Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" Created by: Approved: Approved: Approved Name Timm Greschner Erhard Rieder Sylvia Roehner Thilo Schietinger Position Process Engineer Head of Process Engineering Automation Engineering Commissioning Signature Date © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals Revisions: Version V1 Date 16.05.2011 Name Timm Greschner Description Creation P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 2 of 38 Functional Sequence Description 1. 2. 2.1 Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals TABLE OF CONTENTS INTRODUCTION............................................................................................................4 DESCRIPTION OF CONTROL SYSTEM.......................................................................5 Operating modes..........................................................................................................5 Basic position.......................................................................................................................6 Pre-purge...............................................................................................................................7 Heat-up..................................................................................................................................9 Fresh air mode....................................................................................................................10 Process air mode................................................................................................................11 Shutdown step....................................................................................................................12 Emergency shutdown........................................................................................................14 Fault shutdown...................................................................................................................15 LEL Fault (Alarm group \"C\").............................................................................................16 Quick cooling......................................................................................................................17 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 2.1.9 2.1.10 2.2 2.3 Manual mode..............................................................................................................18 Process values and parameters................................................................................19 Temperature........................................................................................................................19 Pressure..............................................................................................................................19 Frequency, speed...............................................................................................................19 Flow rates............................................................................................................................19 Time.....................................................................................................................................20 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 3. 3.1 3.2 3.3 4. 5. 5.1 5.2 5.3 5.4 6. 6.1 ALARMS......................................................................................................................21 Alarm groups..............................................................................................................21 Alarm list.....................................................................................................................22 Summary of causes and consequences of safety function faults..........................26 SIGNAL EXCHANGE...................................................................................................28 ANNEX A: RTO VALVE CONTROL............................................................................29 Functional description - phase 1 (inlet tank 1).........................................................29 Functional description - phase 2 (inlet tank 2).........................................................30 Functional description - phase 3 (inlet tank 3).........................................................31 RTO valve time diagram.............................................................................................32 ANNEX B: BURNER CONTROL.................................................................................33 Burner startup............................................................................................................33 Checking of differential pressure measuring devices....................................................33 Burner ignition....................................................................................................................34 Burner control (air / gas ratio pressure control).............................................................34 Burner cool down...............................................................................................................35 6.1.1 6.1.2 6.1.3 6.1.4 6.2 6.3 Autothermal operation...............................................................................................36 Control of excess energy at the RTO (KR103-T05 TIC)............................................36 P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 3 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 1. INTRODUCTION The process air streams produced by production machinery at BASF Paper Chemicals's plant in Zhenjiang NewZone, China 212132 are treated by the newly installed thermal oxidizer. The oxidizer consists of the following main components: • Exhaust air fanVP111 will be provided by BASF • Process air collecting ducts KA163 incl. 2 Demisters • RTO unit BK124, BK125, BK126, KL131, KL231, KL331 • Combustion air supply VV141 • Burner equipment WG153 • Hot gas bypass KR103 • Purge air/ Fresh air supply VQ112 All items of equipment are shown on flow chart, drawing no. 500064643. This schematic is the basis for this description. The following description gives detailed information on equipment functioning with regard to • Start-up • Operation • Shutdown • and the safety functions P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 4 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2. DESCRIPTION OF CONTROL SYSTEM 2.1 Operating modes The RTO has the following modes of operation: • Basic position • Pre-purge • Heat-up • Fresh air mode • Process air mode • Shutdown step • Fault shutdown • Emergency shutdown • RTO quick cooling (cool-down, for maintenance only) Fig. 1 shows the order in which the operation modes occur. Fault shutdown Emergency shutdown RTO quick cooling Shutdown step Basic position Prepurge Heat-up Fresh air mode Process air mode Fig. 1: Order of operating modes Please note: An emergency or fault shutdown can occur in any operational status. All modes of operation are described in more detail in the following sections. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 5 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.1.1 Basic position This operation mode is the basic or rest position of the RTO. After termination of the safety run and after an emergency or fault shutdown, the system switches to this status. For a defined initial status of the RTO, the control system performs the following operations: • Process air damper KA163-K107 is closed. • Fresh air damper KA163-K117 is opened. • Fresh air damper VQ112-K107 is opened. • Purge air damper VQ112-K117 is closed. • Inlet air valve KL131-V107 is closed. • Outlet air valve KL131-V127 is closed. • Purge air damper KL131-K147 is closed • Inlet air valve KL231-V107 is closed. • Outlet air valve KL231-V127 is closed. • Purge air damper KL231-K147 is closed. • Inlet air valve KL331-V107 is closed. • Outlet air valve KL331-V127 is closed. • Purge air damper KL331-K147 is closed. • Combustion air damper WG153-K106 is closed. • Exhaust air fan VP111-V101 is switched off. • Combustion air fan VV141-V101 is switched off (Exception: When burner cooldown mode is active, combustion air fan VV141-V101 is switched on) • Solenoid valve VV141-V07 is switched to venting. • Solenoid valve AP191-V07 is switched to venting. • Gas solenoid valves WG153-V07 and WG153-V17 are closed. • Hot gas damper KR103-K107 is closed. Signal exchange in this operating mode (also refer to section 4: Signal exchange): • \"RTO in operation\" signal is switched off. • \"RTO heat-up\" signal is switched off. • \"RTO fresh air mode\" signal is switched off. • ‘RTO process air mode\" signal is switched off. • \"RTO safety run\" signal is switched off. • \"RTO fault\" signal is switched on as long as there are no A, C, D or S alarms (for details also refer to section 3.1: Alarm groups). • \"RTO emergency shutdown\" signal is switched on. • \"RTO warning\" signal is switched on as long as there are no B-alarms (for details also refer to section 3.1: Alarm groups). • \"RTO remote operation\" signal is switched on if the RTO was set to remote operation on control panel. Please note: To prevent broken wires, fault signals are switched off when a fault occurs, and switched on in OK status. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 6 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.1.2 Pre-purge In this operating mode, the RTO is purged with fresh air in order to remove all inflammable gas mixtures before the burner is started. If there are no fault messages, the RTO can be started from basic position as follows: - when \"LOCAL\" operating mode is selected, by pressing the \"RTO START\" push button on the operator panel - when \"REMOTE\" operating mode is selected, by activating the \"RTO Start\" signal via signal exchange (also see chapter 4 : Signal exchange). After start-up, the following operations take place: • RTO valve control for inlet air valves and outlet air valves (KL131-V107/V127, KL231-V107/V127 and KL331-V107/V127) is started (see Annex A: RTO valve control). • Combustion air damper WG153-K106 moves to ignition position (WG153-G08). • Purge air fan VQ112-V101 is started at fixed speed 1 (ca. 45Hz ⇒ 2800Nm³/h) (This value has to be adjusted during commissioning.) • Combustion air fan VV141-V101 is started. Before the failsafe pre-purge time relay (within the Pilz PNOZmulti) is started, differential pressure measuring devices AP191-P02 and VV141 P02 are checked (see section 6.1.1 „Checking of differential pressure measuring devices\"). The following signals are monitored during the pre-purge cycle to make it failsafe1: - Process air damper KA163-K107 must be closed (KA163-G18). - Fresh air damper KA163-K117 must be open (KA163-G28). - Fresh air damper VQ112-K107 must be open (VQ112-G08). - Purge air damper VQ112-K117 must be closed (VQ112-G38). - The speed monitor of the Purge air fan (V101-S08B) must display that the fan speed is above minimum speed. - The differential pressure on AP191-P02 and VV141-P02 must be OK. - Combustion air fan VV141-V101 must be switched on. The pre-purge cycle ends after 6 minutes (this allows the volume of the RTO tank to be replaced 5 times) or immediately, when the combustion chamber temperature BK126-T65 is above 750°C. When the purge cycle is over, ignition of the burner takes place. The system does not switch over automatically to heat-up before the burner is burning. 1 IMPORTANT !! All measuring points marked with Z in the schematic must always be processed in a failsafe manner. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 7 of 38 Functional Sequence Description If a fault occurs during pre-purge, the RTO reacts according to the alarm list (see section 3.2 Alarm list). Signal exchange in this operating mode (also refer to section 4: Signal exchange): • \"RTO in operation\" signal is switched on. • \"RTO heat-up\" signal is switched off. • \"RTO fresh air mode\" signal is switched off. • \"RTO process air mode\" signal is switched off. • \"RTO safety run\" signal is switched off. • \"RTO fault\" signal is switched on as long as there are no A, C, D or S alarms (for details also refer to section 3.1: Alarm groups). • \"RTO emergency shutdown\" signal is switched on. • \"RTO warning\" signal is switched on as long as there are no B-alarms (for details also refer to section 3.1: Alarm groups). • \"RTO remote operation\" signal is switched on if the RTO was set to remote operation on control panel. Please note: To prevent broken wires, fault signals are switched off when a fault occurs, and switched on in OK status. Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 8 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.1.3 Heat-up After termination of the pre-purge cycle, the system switches to heat-up mode. This step is designed to bring the RTO to the desired operating temperature. The burner is started for this purpose (see section 6.1 “Burner startup”). As soon as the burner is in operation, the following takes place: • TIRC WG153-T151 starts with control of combustion air damper WG153-K106. The setpoint of TIRC WG153-T15 is ramped up, beginning with the actual temperature at 3,3°C/min to 820°C. The actual value for WG153-T15 is the combustion chamber temperature of the outlet bed (BK126-T05, BK126-T15 or BK126-T25) in each case. When the combustion chamber temperatures of the RTO BK126-T05, BK126-T15 and BK126-T25 reach 780°C, the oxidizer switches over automatically to fresh air mode after 3 minutes. (The system is now ready for process air mode and waits in fresh air mode until it receives a request for air treatment from BASF Paper Chemicals). Signal exchange in this operating mode (also refer to section 4: Signal exchange): • \"RTO in operation\" signal is switched on. • \"RTO heat-up\" signal is switched on. • \"RTO fresh air mode\" signal is switched off. • \"RTO process air mode\" signal is switched off. • \"RTO safety run\" signal is switched off. • \"RTO fault\" signal is switched on as long as there are no A, C, D or S alarms (for details also refer to section 3.1: Alarm groups). • \"RTO emergency shutdown\" signal is switched on. • \"RTO warning\" signal is switched on as long as there are no B-alarms (for details also refer to section 3.1: Alarm groups). • \"RTO remote operation\" signal is switched on if the RTO was set to remote operation on control panel. Please note: To prevent broken wires, fault signals are switched off when a fault occurs, and switched on in OK status. 1 In control mode, combustion air damper WG153-K106 only close until low fire position is reached (otherwise the burner would go out). P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 9 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.1.4 Fresh air mode In this operation mode, the RTO is operated on fresh air and is kept at operating temperature with the aid of the burner1. Should the combustion chamber temperatures BK126-T05, BK126-T15 or BK126-T25 rise above 850°C, the RTO switches over to autothermal mode (see section 6.2 “Autothermal operation”). In this operation mode, the RTO can be operated on fresh air for an unlimited period of time at a flow rate of approx. 2800Nm³/h (VQ112 at speed 1). As soon as the \"Request for air treatment\" signal is activated, the RTO automatically switches over to process air mode. Signal exchange in this operating mode (also refer to section 4: Signal exchange): • \"RTO in operation\" signal is switched on. • \"RTO heat-up\" signal is switched off. • \"RTO fresh air mode\" signal is switched on. • \"RTO process air mode\" signal is switched off. • \"RTO safety run\" signal is switched off. • \"RTO fault\" signal is switched on as long as there are no A, C, D or S alarms (for details also refer to section 3.1: Alarm groups). • \"RTO emergency shutdown\" signal is switched on. • \"RTO warning\" signal is switched on as long as there are no B-alarms (for details also refer to section 3.1: Alarm groups). • \"RTO remote operation\" signal is switched on if the RTO was set to remote operation on control panel. Please note: To prevent broken wires, fault signals are switched off when a fault occurs, and switched on in OK status. 1 As long as the RTO is not in autothermal mode (see section 6.2 „\") burner is switched on and TIRC-WG153-T15 control combustion air damper WG153-K106 with a setpoint of 820°C. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 10 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.1.5 Process air mode The RTO switches over automatically from fresh air mode to process air mode when the \"Request for air treatment\" signal is activated by BASF Paper Chemicals: • RTO-Valve Control for purge air valves (KL131-V147, KL231-V147 and KL331-V147) would activated (see 5 “Annex A: RTO valve control”). • Process air damper KA163-K107 is opened. • Purge air damper VQ112-K117 is opened. • Start of the exhaust air fan VP111-V101 via signal exchange. • 20 sec. (this value has to be adjusted during commissioning) after the process air damper KA163-K107 and purge air damper VQ112-K117 are open, fresh air dampers KA163-K117 and VQ112-K107 will be closed. • The purge air fan VQ112-V101 is then reduced to fixed speed 3 (ca. 25Hz ⇒ 900Nm³/h) (This value has to be adjusted during commissioning). • Control of hot gas bypass KR103-TIC05 is enabled with setpoint 900°C for combustion chamber (actual value is the maximum outlet temperature of BK126-T05, BK126-T15 or BK126-T25) [see chapter: 6.3]. Signal exchange in this operating mode (also refer to section 4: Signal exchange): • \"RTO in operation\" signal is switched on. • \"RTO heat-up\" signal is switched off. • \"RTO fresh air mode\" signal is switched off. • \"RTO process air mode\" signal is switched on. • \"RTO safety run\" signal is switched off. • \"RTO fault\" signal is switched on as long as there are no A, C, D or S alarms (for details also refer to section 3.1: Alarm groups). • \"RTO emergency shutdown\" signal is switched on. • \"RTO warning\" signal is switched on as long as there are no B-alarms (for details also refer to section 3.1: Alarm groups). • \"RTO remote operation\" signal is switched on if the RTO was set to remote operation on control panel. Please note: To prevent broken wires, fault signals are switched off when a fault occurs, and switched on in OK status. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 11 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.1.6 Shutdown step When the operator presses the \"RTO STOP\" switch on the operator panel, or the \"RTO stop\" signal is deactivated by BASF Paper Chemicals, the system switches to the safety cycle. The process air damper is closed and the RTO is purged with fresh air. • Fresh air damper VQ112-K107 is opened. • Fresh air damper KA163-K117 is opened. • Process air damper KA163-K107 is closed. After 3 minutes of hot safety cycle with fresh air, the burner and the fans are switched off: • Gas solenoid valves WG153-V07 and WG153-V17 are closed. • After the burner has been switched off, combustion air damper WG153-K106 is closed. • Purge air fan VQ112-V101 is switched off. • Hot gas damper KR103-K107 is closed. • Combustion air fan VP141-V101 is switched off after a purge cycle of 20 seconds. After 60 seconds (this is the time required by the fans to slow down and stop) the inlet air valves and the outlet air valves plus the purge air dampers are closed (KL131-V107/V127/K147, KL231-V107/V127/K147 and KL331-V107/V127/K147) and the RTO automatically goes to basic position. (See section 2.1.1 “Basic position”). Note: In case the RTO was not in process air mode, the oxidizer switches off immediately without safety cycle. Note: If the RTO would be cleaned or maintained the exhaust air duct system in front and behind the unit must be blocked with an isolating plate. Only this isolation of duct system allows a safe work in the RTO! Signal exchange in this operating mode (also refer to section 4: Signal exchange): • \"RTO in operation\" signal is switched on. • \"RTO heat-up\" signal is switched off. • \"RTO fresh air mode\" signal is switched off. • \"RTO process air mode\" signal is switched off. • \"RTO safety cycle\" signal is switched on. • \"RTO fault\" signal is switched on as long as there are no A, C, D or S alarms (for details also refer to section 3.1: Alarm groups). • \"RTO emergency shutdown\" signal is switched on. • \"RTO warning\" signal is switched on as long as there are no B-alarms (for details also refer to section 3.1: Alarm groups). • \"RTO remote operation\" signal is switched on if the RTO was set to remote operation on control panel. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 12 of 38 Functional Sequence Description Please note: To prevent broken wires, fault signals are switched off when a fault occurs, and switched on in OK status. Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 13 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.1.7 Emergency shutdown In emergencies, the RTO can be switched off by \"D-alarms\" (see section 3.1 Alarm groups). All \"D\" alarms are failsafe signals (e.g. emergency stop). The following actions take place: • All fans are switched off immediately (without safety cycle). • All dampers and valves except for the fresh air dampers are closed immediately. Fresh air dampers VQ112-K107 and KA163-K117 are opened. The control system keeps the plant in this status until the fault has been corrected and the fault has been reset on the control panel. Signal exchange in this operating mode (also refer to section 4: Signal exchange): • \"RTO in operation\" signal is switched off. • \"RTO heat-up\" signal is switched off. • \"RTO fresh air mode\" signal is switched off. • \"RTO process air mode\" signal is switched off. • \"RTO safety run\" signal is switched off. • \"RTO fault\" signal is switched off. • \"RTO emergency shutdown\" signal is switched off. • \"RTO warning\" signal is switched on as long as there are no B-alarms (for details also refer to section 3.1: Alarm groups). • \"RTO remote operation\" signal is switched on if the RTO was set to remote operation on control panel. Please note: To prevent broken wires, fault signals are switched off when a fault occurs, and switched on in OK status. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 14 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.1.8 Fault shutdown A fault shutdown is triggered by \"A\" and \"S\" alarms (see section 3.1 Alarm groups). The following actions take place: • Purge air fan VQ112-V101 is switched off. • Fresh air damper VQ112-K107 is opened. • Fresh air damper KA163-K117 is opened. • Process air damper KA163-K107 is closed. • Hot gas damper KR103-K107 is closed. • Combustion air fan VP141-V101 is switched off after a purge cycle of 20 seconds. • Gas solenoid valves WG153-V07 and WG153-V17 are closed. • After the burner has been switched off, combustion air damper WG153-K106 is closed. After 60 seconds, the raw gas and outlet air valves plus the purge air dampers are closed (KL131-V107/V127/K147, KL231-V107/V127/K147 and KL331-V107/V127/K147). The control system keeps the plant in this status until the fault has been corrected and the fault has been reset on the control panel. Signal exchange in this operating mode (also refer to section 4: Signal exchange): • \"RTO in operation\" signal is switched off. • \"RTO heat-up\" signal is switched off. • \"RTO fresh air mode\" signal is switched off. • \"RTO process air mode\" signal is switched off. • \"RTO safety run\" signal is switched off. • \"RTO fault\" signal is switched off. • \"RTO emergency shutdown\" signal is switched on. • \"RTO warning\" signal is switched on as long as there are no B alarms (for details also refer to section 3.1: Alarm groups). • \"RTO remote operation\" signal is switched on if the RTO was set to remote operation on control panel. Please note: To prevent broken wires, fault signals are switched off when a fault occurs, and switched on in OK status. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 15 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.1.9 LEL Fault (Alarm group \"C\") The RTO Unit is equipped with one LEL measurement device in the inlet pipe to the RTO. The LEL meter should be installed after mixing (dilution) point in the ductwork to the RTO. In case of a high LEL (25%) at the Measurement point, the RTO must be switched over to bypass by BASF (RTO fresh air mode) to prevent waste gases above the safe level of LEL reaching the RTO. Exhaust air damper KA163-K107 must be closed. Fresh air damper KA163-K117 must be opened. Fresh air damper VQ112-K107 must be opened. These changeovers to fresh air mode are executed by the LEL analyser QIZA+ Q24. The retention time of the air after the LEL analysers and the RTO inlet is long enough to changeover to Fresh Air Mode before the high LEL load gets in the RTO inlet damper KA163-K107. The Fresh Air valve KA163 K117 is located before the inlet into the RTO. The exhaust air damper KA163-K107 must be retained closed and the exhaust air fan VP111 by BASF) must be running until the LEL measurement device is detecting LEL below 20% for at least 10 minutes. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 16 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.1.10 Quick cooling This operation mode can only be started when the RTO is in basic position. The quick cooling function is used to cool down the combustion chamber for maintenance work. This operation mode is started by pressing the \"START QUICK COOLING\" push button on the operator panel. • Process air damper KA163-K107 remains closed. • Fresh air damper VQ112-K107 remains open. • Fresh air damper KA163-K117 remains open. • RTO valve control for inlet air valves, purge air damper and outlet air valves (KL131-V107/V127/K147, KL231-V107/V127/K147 and KL331-V107/V127/K147) is started (see Annex A: RTO valve control). • Combustion air damper WG153-K106 moved to starting position (WG153-G08). • Purge air fan VQ112-V101 is started at fixed speed 2 (50Hz ⇒ 3000Nm³/h). • Combustion air fan VP141-V101 is started. • Hot gas damper KR103-K107 is opened 50%. • Gas solenoid valves WG153-V07 and WG153-V17 remain closed. The cooling operation is switched off by pressing the \"RTO STOP\" push button on the operator panel. Signal exchange in this operating mode (also refer to section 4: Signal exchange): • \"RTO in operation\" signal is switched on. • \"RTO heat-up\" signal is switched off. • \"RTO fresh air mode\" signal is switched off. • \"RTO process air mode\" signal is switched off. • \"RTO safety run\" signal is switched off. • \"RTO fault\" signal is switched on as long as there are no A, C, D or S alarms (for details also refer to section 3.1: Alarm groups). • \"RTO emergency shutdown\" signal is switched on. • \"RTO warning\" signal is switched on as long as there are no B-alarms (for details also refer to section 3.1: Alarm groups). • \"RTO remote operation\" signal is switched on if the RTO was set to remote operation on control panel. Please note: To prevent broken wires, fault signals are switched off when a fault occurs, and switched on in OK status. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 17 of 38 2.2 Manual mode All electric controlled components, which have no safety function for the unit, can operate directly by hand. For this hand operation following release conditions must be fulfilled: • The RTO is switched off in basic position. • The combustion chamber temperature (BK126-T05/-T15/-T25) is below 250°C. These functions allow a similar maintenance and commissioning of replaced components, like limit switch, dampers or motors. Note: To save a long time function of the under pressure relief damper KA163-V130 the switch KA163-G48 must be checked manually one time per year. © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 2.3 Process values and parameters The process values which are described in this document above are setpoints during the design of the RTO unit. These values have to be adjusted during commissioning. Description Setpoint Actual value Unit (design) (commissioning) 2.3.1 Temperature Control temperature, burner WG153 Temperature ramp-up WG153 Autothermal mode ON High temperature mode up Burner cooldown ON Burner cooldown OFF 820 3,3 850 750 320 300 °C °C/min °C °C °C °C 2.3.2 Pressure Underpressure before fan (process air mode) Min. gas pressure Max. gas pressure -20 100 200 mbar mbar mbar 2.3.3 Frequency, speed VQ112-X09 fixed speed 1, Heat-up / fresh air mode (approx.) VQ112-X09 fixed speed 2, Quick cooling (approx.) VQ112-X09 fixed speed 3, Process air mode / purging (approx.) VP111-X09 controlled speed in process air mode (approx.) VV141-X09 fixed speed 1, burner cool down 45 50 25 24 15 Hz Hz Hz Hz Hz 2.3.4 Flow rates Heat-up at fixed speed 1 2800 Nm³/h P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 19 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 4228 3000 Nm³/h Nm³/h Process air mode Quick cooling at fixed speed 2 Delay of oxidizer's readiness for treatment cycle Safety run time, damper program 3 60 min. s P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 20 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 3. ALARMS 3.1 Alarm groups The following list shows the alarms of the RTO oxidizer. There are 5 alarm groups: Alarm group \"A\": Alarms that trigger an RTO fault shutdown. Alarm group \"B\": Pre-alarms, without an immediate effect on the RTO. Alarm group \"C\": Alarms that lead to a switchover to fresh air mode. Alarm group \"D\": Alarms that trigger an RTO emergency shutdown. Alarm group \"S\": Alarms that trigger a fault shutdown in quick cooling mode. The following table shows the interrelationship between operation mode and alarm group: Mode A B C D S Initial position X X - X - Purge mode X X - X - Heat-up mode X X - X - Fresh air mode X X - X - Process air mode X X X X - Safety run X X - X - Rapid cooling - X - X X X: Alarm group applies to this operation mode. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 21 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 3.2 Alarm list Syntax of warnings/alarms: ExplanatiFunction group on Example AP191 Item of equipment - P02 - Description Min. diff. pressure, RTO ( Alarm group ( A ) ) * Selection of 2 out of 3 from BK126-T05, BK126-T15 and BK126-T25. ** When the burner fails, this is a \"A\" fault. item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Warning/alarm Air condition unit fault control cabinet (B) Airway across RTO fault (A) AP191-P02 Diff.pressure RTO min.(A) AP191-P02 Diff.pressure switch RTO test fault (A) AP191-P02 Diff.pressure switch RTO warning (B) At least one controller in manual mode (B) AT192-T05 RTO outlet temperature analog value fault (A) AT192-T05 RTO outlet temperature max.fault (A) AT192-T05 RTO outlet temperature max.warning (B) AT192-T15 RTO outlet temperature analog value fault (A) AT192-T15 RTO outlet temperature max.fault (A) AT192-T15 RTO outlet temperature max.warning (B) BK126-T05 Combustion chamber bed 1 temperature analog value fault (A) BK126-T05 Combustion chamber bed 1 temperature max.fault (A) BK126-T05 Combustion chamber bed 1 temperature max.warning (B) BK126-T05/15/25 2 of 3 Temp.below disposal temp. (C) BK126-T15 Combustion chamber bed 2 temperature analog value fault (A) BK126-T15 Combustion chamber bed 2 temperature max.fault (A) BK126-T15 Combustion chamber bed 2 temperature max.warning (B) BK126-T25 Combustion chamber bed 3 temperature analog value fault (A) BK126-T25 Combustion chamber bed 3 temperature max.fault (A) BK126-T25 Combustion chamber bed 3 temperature max.warning (B) BK126-T65 Combustion chamber safety temperature switch (A) BK126-T65 Safety teperature analog value fault (A) BK126-T65 Temperature switch 750°C below (C) BK126-T65 Temperature switch 750°C plausibility warning (B) Burner safety chain monitoring (A) Control cabinet - temperature high (B) Emergency stop burner tripped (D) Emergency stop control cabinet tripped (D) Emergency stop customer tripped (D) Emergency stop exhaust air fan tripped (D) Emergency stop monitoring PNOZ Multi (D) Fuse monitoring 230V (A) Fuse monitoring 24V (A) * P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 22 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals * Selection of 2 out of 3 from BK126-T05, BK126-T15 and BK126-T25. ** When the burner fails, this is a \"A\" fault. item 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 Warning/alarm Fuse monitoring heater / aircondition (B) KA163/V07 Process air damper limit switch position lost (A) VP111-P02 Underpressure analog value fault (C) VP111-P02 Underpressure max.fault (C) VP111-P02 Underpressure max.warning (B) VP111-P02 Underpressure min.fault (C) VP111-P02 Underpressure min.warning (B) KA163-P12 Pressure max. exhaust air (C) KA163-Q24 LEL Alarm (C) KA163-T05 Process air temperature analog value fault (A) KA163-T05 Process air temperature max.fault (A) KA163-T05 Process air temperature max.warning (B) KA163-V07 Process air damper limit switch fault (A) KA163-V07 Process air damper run time fault close (A) KA163-V07 Process air damper run time fault open (A) KA163-V17 Fresh air damper limit switch fault (A) KA163-V17 Fresh air damper run time fault close (A) KA163-V17 Fresh air damper run time fault open (A) KA163-P22 Diff.pressure Demister min.(A) KA163-P22 Diff.pressure Demister max. fault (A) KA163-P22 Diff.pressure Demister warning (B) VQ112-V07 Purge air damper limit switch fault (A) VQ112-V07 Purge air damper run time fault close (A) VQ112-V07 Purge air damper run time fault open (A) VQ112-V17 Fresh air damper limit switch fault (A) VQ112-V17 Fresh air damper run time fault close (A) VQ112-V17 Fresh air damper run time fault open (A) KL131-V07 Inlet air valve limit switch fault (A) KL131-V07 Inlet air valve limit switch position lost (A) KL131-V07 Inlet air valve run time fault close (A) KL131-V07 Inlet air valve run time fault open (A) KL131-V27 Outlet air valve limit switch fault (A) KL131-V27 Outlet air valve limit switch position lost (A) KL131-V27 Outlet air valve run time fault close (A) KL131-V27 Outlet air valve run time fault open (A) KL131-V47 Purge air damper limit switch fault (B) KL131-V47 Purge air damper limit switch position lost (B) KL131-V47 Purge air damper run time fault close (B) KL131-V47 Purge air damper run time fault open (B) KL231-V07 Inlet air valve limit switch fault (A) KL231-V07 Inlet air valve limit switch position lost (A) KL231-V07 Inlet air valve run time fault close (A) KL231-V07 Inlet air valve run time fault open (A) KL231-V27 Outlet air valve limit switch fault (A) KL231-V27 Outlet air valve limit switch position lost (A) KL231-V27 Outlet air valve run time fault close (A) KL231-V27 Outlet air valve run time fault open (A) P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 23 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals * Selection of 2 out of 3 from BK126-T05, BK126-T15 and BK126-T25. ** When the burner fails, this is a \"A\" fault. item 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 Warning/alarm KL231-V47 Purge air damper limit switch fault (B) KL231-V47 Purge air damper limit switch position lost (B) KL231-V47 Purge air damper run time fault close (B) KL231-V47 Purge air damper run time fault open (B) KL331-V07 Inlet air valve limit switch fault (A) KL331-V07 Inlet air valve limit switch position lost (A) KL331-V07 Inlet air valve run time fault close (A) KL331-V07 Inlet air valve run time fault open (A) KL331-V27 Outlet air valve limit switch fault (A) KL331-V27 Outlet air valve limit switch position lost (A) KL331-V27 Outlet air valve run time fault close (A) KL331-V27 Outlet air valve run time fault open (A) KL331-V47 Purge air damper limit switch fault (B) KL331-V47 Purge air damper limit switch position lost (B) KL331-V47 Purge air damper run time fault close (B) KL331-V47 Purge air damper run time fault open (B) KR103-V07 Hot gas damper limit switch fault (A) KR103-V07 Hot gas damper run time fault close (A) KR103-V07 Hot gas damper run time fault open (A) MD107-P02 Compressed air - pressure min. (A) MG151-P02 Gas pressure min. (A) MG151-P12 Gas pressure max. (A) PLC Communication fault [OB87] (B) PLC Cycle time monitoring [OB80] (B) PLC Diagnostic fault [OB82] (B) PLC Hardware fault CPU [OB84] (B) PLC Periphery fault [OB122] (B) PLC Plug/unplug modules [OB83] (B) PLC Program fault [OB121] (B) PLC Program runtime fault [OB85] (B) PLC Rack fault [OB86] (B) PNOZ Multi fault Profibus diagnostic: fault connection freq.converter VP111-M01 (A) Profibus diagnostic: fault connection freq.converter VV141-M01 (A) Profibus diagnostic: fault connection PNOZ (A) Profibus diagnostic: fault connection recorder (B) Profibus diagnostic: Spare Profibus diagnostic: VQ112-M01 Purge air fan feedback signal main contactor (A) VQ112-M01 Purge air fan frequency converter fault (A) VQ112-M01 Purge air fan fuse monitoring (A) VQ112-M01 Purge air fan maintanance switch (A) VQ112-M01 Purge air fan motor protection switch (A) VQ112-M01 Purge air fan motor temperature fault (PTC resistor) (A) VQ112-M01 Purge air fan motor temperature warning (PTC resistor) (B) VQ112-M01 Purge air fan speed monitoring fault (A) VQ112-M01 Purge air fan speed monitoring Profibus fault (A) P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 24 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals ** ** * Selection of 2 out of 3 from BK126-T05, BK126-T15 and BK126-T25. ** When the burner fails, this is a \"A\" fault. item 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 Warning/alarm VQ112-M01 Purge air fan speed monitoring sensor warning (B) VQ112-M01 Purge air fan speed monitoring warning (B) VQ112-M01 Purge air fan warning (B) VP111-M01 Exhaust air fan feedback signal main contactor (A) VP111-M01 Exhaust air fan frequency converter fault (A) VP111-M01 Exhaust air fan fuse monitoring (A) VP111-M01 Exhaust air fan maintanance switch (A) VP111-M01 Exhaust air fan motor protection switch (A) VP111-M01 Exhaust air fan motor temperature fault (PTC resistor) (A) VP111-M01 Exhaust air fan motor temperature warning (PTC resistor) (B) VP111-M01 Exhaust air fan speed monitoring fault (A) VP111-M01 Exhaust air fan speed monitoring Profibus fault (A) VP111-M01 Exhaust air fan speed monitoring sensor warning (B) VP111-M01 Exhaust air fan speed monitoring warning (B) VP111-M01 Exhaust air fan warning (B) VV141-M01 Combustion air fan feedback signal main contactor (A) VV141-M01 Combustion air fan frequency converter fault (A) VV141-M01 Combustion air fan fuse monitoring (A) Reserve VV141-M01 Combustion air fan maintanance switch (A) VV141-M01 Combustion air fan motor protection switch (A) VV141-M01 Combustion air fan motor temperature fault (PTC resistor) (A) VV141-M01 Combustion air fan motor temperature warning (PTC resistor) (B) VV141-M01 Combustion air fan speed monitoring fault (A) VV141-M01 Combustion air fan speed monitoring Profibus fault (A) VV141-M01 Combustion air fan speed monitoring sensor warning (B) VV141-M01 Combustion air fan speed monitoring warning (B) VV141-M01 Combustion air fan vibration monitoring (A) Reserve VV141-M01 Combustion air fan warning (B) VV141-P02 Combustion air pressure min. fault (A) VV141-P02 Combustion air pressure switch test fault (A) VV141-P02 Combustion air pressure switch warning (B) WG153-M06 Combustion air control damper limit switch fault (A/B) WG153-M06 Combustion air control damper run time fault close (B) WG153-M06 Combustion air control damper run time fault open (B) WG153-X200 Burner start without flame signal (A/B) WG153-X200 Extraneous light before starting (A/B) WG153-X200 Extraneous light during purging (A/B) WG153-X200 Extraneous light during stop (A/B) WG153-X200 Flame off during operation (B) WG153-X200 Flame sensor fault (A/B) WG153-X200 Temp. above 750'C / no flame signal detected (B) P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no.: Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 25 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 3.3 Summary of causes and consequences of safety function faults Safety functions are monitored with the programmable PNOZmulti relay. The following functions are programmed: X: Switch off output when input signal is not good (logically \"0\") -: Has no influence *: Is only monitored during pre-purge cycle ® Note: When the EcopureBMS outputs switch off, burner ignition is also switched off. Function SZA- SZA- TZA+ TZ- PZA- PZA- PZA+ GZ GZ- GZ+ PDZA- Function identification VP111-S08 VQ112-S08 BK126-T65 BK126-T65 VV141-M01 1VV141-P02 MG151-P02 MG151-P12 WG153-X09 WG153-X09 WG153-G18 KA163-G18 KA163-G28 1AP191-P02 Description Exhaust air fanspeed too low Purge air fanspeed too low Combustion chamber temp. too high Combustion chamber temp. >750°C Combustion air fan not running Combustion air pressure too low Gas pressure too low Gas pressure too high Burner fault WG153 Burner WG153 in operation Combustion air damper not in ignition position Process air damper not closed Fresh air damper not open Differential pressure across RTO too low PNOZmulti outputs Ecopure® BMS Suppression of pre-purge (WG153-V07, WG153-V17, WG153-V27), Ignition electrode WG153-X29 X X X - X X X X X - X* X* X* X Suppression of flame detection - - - X - - - - - - - - - - - - - X - - - - - - - - - - 1 P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 26 of 38 PNOZmulti inputs Would tested before every burner start (see chapter 6.1.1 “ Checking of differential pressure measuring devices”) Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals PNOZmulti outputs X: Switch off output when input signal is not good (logically \"0\") -: Has no influence *: Is only monitored during pre-purge cycle ® Note: When the EcopureBMS outputs switch off, burner ignition is also switched off. Function PDZA+ E-Stop GZ- GZ+ GZ- GZ- GZ- QZA+ PZA+ Ecopure® BMS Suppression of pre-purge (WG153-V07, WG153-V17, WG153-V27), Ignition electrode WG153-X29 X X X* X* X* X* X* X X Suppression of flame detection - - - - - - - - - Function identification 1AP191-P02 VQ112-G38 VQ112-G08 KL131-G58 KL231-G58 KL331-G58 KA163-Q24 KA163-P12 Description Differential pressure across RTO too high Emergency stop circuit on RTO Purge air damper not closed Fresh air damper not open Purge air damper not closed Purge air damper not closed Purge air damper not closed LEL too high Pressure too high - - - - - - - - - P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 27 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 4. SIGNAL EXCHANGE Signals between RTO and BASF Paper Chemicals's production plant would exchanged via voltage-free contacts according to the following table: No. FROM TO Dürr RTO cabinet DESCRIPTION Emergency stop REMARK Leads to emergency stop of RTO 2.1 BASF Paper Chemicals 2.2 BASF Paper Chemicals 2.3 BASF Paper Chemicals 2.4 BASF Paper Chemicals Dürr RTO cabinet Dürr RTO cabinet Dürr RTO cabinet BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals BASF Paper Chemicals Request for air treatment RTO start-up RTO stop RTO in operation Heat-up RTO RTO fresh air mode RTO process air mode RTO safety cycle RTO emergency shutdown RTO fault RTO warning 4.1 Dürr RTO cabinet 4.2 Dürr RTO cabinet 4.3 Dürr RTO cabinet 4.4 Dürr RTO cabinet 4.5 Dürr RTO cabinet 4.6 Dürr RTO cabinet 4.7 Dürr RTO cabinet 4.8 Dürr RTO cabinet 4.9 Dürr RTO cabinet RTO in remote operation mode RTO ready for treatment Exhaust air fan start Exhaust air fan stop High LEL fault Leads to switch to Bypass 4.10 Dürr RTO cabinet 4.11 Dürr RTO cabinet 4.12 Dürr RTO cabinet 4.12 Dürr RTO cabinet P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 28 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 5. ANNEX A: RTO VALVE CONTROL 5.1 Functional description - phase 1 (inlet tank 1) During the first operating phase, the process air to be purified is transferred through tank 1 into the combustion chamber, so that the process air flows through the hot ceramic bed of this tank, cooling it down in the process. Parts of the solvents in the process air are oxidized in this phase. While the process air is flowing through the combustion chamber, the pollutants still contained in the exhaust air are oxidized with the aid of the gas burner. The hot and purified gases now flow through tank 2 where they heat up the cold ceramic elements. In this operating phase 1, tank 3 is purged in the process air mode. The Exhaust air fanextracts the unpurified process air having remained in the bottom section of the bed during the inlet phase from this tank. This purge air is transferred by the Exhaust air fanback to the combustion chamber, so that the solvent particles still contained in the air can be oxidized. Phase 1 BurnerTank 1Tank 2Tank 3HotColdColdCeramicelementsPoppet valvesystemPurge airProcess airClean air Burner Control variable for TIRC WG153-TIRC BK126-T15 P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 29 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 5.2 Functional description - phase 2 (inlet tank 2) During the second operating phase, the process air to be purified is transferred through tank 2 into the combustion chamber, so that the process air flows through the hot ceramic bed of this tank, cooling it down in the process. Parts of the solvents in the process air are oxidized in this phase. While the process air is flowing through the combustion chamber, the pollutants still contained in the exhaust air are oxidized with the aid of the gas burner. The hot and purified gases now flow through tank 3 where they heat up the cold ceramic elements. In this operating phase 2, tank 1 is purged in the process air mode. The Exhaust air fanextracts the unpurified process air having remained in the bottom section of the bed during the inlet phase from this tank. This purge air is transferred by the Exhaust air fanback to the combustion chamber, so that the solvent particles still contained in the air can be oxidized. Phase 2 BurnerTank 1Tank 2Tank 3ColdHotColdCeramicelementsPoppet valvesystemPurge air Process airClean air Burner Control variable for TIRC WG153-TIRC BK126-T05 P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 30 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 5.3 Functional description - phase 3 (inlet tank 3) During the third operating phase, the process air to be purified is transferred through tank 3 into the combustion chamber, so that the process air flows through the hot ceramic bed of this tank, cooling it down in the process. Parts of the solvents in the process air are oxidized in this phase. While the process air is flowing through the combustion chamber, the pollutants still contained in the exhaust air are oxidized with the aid of the gas burner. The hot and purified gases now flow through tank 1 where they heat up the cold ceramic elements. In this operating phase 3, tank 2 is purged in the process air mode. The Exhaust air fanextracts the unpurified process air having remained in the bottom section of the bed during the inlet phase from this tank. This purge air is transferred by the Exhaust air fanback to the combustion chamber, so that the solvent particles still contained in the air can be oxidized. Phase 3 BurnerTank 1Tank 2Tank 3ColdColdHotCeramicelementsTellerventil-systemPurge airProeess air Clean air Burner Control variable for TIRC WG153-TIRC BK126-T05 After the third phase the operating cycle is finished. The next cycle begins with phase 1. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 31 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 5.4 RTO valve time diagram The following diagram shows the open/closed status of the RTO valves as a function of time: Raw gas valve KL131-V107 ed 1 inlet valve XV-3136 BPurge air damper KL131-K147 B ed 1 purge valve XV-3135 Clean air valve KL131-V127 Bed 1 outlet valve XV-3139 Raw gas valve KL231-V107 Bed 2 inlet valve XV-3336 Purge air damper KL231-K147 Bed 2 purge valve XV-3335 Clean air valve KL231-V127 Bed 2 outlet valve XV-3339 Raw gas valve KL331-V107 Bed 3 inlet valve XV-3536 Purge air damper KL331-K147 Bed 3 purge valve XV-3535 Clean air valve KL331-V127 Bed 3 outlet valve XV-3539 P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Author: Revision: Date: Timm Greschner 0 16.05.2011 Page 32 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 6. ANNEX B: BURNER CONTROL 6.1 Burner startup 6.1.1 Checking of differential pressure measuring devices A function test of differential pressure measuring devices VV141-P02 and AT191-P02 is carried out prior to every burner start-up. This failsafe safety check takes place either during start-up or, in case two of three combustion chamber temperatures BK126-T05, BK126-T15, BK126-T25 are above 750°C, immediately before burner start-up. The functional test of pressure switches VV141-P02 and AT191-P02 occurs according following steps: • Solenoid valve VV141-V07 is switched over to air vent mode. (Basic position: solenoid valve is in pass position, pressure switch VV141-P02 is de-energized) • Solenoid valve AT191-V07 is switched over to air vent mode. (Basic position: solenoid valve is in pass position, pressure switch AT191-P02 is de-energized) The fans VQ112-V101 and VV141-V101 rub by start of the RTO. After a delay time of 30 seconds the pressure switches switch to pass position and are activated. If the pressure switches VV141-P02 and AT191-P02 are in pass position, the solenoid valves VV141-V07 and AT191-V07 are controlled for checking and short term opened. If the system has no pressure during normal RTO operation a fault alarm is generated. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 33 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals 6.1.2 Burner ignition After the function of the pressure measuring devices has been successfully checked, the system is ready for burner ignition: • Combustion air damper WG153-K106 is moved to ignition position (WG153-G08). • Signal for burner start-up is sent to Ecopure® BMS WG153. (BMS = Burner Management System) • Ignition transformer WG153-X09 is switched on by Ecopure® BMS WG153. • Gas solenoid valves WG153-V07 and WG153-V17 are opened by Ecopure® BMS WG153. • When the burner is in operation, ignition transformer WG153-X19 of Ecopure® BMS WG153 is switched off. As soon as the burner is in operation, the following actions take place: • TIC-WG153-T15 starts with the control of combustion air damper WG153-K106. If the burner does not start operating with the first ignition attempt, then up to 3 repeat ignitions can be performed. If a flame signal is detected before start-up in the test for an external light source, the test time is prolonged to a maximum time of 10 seconds. If the external light goes out during this time, the burner starts up. Otherwise a fault shutdown is triggered and the fault message \"External light source before start-up\" is generated. If a flame signal is detected after a certain time after the burner was switched off, a fault shutdown takes place and the fault message \"Flame after stop\" is generated. After a flame failure during operation, Ecopure® BMS triggers a fault shutdown, i.e. in case of a flame failure, the enable signal is taken away from the outputs after the safety time (close valves V07/V17/V27 of the respective burner) and the fault message \"Flame failure\" is generated. A burner re-start is not possible before the fault has been reset. 6.1.3 Burner control (air / gas ratio pressure control) Air gas/ratio controller (WG153-V120) is installed to keep the air / gas mixing ratio constant in all operation modes. They have the following functions: When solenoid valves WG153-V07 and WG153-V17 are opened, gas flow follows according the air pressure which is measured in the combustion air pipe (see figure below). Hence the mixing ratio of gas and air remains constant. Two impact air pipes (pressure in air pipe and pressure in gas pipe) are installed for this purpose on the membrane drive of the controller. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 34 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals The combustion chamber temperature is controlled by WG153-TIRC T15 with the aid of combustion air damper WG153-K106. The burner get adjusted during the commissioning according the burner-curve. It means that the air / gas ratio would calibrate against combustion chamber pressure by pressure instrument (min-/ max- capacity of the burner). For these measurements adequate sample points are installed near to the burner. 6.1.4 Burner cool down The burner cool down function is provided to protect the burner instruments when the combustion chamber temperature is high. Should combustion chamber temperatures BK126-T05, BK126-T15, BK126-T25 be above 300°C when the \"Oxidizer is off\burner cool down is activated. During this cooling process combustion air fan VV141-V101 operate with minimum speed at a frequency VV141-X09 of 15Hz. The combustion air damper WG153-K106 is closed during that time. The burner cool down is activated as long as the combustion chamber temperatures BK126-T05, BK126-T15, P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 35 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals BK126-T25 are below 300°C. If the combustion chamber temperatures rise up above 320°C, the burner cool down would activated again. 6.2 Autothermal operation When combustion chamber temperatures BK126-T05 or BK126-T15 or BK126-T25 are higher than 850°C, the RTO can be operated without the burner. The following cases can occur: If combustion chamber temperatures BK126-T05 or BK126-T15 or BK126-T25 are higher than 850°C, burner WG153 runs in autothermal mode: • Gas solenoid valves WG153-V07 / WG153-V17 are closed. • Combustion air damper WG153-K106 is driven to low fire position. • If the combustion chamber temperature exceeds more than 930°C the combustion air damper will be driven to start position to prevent from over temperature. • If the combustion chamber temperature droops below 925°C the combustion air damper will be closed. When the combustion chamber temperatures BK126-T05 or BK126-T15 or BK126-T25 in the outlet bed drops below 830°C, the burner is re-started (see section 6.1 Burner startup). 6.3 Control of excess energy at the RTO (KR103-T05 TIC) The preconditions for activating the signal are: The RTO is in autothermal mode Control variables are a) Combustion chamber temperatures BK126 T05/T15/T25 from outlet bed Setpoint: Combustion chamber 900°C Actuator: Hot gas damper KR103-K107 If the RTO is in autothermal mode and the temperature in the combustion chamber or in the respective outlet bed rises continuously, hot gas is fed out directly from the combustion chamber into the stack at a set maximum temperature setpoint. This bypassing of hot gas takes place when one of the three temperatures are above the setpoint in the outlet cycle, i.e.: Phase1 (see item 5.1) Phase 2 (see item 5.2) Phase 3 (see item 5.2) Adjusted setpoint BK 126 T15 BK 126 T25 BK 126 T05 900°C As soon as the temperature in the heat exchanger bed drops to below the adjusted setpoint, hot gas damper KR103-K107 closes again. P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 36 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals REMARKS P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 37 of 38 Functional Sequence Description Thermal exhaust purification \"RTOe 3010\" BASF Paper Chemicals REMARKS P:\\EES\\BASF Paper\\DE04-2101202\\08 Produktabwicklung\\07 Funktion\\Funktionsbeschreibung\\FB_RTO_1.3-en_BASF Paper_GRES_20110525.doc © Dürr 2011 This document contains confidential information, and shall not be duplicated or disclosed to others without the prior written consent of Dürr Systems GmbH / EES, Bietigheim-Bissingen. Customer: Equipment: Order no. Series no.: BASF Paper Chemicals, Zhenjiang NewZone, China 212132 [RTOe 3010] De04-2101202 32301 Dürr Systems GmbH, Environmental and Energy Systems Project Manager: Timm Greschner Revision: Date: 0 16.05.2011 Page 38 of 38