instrument section - oil india lpg inst.pdf · safety in oil’s lpg recovery plant includes: •...

INSTRUMENT SECTION OF

LPG DEPARTMENT A

PART

OF

INSTRUMENTAION DEPARTMENT

INCORPORATED

SOPHISTICATED INSTRUMENTATION & CONTROL SYSTEM

FOR

SAFE & EFFICIENT OPERATION OF THE PLANT

SOPHISTICATED INSTRUMENTATION & CONTROL

SYSTEM

• Programmable Logic Controller

• Distributed Control System

• Advance Process Controller

SAFETY IN OIL’S LPG RECOVERY PLANT INCLUDES:

• ALARM AND SHUT-DOWN SYSTEM • SAFETY RELIEF VALVES • GAS DETECTION SYSTEM • FIRE ALARM SYSTEM • FIRE PROTECTION SYSTEM • FIRE EXTINGUISHERS • FIRE DRILL • REGULAR INSPECTION OF PLANT

L P G D E P A R T M E N T

ALARM AND SHUT-DOWN SYSTEM

• All the important equipment, process vessels etc. are provided with alarm and shut-down devices for critical operating parameters. • All the storage vessels are provided with high level alarms. • Emergency shut-down switches are provided in three different locations to shut-down the plant in case of any emergency. • Remote shut-down switches are provided in the local panels of two most important equipment- inlet gas compressor and expander- compressor. • Break glass type emergency/fire push buttons stations are provided at specific locations.

ALARMS FOR THE I/L COMPRESSOR

Alarm Parameters 1. Comp Low Oil Level (LSL-0401) 2. Comp Hi Oil Filter Pr. Diff. Pr.(PDSH)

3. Gear Hi Oil Filter Pr. Diff. Pr (PDSH-0501)

4. Comp Low Oil Pr (PDSL-0401)

5. Gear Low Oil Pr. (PSL-0502) 6. Comp Gas Filter Hi Diff. Pr. (PDSH-0413)

ALARM AND SHUT-DOWN SYSTEM OF INLET COMPRESS0R

The Inlet Compressor may be shutdown by depressing the STOP button or by opening of any safety interlock device.

Shutdown Parameters 1. Comp Low Oil Pr (PDSLL-0401) 2. Gear Low Oil Pr.(PSLL-0501) 3. Gear Hi Oil Temp(TSHH-0501) 4. Comp Hi Oil Temp(TSHH-0401) 5. Comp Hi Disch Temp (TSHH-0402) 6. Motor Over Load 1-OL 7. Comp Hi Pr (PSHH-0002) . Comp Low Suct. Pr (PSLL-0001)

3.374kg/sq.cm ; 2.812kg/sq.cm 1.100kg/sq.cm ; 1.00kg/sq.cm 57deg.C ; 85deg.C

135deg.C

1.055kg/sq.cm ;

204 Amp 37.962kg/sq.cm

Alarm & S/D Set Point

ALARM AND SHUT-DOWN SYSTEM OF EXPANDER COMPRESS0R

The Expander Compressor may be shutdown by pressing the red STOP button or by opening of any safety interlock device.

It is important to observe that all automatic valves have closed and the expander has stopped.

1. Exp.Comp Speed (SPD-) 2. Exp. I/L Screen (PDSDH-404) 3. Exp. Seal Gas (PDAL-700) 4. Exp. Thrust Bearing(PDSH-701 & 702) 5. Exp.Lub. Oil Pr Diff.Low (PDSDL-704)

Shutdown Parameters Alarm / S/D Set Point

6. Exp. Lub Oil Pr Diff alarm Low (PDAL-703) 7. Seal Gas Temp Low (TSDL-723) 8. Bearing Temp. Hi/Low (TSDH/TSDL-724) 9. Drain Lub Oil Temp. (TSDL/TSDH-725)

28350rpm / 29700rpm 3.516kg/sq.cm 2.45kg/sq.cm

14.064kg/sq.cm 26.371kg/sq.cm 27.777kg/sq.cm 16deg.C 82.2/15.55deg.C 82.2/26.60deg.C

Regen Gas & Hot Oil Heater :

1. Reg. Stack temp.(TSDH338) ; Set Pt. 477deg.C

2. Reg. Heater Outlet temp(TSDH337) ; Set Pt. 400deg.C 3. Hot Oil Stack temp (TSDH 817) ; Set Pt.350deg.C

4. Hot Oil Outlet temp(TSDH316) ; Set Pt. 345deg.C 5. Reg. Gas Low Flow (FSDL300) ; Set Pt. 0.422kg/sq.cm 6. Hot oil to Dr. Heater(FSDH-800) ; Set Pt. 0.844kg/sq.cm 7. HOT Oil to Dr.Heater (FSDL-800) ; Set Pt.0.428kg/sq.cm

MISCELLANEOUS ALARM/SHUTDOWN PARAMETERS 1. Instrument Air Pr Set Pt : 4.219 kg/sq.cm 2. Dust Filter (PDSDH306) ,, 2.461kg/sq.cm 3. Exp. Separator (PDSD406) ,, 16.174kg/sq.cm 4. Cooling water Pr. (PSDL900) ,, 1.85kg/sq.cm 5. Cooling Water temp (TSAH 900) ,, 40.5deg.C 6. Reg. Gas Cooler outlet temp(TSDH340) ,, 65deg.C 7. Dehydrator Outlet temp.(TSDH 339) ,, 76deg.C 8. Gas Detector Hi/HI-Hi Alarm ,, 20/40 % 9. I/L Motor winding temp ,, 120deg.C

10. I/L Comp. Bearing Temp. ,, 80deg.C 11. Debutaniser Reboiler Pump Leak Pr. ,, 0.105kg/sq.cm

12. I/L Filter Sep. High Level (LSDH 333) 13. De-ethaniser High Level (LSDH 440) 14. Booster Comp. Suct. Scrubber Hi. Level (LSDH 438) 15. Cold Separator High level (LSDH 439)

33 75

110 V. A.C N

44

INLET COMP.AUX.OIL PUMP MTR START RELAY CONTACT

4

3 2

2TR 180 Sec

4TR 16 ON DELAY(100Sec)

33

PDS 0401 Comp. Hi Oil Filter

31

2 3

4 4 TR 100Sec MAN

AUT

Rotary Switch

17 2MR

13L 18 2M

Comp.Aux.Oil.Pump Running

45

2MR

COMP.AUX.OIL PUMP MTR START RELAY CONTACT

GAS DETECTION SYSTEM:

•Flammable Gas Sensor •Sensing principle: Catalytic Combustion & Infrared •Detects most hydrocarbon gases in the LEL region •Rapid detection of leaky natural gas and LPG •Sensors are LPG and Natural Gas based type •Degree of Protection : IP 65 •Response Time : 10 seconds •Measuring Range : 0 – 100% • Analog Output : 4 – 20 mA with alarm facility • DCS compatibility

LOCATION OF GAS DETECTORS : •LPG Recovery Plant : • Total No of on line G.D : 20nos

•LPG Filling Plant : i) Empty & Filling shed :5nos

ii) Tanker Yard :3nos

Area: I/L Comp, Exp. Comp, De-Eth. & But.Reflx.Pump, Cooling tower, Gas & hot oil ,Bullet,Horton & Gasoline

GAS DETECTION SYSTEM Location Tag No. 1. Inlet compressor GD-01 2. Expander GD-02 3. De-ethanizer reflux pump GD-03 4. De-butanizer reflux pump GD-04 5. Old cooling tower top GD-05 6. LPG Bullet area A GD-06 7. LPG Bullet area B GD-07 8. Horton sphere pump area GD-08 9. Gasoline storage pump area GD-09 10. Hot oil heater area GD-17 11. Regen. gas heater area GD-18 12. Between de-butanizer & heater GD-19 13. De-butanizer pump area GD-20 14. New cooling tower top GD-21 15. Bullet pump house area C GD-22

Location Tag No. 16. Near Gasoline Tk. SV-18.06 GD-23 17. Near Gasoline Tk. SV-18.07 GD-24 18. Below horton sphere, S-101 GD-25 19. Below horton sphere, S-102 GD-26 Filling Plant: 20. FP cyl. Evacuation area GD-10 21. FP carousel area GD-11 22. Filling floor area 1 GD-12 23. Filling floor area 2 GD-13 24. Empty cyl. Floor 3 GD-14 25. LPG tanker filling pt. 2 GD-27 26. LPG tanker filling pt. 3 GD-28 27. LPG tanker filling pt. 4 GD-29

GAS DETECTION SYSTEM

RECOVERY PLANT AREA

BULLET AREA

HORTON SPHERE AREA

MCC ROOM

PUMP HOUSE

CT1 CT2

AIR COMP HOUSE

NEAR GATE

NEAR MCC ROOM

GD-01

NEARFIRE PUMP HOUSE

NEAR AIR COMP. HOUSE

CONDENSATE AREA

GAS DETECTION SYSTEM LOCATION OF DETECTORS: LPG RECOVERY PLANT

TOTAL QUANTITY OF DETECTORS IN RECOVERY PLANT: 19 NOS.

GD-02

GD-03

GD-04

GD-05 GD-21

GD-08

GD-25 GD-26

GD-06

GD-07

GD-22

GD-09

GD-17

GD-18

GD-19

GD-23

GD-24

EMPTY CYL. SHED FILLING SHED

CAROUSEL

GD-10 GD-11

Cy. Ev. Unit

GD-14

GD-12

GD-13

TANKER FILLING POINTS GD-27 GD-28 GD-29

GAS DETECTION SYSTEM LOCATION OF DETECTORS: LPG FILLING PLANT

TOTAL QUANTITY OF DETECTORS FILLING PLANT: 8 NOS.

FIRE PROTECTION SYSTEM :

Instrument section has provided the remote operation of deluge valves for bullet, horton spheres, condensate tanks,Debutanizer & De-ethanizer deluge valves,LPG filling sheds and tanker yards. The individual switch for LPG recovery is installed in the control panel of OLD CONTROL ROOM and for LPG Filling Plant in the outside varandha of Installation Manager’s office room.

THANKS TO ALL

1 MR 2 10

Comp. Motor Start Relay

19 R 10 2

7 5

6

3TR (30 sec) 44 43,75

22,24,59

S 39 1 4 43 1 MR

SV - 0401 Comp.Sump Vent Line valve Air Load 110 v A.C

N

42 43 1 MR

Comp. Motor Start relay

75

REMOVED

INLET COMP. CONTROL PANEL

7TR (30 min) 27

44

ON DELAY TIMER ( 30 SEC )

110 V. A.C N

1R 8 3 TR 1 15 14 3 1 6 2

1

13R

3 13 R 10 2

4

28

12L

7 TR L1 L2 3 4 3

1M

48

RUN INTERLOCK IN ELECTRICAL H.T PANEL

OFF DELAY ( 30 MIN )

ANTI RECYCLE TIMER

3, 27

5 1 3

7

COMP START

8 1TR 8 8

OFF DELAY

1 SEC COMP. STOP

RESET 6 7TR

(30 min)

REMOTE STOP 3

3

4 2

4 5

1R 10 2 7 6

5

1 TR (1Sec)

1 TR

INLET COMP. CONTROL PANEL (MODIFIED)

1, 5

26, 27

7, 52

7TR (30 min) 27

44

ON DELAY TIMER ( 30 SEC )

110 V. A.C N

1R 8 3 TR 1 15 14 3 1 6 2

1

13R

3 13 R 10 2

4

28

12L

7TR

3 4 3

1M

48

RUN INTERLOCK IN ELECTRICAL H.T PANEL

OFF DELAY ( 30 MIN )

ANTI RECYCLE TIMER

3, 27

5 1 3

7

COMP START

8 1TR 8 8

OFF DELAY

1 SEC COMP. STOP

RESET 6 7TR

(30 min)

REMOTE STOP 3

3

4 2

4 5

1R 10 2 7 6

5

1 TR (1Sec)

1 TR

INLET COMP. CONTROL PANEL (ORIGINAL)

1, 5

26, 27

7, 52

6TR

4

3 2 6TR

ON DELAY (10Sec)