145 K245 Master gas shut off valve, OPEN order
K146 K246 Master N2 purge valve, OPEN order
K147 K247 Master vent valve, OPEN order
K148-170 K248-270 Signals to lamps in ECR mimic panel
K171 K271 Spare
K172 K272 Signal to IMS "Boiler control system fail"
K173-174 K273-274 Spare
K175 K275 Signal to F.W. motor valve to close
K176-179 K276-279 Hi/Lo drum levels, signals to M/E control system
K180 K280 Start signal to large fuel oil pump
K181 K281 Signal to IMS "Steam dump control"