A04_0040532962_Control_System_User_Manual.pdf

CNG Fuel Station Control System User Manual

South Rim Grand Canyon Rev03

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Table of Contents

Introduction

Purpose of the User Manual

Safety Systems

E-Stops

Safety Instrumentation

Safety System Reset

System Process Control

HMI Screens and Navigation

HMI Color Schemes

Overview Screen

Navigation Bar

Password and Login

Auto/Manual Control of Valves

Boost Pump A/B Button

Control Section

Status Section

Run Time Hours and Starts Section

Chilldown Settings Section

Alarms Section

System Setpoints Screen

System Shutdown - Temperature

Building Vap SP

Reset SP

Vaporizer Fan

Offload Retries

Data Trend Menu Button

Boost Pump & High Pressure Pump Temperature

Discharge Temperature

Boost Pump Discharge Pressure

Instrument Air Pressure

Event Log Button

Alarms Button

Trip / Alarm Reset

Alarm History

System Valve Controls

Transmitter Pop-Up Screens

Time and Date Settings Screen -

Critical Alarms

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Shuttle Bus CNG Fueling User Manual

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Introduction

Liquefied Natural Gas (LNG) is a popular fuel source in many regions of the world. The low cost of LNG makes it attractive to users of all industries using turbines and heavy equipment. LNG is odorless, colorless, and non-toxic, and offers lower emissions compared with traditional fossil fuels. LNG has unique properties and hazards which must be considered when designing engines, fueling stations, and workshops. Information in this manual assist’s in making sound decisions with respect to fueling station operations and troubleshooting.

The South Rim Grand Canyon LCNG Shuttle Bus Fueling Station consists of a 16,000 Gallon LNG Storage Tank, an LNG dual boost pump skid through, two LCNG high pressure piston pumps, priority panel, high/mid/low storage bottles, and two fueling islands with 4 dispenser hoses total. The system automatically converts the LNG in the storage tank into CNG that gets stored in the high/mid/low storage bottles.

The system also has a building gas line tied into it, which will provide natural gas to the nearby structures as needed. The system pulls either vapor or liquid from the tank in order to maintain tank pressure and limit the amount of fuel that gets vented from the storage tank.

Purpose of the User Manual The purpose of this user manual is to explain basic functions of the safety systems and automated control methods used for CNG station operations. The manual also describes the various HMI screens, including navigation and functionality.

Sections of the manual include:

● Major Components (Optional)

● Safety Systems

● Controls Description

● HMI Screens and Navigation

● Critical Alarm Response

Vendor OEM manuals and data sheets are supplied separately and are not included in this User Manual.

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Safety Systems The primary goal of the safety system is personnel and equipment protection. The safety system monitors system conditions and provides automatic shutdown when unsafe or potentially damaging conditions are present.

There are three major components of the safety system:

● Emergency Stop Loop (E-Stop)

● Gas and Flame Detection (E-Stop)

● Safety Instrumentation (Transmitters, Pressure Switches)

E-Stops The E-Stop loop consists of five pushbuttons distributed throughout the site. Any employee can press an E-stop to immediately shutdown the system. Any one of the five E-Stop buttons can be pressed to perform an emergency shutdown.

E-stop locations are:

● One E-Stop button on the fueling island

● One E-Stop button outside the containment fence, across from the fueling island

● One E-Stop button at the bottom of each of the containment area stairs (2 places)

● One E-Stop button on the Main Control Panel CP100

Safety Instrumentation Pressure Switch and Pressure and Level Transmitters are strategically placed on the Boost Pump Skid to monitor the process and take immediate action upon configuring the set-points. The Transmitters have two shut down and two warning setpoints:

● LoLo Setpoint Alarm

● Lo Setpoint Warning

● Hi Setpoint Warning

● HiHi Setpoint Alarm

If a LoLo or HiHi level or Pressure exists for more than a specified time (default is 2 seconds), it immediately shuts down the system (similar to the E-Stop pushbuttons).

If a Lo or Hi Reading exists for more than a specified time (default is 2 Seconds) The system issues a Warning displayed in the Alarm List Window.

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Safety System Reset The safety system is the most critical element of the LNG system, ONLY qualified Personnel must be responsible for resetting the system in the event of an emergency shutdown. An Emergency Shutdown can ONLY be reset at CP100.

System Process Control The system is composed of one LNG dual boost pump skid, two separate LCNG high pressure pumps, a priority panel, CNG storage bottles, CNG dispensing islands, and the main control panel.

During normal operation, the process would start at parking the shuttle bus and following instructions to begin fueling. Once the CNG storage bottles drain below the Low Pressure setpoint the chilldown process begins.

If this is the first bus of the day and the system has been in boil-off or idle mode, the system needs to perform a pump chill and line chill. Pump chill begins by opening the pump supply valve called AOV-102A/B. By opening this valve, we let LNG pour from the LNG Storage Tank into the primary pump can, cooling it down. Once the pump reaches the desired cooldown temperature it will automatically kick on and start pumping LNG through the line to cooldown the line to the primary LCNG pump.

The high-pressure reciprocating cryogenic pump sends liquid through a vaporizer (which turns the liquid natural gas into a high-pressure gas) and into high-pressure carbon steel storage bottles. Vehicle tanks are filled with fuel drawn from the storage bottles. Pumps P-300A & P-300B can also supply fuel directly to the dispenser should the storage cylinders be depleted during dispensing. The PLC (Programmable Logic Computer) controls all CNG production. The PLC performs the following actions once low storage pressure is detected:

a. Valves AOV-102x, AOV-103, AOV-104x, AOV-300x, AOV-306x are opened. HCV-205x should always remain open unless the pump is under maintenance.

b. LCNG pump P-300x is started and after another short delay, valve AOV-306x is closed.

The CNG discharge will fill the CNG storage vessels and/or the CNG dispenser as needed. The vaporizer fan will also kick on once the LCNG pump begins running.

c. After the CNG Vessel is filled, LCNG pump (P-300x) stops, AOV-102x is closed and the system goes back into Boil-Off Mode.

d. After Boil-Off timer is complete, the system goes into idle mode.

Note: “x” is A when P-300A is the lead LCNG pump, and “x” is B when P-300B is the lead LCNG pump.

The LNG tank also supplies building gas to the nearby structures. AOV-106, AOV-107 have been added to better control LNG Storage Tank pressure and prevent unnecessary venting of the tank. Instead, tank pressure is controlled and vented into the building gas line. Based on the system status, either liquid or gas will be sent down the building as line and into the building gas vaporizer.

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HMI Screens and Navigation The control system has only one HMI touchscreen. It is located on the front of the Main Control Panel CP100 whose purpose is to allow personnel to view system parameters and status as well as control the system when needed.

HMI Color Schemes The meanings for different HMI colors used for devices and process values is shown in the following table:

HMI Color Scheme

In Service, Running, On, Okay, Open, Auto Mode Equipment or Process is in Auto Mode

Out of Service, Faulted, Unavailable, Valve Partially Open

Valve Closed, Pump Off, Process Stopped or Idle

Valve in Open State

Valve is Transitioning state

Equipment in Manual, or Warning state

Valve Faulted, Equipment in Alarm or Tripped State

Analog value. Blue with white numbers. Information Only, Cannot be changed.

Setpoint. Turquoise Blue with Black Letters. Can only be changed with Level 2 login.

CHANGES WILL AFFECT THE WAY THE SYSTEM FUNCTIONS!

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Overview Screen The Overview Screen provides a comprehensive view of the entire LNG/CNG system. At this screen you can check status of Devices related to the Storage Tank, LNG Dual Boost Pump Skid, LCNG High Pressure Pumps. Devices such as FSU transmitters and Valves as well as pumps status and Line Status.

This screen provides the current status of all devices in this area that may be operated from the HMI, or automatically by the PLC.

Process transmitters provide indications of level, temperature, flow rates, and pressure.

Transmitter values that are forced to a fixed value displays a yellow “F” next to the parameter. If any alarm associated with a transmitter is disabled, a black “D” appears next to the parameter box.

The Overview Screen show manually operated devices if the Pump Skid Valves Auto PB is pressed. Equipment controls and instrumentation are available from the Overview screen.

The Overview screen and all other full sized screens have a navigation bar along the bottom of the screen.

Overview Screen

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Navigation Bar The Navigation Bar appears at the bottom of each screen, as shown in the figure below.

Navigation Bar

Touching a menu button navigates to a different screen or performs some other function.

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Password and Login There are three levels of access; Level 1, Level 2 and Level 3. The default login is Level 1. If a Level 2 or 3 password is entered, users have 15 minutes before being automatically logged out (system reverts to Level 1). The Level 2 or 3 user may logout at any time by pressing the Logout button.

The following table shows login levels and the associated access permissions for each level.

User Login Levels

Level 1

Default login. No password required. This is the normal state of the HMI and is a view only mode. A green box surrounds the login button indicating “press to login at a higher level.”

Level 2

Password required. Personnel are able to place equipment In Service and Out of Service,and are able to manually start or stop LNG offload.

Level 3

Password required. Personnel have full access to change system setpoints and settings.

Auto/Manual Control of Valves

All valves on the Overview screen can be placed in either Auto or Manual control from the HMI Screen by first clicking on the valve and then pressing the Auto or Manual Push Button on the Screen. Once we change the valve to Manual, there will be an icon at the side of the valve that indicates the valve is now in Manual.

**Changing the status of devices between automatic and manual control requires a Level 3 login!**

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Boost Pump A/B Button Pressing the Boost Pump A or B button on the Navigation Bar takes you to the respective pump screen. The five main sections of this screen include:

● Control

● Status

● Hours and Starts

● Chilldown Settings

● Alarms

Pump 200A Screen

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Control Section

The Control Section has several parts; Primary/Backup Selection, Service Mode, and Pump Control SP:

Control Section

Primary/Backup Selection

Primary or Backup can be selected for Pump A/B. Primary/Backup selection requires a Level 2 or Level 3 user login.

Service Mode

Pump A/B can be placed In Service (Green) or Out of Service (Yellow) by pressing this button.

Placing equipment in or out of service requires a Level 2 or Level 3 user login.

When In Service, pump A/B is controlled automatically by the Control System PLC (Programmable Logic Controller). Control system programming determines when the pump runs and stops, based on process conditions. When Out of Service, Pump A is not available for use and Pump B will automatically be listed as the Primary Pump.

**Only one boost pump and one LCNG pump can run at a time**

Pump Control Setpoint

Level 3 users may press the Pump Control Setpoint button to change the speed of pump A/B.

Pressing the button causes a pop-up to appear for numerical entry. This value is the percent speed of the pump, from 0% to 100% of rated speed. After entering the desired value, press the

Enter key . To close the pop-up without changes, press the escape key .

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Numeric Keypad Pop-Up

Parameter Setpoints

Level 3 users may choose to change any of the multiple parameters for pump A/B. Pressing a parameter causes a pop-up to appear for numerical entry. The value depends on the parameter chosen. For PID k and SP parameters, there are no units associated with them. The Boil Off Time is entered in minutes, and the Ramp Time in seconds. The remaining parameters are entered from 0%-100%. After entering the desired value, press the Enter key . To close the pop-up without changes, press the escape key .

Numeric Keypad Pop-Up

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Status Section

This section provides information about pump performance and operating conditions. No control functions or setpoint changes can be made in this section of the screen.

Status Section

Pump Status

Displays a green status for ‘Running’, gray status for ‘Off’, orange status for ‘Warn’, yellow status for ‘Fault’, solid red status for ‘Alarm’ and flashing red status for ‘Tripped’.

Primary/Backup

Displays whether the pump is selected as the primary or backup pump. Pumps will automatically switch every 8hrs of run time.

Current Run Time

Displays the current run time in minutes.

Pump Speed Status

Displays the current status of pump speed, from 0% to 100%.

Pump Amps

Displays the current pump amperage draw.

Pump Press

Displays the current discharge pressure. The standard operating range is 0-200 psig

Pump Temp

Displays the current temperature in the pump can. These temperature transmitters have a range of -260 °F to 150 °F.

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Run Time Hours and Starts Section

Pump Run Time Hours and Number of Starts are tracked to determine the amount of usage the Pump has experienced. These values may be used for preventive maintenance scheduling and trending.

Hours and Starts Section

Run Time Hours

The Current, Previous and Non-Resettable Run Time Hours are logged in the PLC.

Current Run Time Hours tracks pump run hours until the ‘Reset’ pushbutton is pressed. The reset button only shows on the screen if a Level 3 user is logged in. Level 1 and Level 2 users do not have access to the reset function.

When the ‘Reset’ button is pressed, it moves the value of Current Run Time Hours over to the Previous Run Time Hours display and resets the value of Current Run Time Hours to zero. In most cases the reset function should only be used following maintenance, or when a new Pump has been installed. The ‘Reset’ pushbutton is only visible and usable to a Level 3 user.

Non-Resettable Hours will continue to accumulate for the lifetime of the pump and can only be changed in the PLC program.

Number of Starts

The Current, Previous and Non-Resettable Number of Starts are logged in the PLC The Current Number of Starts will track the number of times the Pump has started until the ‘Reset’ pushbutton has been pressed. The reset button only shows on the screen if a Level 2 user is logged in.

When the ‘Reset’ button is pressed, it moves the value of Current Number of Starts over to the Previous Number of Starts display and resets the Current Number of Starts to zero. In most cases the reset function should only be used following maintenance, or when a new Pump has been installed. The ‘Reset’ pushbutton is only visible and usable to a Level 3 user.

Non-Resettable Starts will continue to accumulate forever and can only be reset in the PLC code.

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Chilldown Settings Section

The Chilldown Settings section displays set points used to chill down the pump to an acceptable temperature before it can run. This process is very important for cryogenic pumps to be cold enough before pumping LNG.

Chilldown Settings Section

Temp

This is the temperature in °F that the Pump must reach before it is allowed to run. This is a calculated setpoint that cannot be adjusted.

Temp Delta

Temperature delta is a set point that allows for temperature increase due to pumping or heat transfer in long lines.

Min/Max Idle Delay & Min/Max Chill Delay

When the Pump has reached its chilldown temperature, the chilldown will continue for a certain delay to ensure the Pump chilldown temperature reading is accurate, and the Pump is ready to run. This delay is calculated based on these 4 set points. These set points have been fine-tuned and should not be adjusted unless Nikkiso ICS is consulted first.

Alarm Delay

This setpoint is a time duration the Pump is given to chilldown. If it fails to reach the desired temperature before this duration expires, a Chilldown Alarm is turned on to notify personnel. The Chilldown Alarm must be reset from the Alarms Screen (explained later in this document).

Typically, if the Chilldown Alarm occurs, something is wrong with the chilldown process, and it should be inspected by personnel before attempting the next chilldown process.

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Alarms Section

There are four (4) separate pump alarms displayed in the alarms section:

● Run Time

● Fail to Start

● Fail to Stop

● Cavitation

The VFD status for the selected pump is also visible in this section.

Note:

All Pump Alarms can be Disabled and Enabled from the HMI Pump Screen. When disabled, they are ignored by the PLC code. All Pump

Alarms must be reset from the Alarms screen.

Alarms Section

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Run Time Alarm

When this Alarm is enabled, if the Pump runs for a duration longer than the Run Time Alarm delay setpoint, the Run Time Alarm activates.

Fail to Start/Stop Alarms

When this Alarm is enabled, if the Pump is called to run and the PLC does not see the ‘Running Feedback’ signal in the PLC code before the duration expires, the Fail to Start Alarm will occur.

Similarly, if the Pump is told to stop running and we continue to receive a ‘Running Feedback’ signal for the duration, the Fail to Stop Alarm will occur.

Cavitation Alarm

When this Alarm is enabled, if the Pump will be allowed to run for the Start Delay duration before the PLC begins tracking the Pump Amps and Diff Pressure. Once the Start Delay has expired, if the Pump Amps drop below the Amps set point or the Differential Pressure (Pump Discharge Pressure minus ISO Container Pressure) drops below the Diff Pressure set point for longer than the Run Delay duration, the Cavitation Alarm will occur and shut off the pump.

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System Setpoints Screen Pressing the System Setpoints button on the Navigation Bar takes you to the System Setpoints screen. This screen provides information and control functions for the Trailer Offload and Gas Dispense Modes.

System Setpoints Screen

System Shutdown - Temperature

This section allows monitoring and changing of system setpoints for the System Shutdown due to low temperature. This setpoint will prevent the CNG storage bottles from freezing over. This set point should not be adjusted unless Nikkiso ICS is consulted first.

Building Vap SP

This section changing system setpoints for the Building Vaporizer Valves, when to open or close depending on the desired rated pressure of the Tank. AOV110 only controls the passthrough of the LNG to which of the two vaporizer uses.

Reset SP

The first SP of this section controls the Reset delay to let the Air Compressor gain pressure before tripping of Instrument Air LoLo alarm. The Stop button in the offload panel has the ability to Reset the system, this Offload TMR Reset SP lets you change the time you need to keep the Stop PB pressed to command the reset.

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Vaporizer Fan

This Set Point allows the operator to control the amount of time the vaporizer fan stays running after the Hi Pressure Pump is done pumping to the priority panel. The range is between 1-30min.

Offload Retries

During offload, the system can keep offloading until we cavitate the pump either on low amperage or low Differential Pressure between the offload pressure and boost pump discharge pressure.

This SP is the number of tries before tripping the pump for exceeding the number of cavitation’s.

Data Trend Menu Button Pressing the Data Trend Menu button on the navigation bar pops up a screen with six selection options:

Trends and Network Status Pop-Up Screen

Trend screens allow the operator to view historical data of any transmitters on the desired Trend Screen. Selecting one of the available pushbuttons opens the respective trend screen.

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Boost Pump & High Pressure Pump Temperature

The Boost Pump & High Pressure Pump Temperature trend screen is shown below:

Boost Pump & High Pressure Pump Temperature Trend Screen

Discharge Temperature

The Discharge Temperature trend displays the temperature of CNG as it flows into the CNG storage bottles, screen is shown below:

Vaporizer Discharge Temperature Trend Screen

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Boost Pump Discharge Pressure

The Boost Pump Discharge Pressure trend screen is shown below:

Boost Pump Discharge Pressure Trend Screen

Instrument Air Pressure

The Instrument Air Pressure trend screen is shown below:

Instrument Air Pressure Trend Screen

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Event Log Button The Events Log tracks every event that occurs in the system. This includes alarm setpoint changes, pump start or stop, valve opened or closed manually, etc.

Each event is listed including the event date and time. If a setpoint is changed, the event log shows the old and new setpoint.

There may be several pages of events captured in the log. Buttons for page 2, Page 3, etc. appear when pages are added to the log.

Event Log Screen

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Alarms Button When the Alarms button on the navigation mbar is pressed, the Alarm screen appears. The Alarm Screen provides status of all Active Trips, Alarms and Faults.

Alarms Screen

When an Alarm is reset, and the condition no longer exists, the alarm disappears from this screen and moves to the Alarm History screen.

Trip / Alarm Reset

The Trip/Reset pushbutton allows the operator to reset Trip, Alarm and Fault conditions from the HMI screen. A physical Alarm Reset Pushbutton on the front of the Site Control Panel performs the same function.

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Alarm History

The Alarm History button appears when viewing the Alarms screen. By pressing the Alarm History button, operators may view alarm status for the previous 200 alarms that have occurred. Arrows allow scrolling up and down on a page.

Alarm History Screen

When logged in with a Level 3 password, a Clear All Alarms button appears on the screen. The user may erase all alarms by pressing this button. This should only be performed by authorized Level 3 users. This function permanently clears all existing alarm history.

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System Valve Controls The overview screen shows system valves that are solenoid or motor operated. Pressing any valve on the screen opens a pop-up screen for that valve. The example shown is for AOV-104A.

Other valves have the same type of indications and pushbuttons. Users must be logged in as Level 3 in order to change the status of valves.

Valve Pop-Up Screen

From the Overview Screen, press on any valve graphic to access its pop-up screen where the valve can be placed in Auto and Manual Control when logged in with the Level 3 Password. The example above shows AOV-202A in Auto Control. Similar to the PBC, when in Auto the PLC will control the opening and closing of the valve. In Manual the Operator is able to open and close the valve manually. If a valve is left in manual control a warning will be displayed on the Overview screen. Typically, valves should be left in Auto control to be controlled by the PLC logic. The type of Valve, Limit Switch and Fault Settings are set by Nikkiso ICS during Start-up and should be left as is.

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Transmitter Pop-Up Screens All temperature, pressure, flow indications on the Overview screen get their data from transmitters in the process. By pressing a transmitter value on the Overview screen, a pop-up screen appears for that transmitter. This example uses Pressure transmitter PT-101.

Pop-Up Screen

This screen offers Level 3 users the ability to perform several functions associated with the transmitter These screens provide the ability to Scale the Raw Value, mA Value and Engineering Value.

Typically, these are scaled by the Controls Engineer during system start-up and commissioning and only need to be altered if a new Transmitter or Analog Input Card is placed in the control panel. Similar to the Forced Value ability, the scaling of the Raw, mA and Engineering Value can only be performed by Level 2 users.

The Transmitter Alarm settings are also set on the Transmitter Pop-Up screens. The Alarm settings are very important to the functionality of the fueling station and should only be altered by appropriate personnel. The Alarm Available is hardcoded into the PLC and can only be changed by a Controls Engineer. When Alarm Available is set to Yes, the Alarm Enable/Disable will become visible and can be toggled between Enabled and Disabled. When the Alarm is Enabled, it’s Setpoint and Delay will become visible and can be changed. When an Alarm is Disabled, it will no longer be turned on by the PLC program and thus may affect the system operates including safety measures. Alarms should only be Disabled by the appropriate personnel.

Each of the Transmitters in the system can be set to a Forced Value.

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When a Transmitter Pop-Up screen has been opened, the operator is able to override or ‘Force’ the Value. When the Value is Forced, it is no longer read from the Transmitter itself and is set to what the operator enters on the HMI screen. This should only be performed by the appropriate personnel as this will affect the way the system operates.

The Force Available setting is hardcoded into the PLC program and can only be changed by a GP Strategies Controls Engineer. If the Force Available is set to Yes, the Force Enable/Disable button will become visible and can be toggled between Enabled and Disabled. When Enabled, the Value setting will become visible and the Value can be changed.

Time and Date Settings Screen - Level 3 users have the ability to change the Time and Date settings of both the PLC and the HMI.

The PLC acts as the master. By changing the PLC date and time, the HI will update itself accordingly. Pressing the Time and Dte Settings button takes you a pop-up screen for making the adjustments.

Time and Date Settings Pop-Up

When the Time and Date Settings screen appears, first press the ‘Set PLC Clock’ button as shown below. It will switch from gray to green. Next press on each date value and each time value and a numeric keypad will pop-up for the user to enter the desired value. Date is in Month/Date/Year and clock is in 24-hour time format.

When finished setting both date and time, press the ‘Set PLC Clock’ button again. It will now save the updated time and date the to the PLC clock and the button will switch from green back to gray.

Now press the ‘Set HMI Clock’ and the HMI time and date will sync up with the PLC. When pressing the ‘Set HMI Clock’ button it will momentarily turn green while it is pressed down and will turn back to gray when released. The setting of the PLC and HMI time and date is now complete.

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Critical Alarms There are seven (5) Critical Alarm conditions that result in automatic Emergency Shutdown of the system.

● Pressing Any Emergency Stop Push Button

● Gas or Flame Sensors under ALARM

● PSH-310A/B HiHi Alarm. Pressure switch triggered on High Pressure in LCNG Pump

● PT-900 Instrument Air Alarm, Having Low Low Air pressure for instruments.

● TT-3 LoLo Alarm. Low Temperature entering Priority Panel/Storage Bottles

Note: External conditions for Shutdown could potentially be added by tying other processes to our system per the system integrator judgement.

All Emergency Shutdown events trip pumps P200A/B & P300A/B (if running and shut all system valves.)

Site personnel should reset the ESD condition locally at the system Control Panel.