INSTRUMENT SECTION OF LPG DEPARTMENT A PART OF INSTRUMENTAION - PowerPoint PPT Presentation

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. Alarm & S/D Set Point Shutdown Parameters 1. Comp Low Oil Pr (PDSLL-0401) 3.374kg/sq.cm ; 2.812kg/sq.cm 1.100kg/sq.cm ; 1.00kg/sq.cm 2. Gear Low Oil Pr.(PSLL-0501) 57deg.C ; 3. Gear Hi Oil Temp(TSHH-0501) 85deg.C 4. Comp Hi Oil Temp(TSHH-0401) 5. Comp Hi Disch Temp (TSHH-0402) 135deg.C 6. Motor Over Load 1-OL 204 Amp 37.962kg/sq.cm 7. Comp Hi Pr (PSHH-0002) 1.055kg/sq.cm ; . Comp Low Suct. Pr (PSLL-0001)

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. Shutdown Parameters Alarm / S/D Set Point 1. Exp.Comp Speed (SPD-) 28350rpm / 29700rpm 2. Exp. I/L Screen (PDSDH-404) 3.516kg/sq.cm 2.45kg/sq.cm 3. Exp. Seal Gas (PDAL-700) 14.064kg/sq.cm 4. Exp. Thrust Bearing(PDSH-701 & 702) 26.371kg/sq.cm 5. Exp.Lub. Oil Pr Diff.Low (PDSDL-704) 6. Exp. Lub Oil Pr Diff alarm Low (PDAL-703) 27.777kg/sq.cm 7. Seal Gas Temp Low (TSDL-723) 16deg.C 8. Bearing Temp. Hi/Low (TSDH/TSDL-724) 82.2/15.55deg.C 9. Drain Lub Oil Temp. (TSDL/TSDH-725) 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)

INLET COMP.AUX.OIL PUMP MTR START RELAY CONTACT 110 V. A.C N PDS 0401 Comp. Hi Oil Filter ON DELAY(100Sec) 31 16 33 4TR Rotary Switch 4 TR 2TR 4 100Sec MAN 180 Sec 33 17 2MR 75 2 3 2 3 AUT 4 Comp.Aux.Oil.Pump Running 2M 2MR 13L 18 44 45 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 Area: I/L Comp, Exp. Comp, De-Eth. & But.Reflx.Pump, Cooling tower, Gas & hot oil ,Bullet,Horton & Gasoline i) Empty & Filling shed :5nos • LPG Filling Plant : ii) Tanker Yard :3nos

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

GAS DETECTION SYSTEM 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 LOCATION OF DETECTORS: LPG RECOVERY PLANT GD-01 GD-03 GD-17 GD-19 MCC ROOM GD-18 GD-04 NEAR MCC GD-02 ROOM RECOVERY PLANT AREA NEAR GATE NEARFIRE C PUMP HOUSE O N GD-05 GD-21 D GD-06 PUMP HOUSE E CT2 GD-24 CT1 N GD-07 S GD-09 BULLET AREA A AIR COMP GD-22 T HOUSE E GD-23 NEAR AIR COMP. HOUSE A R E A GD-26 GD-25 HORTON SPHERE AREA TOTAL QUANTITY OF DETECTORS IN RECOVERY PLANT: 19 NOS. GD-08

GAS DETECTION SYSTEM LOCATION OF DETECTORS: LPG FILLING PLANT CAROUSEL GD-11 GD-12 GD-10 Cy. Ev. Unit GD-14 GD-13 FILLING SHED EMPTY CYL. SHED GD-28 GD-27 GD-29 TOTAL QUANTITY OF DETECTORS TANKER FILLING POINTS 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

INLET COMP. CONTROL PANEL SV - 0401 Comp.Sump 110 v A.C Vent Line valve Air Load N 1 MR S 1 4 39 43 Comp. Motor Start Relay 3TR (30 sec) 5 2 10 1 MR 43,75 44 7 22,24,59 6 2 19 R 10 Comp. Motor Start relay REMOVED 1 MR 75 42 43

INLET COMP. CONTROL PANEL (MODIFIED) 110 V. A.C 3 1 TR 2 OFF DELAY REMOTE STOP 4 N COMP START 1 SEC 3 3 7TR COMP. STOP 7 8 1TR 1, 5 5 1 8 8 4 5 6 RESET (30 min) 1 TR (1Sec) 1R 10 7, 52 7 6 2 5 12L 4 7TR (30 min) 44 3 TR 1 8 14 15 6 2 1 3 27 ON DELAY TIMER 1R ( 30 SEC ) 13R 28 1 3 3, 27 2 13 R 10 OFF DELAY ( 30 MIN ) 1M L1 7 TR L2 48 3 26, 27 3 4 ANTI RECYCLE TIMER RUN INTERLOCK IN ELECTRICAL H.T PANEL

INLET COMP. CONTROL PANEL (ORIGINAL) 110 V. A.C 3 1 TR 2 OFF DELAY REMOTE STOP 4 N COMP START 1 SEC 3 3 7TR COMP. STOP 7 8 1TR 1, 5 5 1 8 8 4 5 6 RESET (30 min) 1 TR (1Sec) 1R 10 7, 52 7 6 2 5 12L 4 7TR (30 min) 44 3 TR 1 8 14 15 6 2 1 3 27 ON DELAY TIMER 1R ( 30 SEC ) 13R 28 1 3 3, 27 2 13 R 10 1M 3 48 26, 27 6TR 3 4 ON DELAY (10Sec) 4 RUN INTERLOCK IN 6TR OFF DELAY ( 30 MIN ) 7TR 2 3 ELECTRICAL H.T PANEL ANTI RECYCLE TIMER