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STD 152
STD 152
STD 152
OISD-STANDARD-152
First Edition
March, 1991
FOR RESTRICTED
CIRCULATION ONLY
SAFETY INSTRUMENTATION
FOR
PROCESS SYSTEM
IN
HYDROCARBON INDUSTRY
Prepared by:
COMMITTEE ON
PROCESS INSTRUMENTATION, MAINTENANCE & INSPECTION
NOTES
FOREWORD
The Oil Industry in India is nearly 100 years old.
Because of various collaboration agreements, a variety of
international codes, standards and practices have been in
vogue. Standardisation in design philosophies and operating
and maintenance practices at a national level was hardly in
existence. This, coupled with feed back from some serious
accidents that occurred in the recent past in India and abroad,
emphasized the need for the industry to review the existing state
of art in designing, operating and maintaining oil and gas
installations particularly using sophisticated instrumentation.
With this in view, the Ministry of Petroleum & Natural
Gas, in 1986, constituted a Safety Council assisted by Oil
Industry Safety Directorate (OISD), staffed from within the
industry, in formulating and implementing a series of self
regulatory measures aimed at removing obsolescence,
standardising and upgrading the existing standards to ensure
safe operations. Accordingly, OISD constituted a number of
Functional Committees of experts nominated from the industry to
draw up standards and guidelines on various subjects.
The present document on Safety Instrumentation For
Process System in Hydrocarbon Industry is prepared by the
Functional Committee on Instrumentation. This document is
based on the accumulated knowledge and experience of
Industry members and the various national and international
codes and practices. It is hoped that provisions of this document
when adopted, may go a long way to improve the safety and
reduce accidents in oil and gas Industry. Users are cautioned
that no standard can be a substitute for a responsible, qualified
Instrumentation Engineer. Suggestions are invited from the
users after it is put into practice to improve the document further.
This standard in no way supercedes the statutory
regulations of CCE, Factory Inspectorate or any other statutory
body which must be followed as applicable.
COMMITTEE
ON
PROCESS INSTRUMENTATION, MAINTENANCE AND INSPECTION
LIST OF MEMBERS
-------------------------------------------------------------------------------------------------------------------------------------Name
Designation / Organisation
Status
-------------------------------------------------------------------------------------------------------------------------------------S/Shri
S. Raghuraman
Leader
K. G. Nair
Member
V.K. Agarwal
Member
C. S. Osman
Member
R. D. Shira
Member
A. Majumdar
Member
S. Rammohan
Member
R. Murlidharan
Member
G. R. Rana
V. M. Ranalkar
Member
Member
Co-ordinator.
-------------------------------------------------------------------------------------------------------------------------------------In addition to the above several experts from industry contributed in the preparation, review and
finalisation of the document.
SCOPE
3.
DEFINITIONS
4.
SAFETY INSTRUMENTATION
FOR PROCESS SYSTEMS
4.1
SEPARATORS
4.2
4.3
GAS DEHYDRATOR
4.4
4.5
ELECTROSTATIC DESALTER
4.6
DISTILLATION COLUMN
4.7
PROCESS HEATERS
4.8
HDS REACTOR
4.9
4.10
FCC REACTOR/REGENERATOR
4.11
4.12
4.13
AIR COMPRESSORS
4.14
TURBINES
4.15
4.16
COKE CHAMBERS
10
-----------------------------------------------------------------------------------------------------------------------
12
4.2
13
4.3
14
4.4.1
15
4.4.2
16
4.4.3
17
4.6
18
4.7.1
4.7.2
20
4.8
21
4.9
22
4.10
23
4.11
24
4.15
25
4.16
26
19
----------------------------------------------------------------------------------------------
1.0
INTRODUCTION
The
complexity
of
refinery
operations have increased due to increase in
the throughput. They are also operated
more efficiently and safely to yield better
quality products. All this has necessitated
additional and more sophisticated process
instrumentation.
Over the years the
operation of these process plants have also
been analysed and need has been felt to
define the instrumentation which must be
provided as a minimum to ensure safe
operation and shutdown of the plant in case
of emergency.
This standard lists the
minimum instrumentation required for
selected refinery processes for consideration
of all concerned associated with design,
operation and maintenance of process
plants.
2.0
3.0
DEFINITIONS
3.1
EMERGENCY
SYSTEM(ESD)
SHUTDOWN
SCOPE
FAILURE:
Improper performance of a device or
equipment item that prevents
completion of its
design
functions.
3.3
3.4
3.5
HIGH TEMPERATURE:
4.1.2
LEAK:
(i)
(ii)
(iii)
(iv)
(v)
SAFETY DEVICE:
(vi)
High
temperature
switch
on
separators like heater-treater to shut
off the source of heat in case of high
temperature of process fluid.
(vii)
LOW FLOW:
Flow in a process system less than
the minimum operation flow rate.
3.8
3.9
3.10
LOW PRESSURE:
SENSOR
A device which detects an abnormal
operating condition and transmits a
signal to perform a specific
shutdown function.
3.12
4.0
Safety Instrumentation
SAFETY INSTRUMENTATION
FOR PROCESS SYSTEMS
4.1
SEPARATORS
4.1.1
Description:
The separator considered here is of
the three phase type to separate
gas, oil and water from the emulsion
produced from the well.
4.2
MAINLINE PUMPS
4.2.1
Description
Main line pumps are the pumps
used
for
hydrocarbon
oil
transportation through pipelines.
The pumps considered here are
electrical motor driven centrifugal
pumps. It is also considered that
the pumps are located in the field
and all parameters related to the
pump are controlled from the central
control room located away form the
pump provided the downstream
equipment are not designed for shut
off pressure.
4.2.2
Safety Instrumentation
The following instrumentation shall
be provided for main-line pumps:(see Fig.4.2)
(I)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
4.3
GAS DEHYDRATORS
4.3.1
Description
Safety Instrumentation:
The following instrumentation shall
be provided for gas dehydrators:(see Fig.4.3)
(I)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
4.4
Description
For this standard the cross country
pipelines considered are pipelines
which carry crude petroleum,
petroleum products and Natural Gas
from producers facilities such as
tank farms, Natural Gas Processing
Plants, Refineries, Pump Stations
etc.
to other delivery and
processing plants.
The minimum safety instrumentation
required for cross country pipelines
are described under the two
system:- Oil pipelines system and
gas pipelines system.
4.4.1
(I)
(ii)
(iii)
(iv)
4.4.2
(I)
Scrubber
(iii)
(a)
(b)
(c)
(d)
Filter Separator
Filter separator is used to remove
finer droplets using centrifuge filters
and wire mesh mist extractors. The
safety instrumentation shall be: (see
Fig.4.4.3)
(a)
(b)
(c)
Pressure
Relief
Disposal System
(vi)
(iv)
(e)
(b)
(c)
(v)
Gas heaters
Scrapper
stations
and
Sectionalising valve stations.
Sectionalising valves shall be
provided to isolate the affected
sections of a pipeline in case of gas
leak or line burst.
These valves
may be with remote operation
facilities.
and
4.5
ELECTROSTATIC DESALTER.
4.5.1
Description
In a Desalter, the crude is mixed
with water and led into a vessel
operating under pressure and
having a electrostatic field. The
water dissolves the undesirable
soluble salts present in the crude
and gets separated from the crude
Safety Instrumentation.
(I)
Safety/Relief
valves
shall
be
provided as per guidelines of OISD
Standard 106 on Pressure Relief
and Disposal System.
(ii)
(iii)
(iv)
(v)
(vi)
4.7
PROCESS HEATERS
4.7.1
Description
(ii)
(iii)
(iv)
(v)
4.6
DISTILLATION COLUMN
4.6.1
Description
The crude distillation column is used
to fractionate the crude oil into
various petroleum products. The
crude from the furnace enters the
flash zone of the column and
flashed vapour rises up and the
liquid flows down. Various products
are withdrawn as side streams. The
vapour from the top is condensed
and partially refluxed back. Heat is
supplied to the column by reboiler
and stripping steam. The top reflux
is controlled by a flow recorder and
controller (FRC) which is reset by
the top temperature recorder and
controller (TRC). Pressure of the
column overhead is controlled by a
PRC. This is split range controller.
When the column pressure is above
the set point, the controller released
gas to flare. When the pressure is
below the set point it maintains the
same by make up gas from the fuel
gas system. Column bottom level
is controlled by level controller (LIC).
4.6.2
Instrumentation
Tripping/stopping of ID/FD
fan shall have provision to
automatically open the
stack damper.
Safety Instrumentation
The following safety instrumentation
shall be considered for safe
operation of the heater. Sketch
showing safety instrumentation of
furnace is shown in fig-4.7.1 & 4.7.2
(ii)
Low low
total feed flow
switch to trip the heater.
Skin
temperature
measurements at 3 locations
for each pass.
Burner System.
4.8
4.8.1
Pilot
flame
detection
should be provided in the
safety interlock wherever
remote
burner
lighting
system is existing so that
main fuel cannot be
admitted
without
establishment
of
pilot
flame.
There shall be two sets
push button emergency trip,
one located in the central
room and one near the
furnace.
HDS
REACTOR
(HYDRO
DESULPHURISATION)
Description
Safety Instrumentation
(ii)
(iii)
(iv)
4.9
PROCESS GAS
COMPRESSORS
4.9.1
Description
Process gas compressors are used
in the petroleum processing and gas
Safety Instrumentation
4.10
4.10.1 Description
The
compressors
should
be
provided
with
the
following
instrumentation
(see
Fig.4.9).
Additional instrumentation shall be
provided as per manufacturers
recommendations.
(I)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
FLUIDISED
CATALYTIC
CRACKING UNIT REACTOR/
REGENERATOR
(ii)
(iii)
4.12
(iii)
(iv)
(v)
(vi)
4.12.1 Description
In petroleum industries, there are usually two
types of storage tanks:
(I)
(ii)
Floating Roof
products.
tanks
for
lighter
(ii)
(iii)
AIR COMPRESSORS
4.11.1 Description
4.13.1 Description
All the gas to be flared come to a
liquid knock out (K.O.) drum. From
the K.O. drum the liquid is pumped
back to Recovery System and the
gas goes to flare through a water
seal drum.
(I)
at
the
(ii)
(iii)
(iv)
(v)
(vi)
4.15
4.4
4.15.1 Description
LPG is received from the plant
through pipelines. it is stored under
pressure
at
atmospheric
temperatures in spheres or bullets.
The LPG is pumped to a loading
gantry from where it is loaded
through loading arms into truck
tankers or rail tankers.
TURBINES
4.14.1 Description:
Turbines are steam/gas driven drive
units used in hydrocarbon industry
for driving compressors, blowers
and alternators in the process units
and captive thermal power station.
ii)
iii)
iv)
v)
vi)
vii)
Emergency trip.
viii)
ix)
Exhaust
alarm.
x)
xi)
xii)
Exhaust
temp.(average
of
3
thermocouples in exhaust) high trip.
xiii)
xiv)
xv)
hood
high
temperature
(ii)
sphere.
Alternatively, the low
pressure leg of the D. P. transmitter
shall be heat traced. The D. P.
transmitter shall be provided with
level elevation or suppression kit.
4.16.1 Description
In a thermal cracking process the
residue from the distillation column
is heated to about 500 Deg .C and
admitted into the coke chamber.
The coke gets deposited on the
chamber and cracked vapour goes
from the top to fractionation section.
After a definite cycle, the reactor is
changed over, quenched with oil and
cooled. The coke is cut into smaller
pieces by high pressure water jet
and dumped through the bottom.
Near ROVS.
(ii)
High
pressure
alarm
independent impulse line.
(iii)
(iv)
COKE CHAMBERS
(a)
(v)
with
Level switches
(b)
If isolation valve on water
line at other chamber is in open
position.
(c)
If the cutting tool is out of
chamber and discharge does not get
routed to
storage.
(v)
LS
LSH
LSHH
LSL
LSLL
LT
LI
LCV
:
:
:
:
:
:
:
:
LEVEL SWITCH
LEVEL SWITCH HIGH
LEVEL SWITCH HIGH HIGH
LEVEL SWITCH LOW
LEVEL SWITCH LOW LOW
LEVEL TRANSMITTER
LEVEL INDICATOR
LEVEL CONTROL VALVE
DP
PSV
PSH
PSL
PSLL
PCV
:
:
:
:
:
:
DIFFERENTIAL PRESSURE
PRESSURE SAFETY VALVE
PRESSURE SWITCH HIGH
PRESSURE SWITCH LOW
PRESSURE SWITCH LOW LOW
PRESSURE CONTROL VALVE
FSV
FSL
FSLL
FCV
:
:
:
:
FLOW
FLOW
FLOW
FLOW
TT
TE
TCV
TSH
TSHH
:
:
:
:
:
TEMPERATURE TRANSMETER
TEMPERATURE ELEMENT
TEMPERATURE CONTROL VALVE
TEMPERATURE SWITCH HIGH
TEMPERATURE SWITCH HIGH HIGH
SDV
BDV
ROV
MOV
VSHH
FO
FG
:
:
:
:
:
:
:
SAFETY VALVE
SWITCH LOW
SWITCH LOW LOW
CONTROL VALVE
NOTE