Title: Process Control Philosophy

Document No.: 14706347-22

Revision: 5

A SUMMARY
The control system functional description refers to the Ultraspin Oil Water Separator to be supplied for
the Santos, Moomba South Central Dirty Water Pond.

The area has the following hazardous area classification:

Area Classification
Class 1
Zone 1
Gas Classification Group IIB
Temperature Class T3

B PROJECT SPECIFIC REQUIREMENTS

The following specifications must be observed when designing the electrical panel and selecting
components.

• AS/NZS 3000 – 2018

• AS/NZS 3008.1.1 – 2017
• AS/NZS 60079.0 – 2019
• AS/NZS 60079.14 – 2017
• AS/NZS 60529 – 2004
• 1540-067-DSG-0001 Rev-1: Electrical Installations in Hazardous Areas
• 1540-070-DSG-0014 Rev-0: Instrument Design

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C ELECTRICAL EQUIPMENT
Tag
Item Rating/Details
No.
Motors
2.2 kW, 415 VAC / 3~ / 50Hz
Motor for Separator Pump PP01 Rated Current: 4.6 A
Ex d
1.1 kW, 415 VAC/3~/50Hz
Motor for Tank Loadout Pump PP02
Rated Current: 2.35 A
Instrumentation
Analogue 4-20 mA output
Ex ia
Pressure Transmitter for Pressure Protection PT01 IECEx certified
Make/Model: Wika ‘IS-3' (or equivalent, supplied
by Ultraspin)
Voltage free open/close contact
Ex ia
Low Level Switch for Pit Level Detection LS01 IECEx certified
Make/Model: Flygt 'ENM-10EX' (or equivalent,
supplied by Ultraspin)
Voltage free open/close contact
IECEx certified
High Level Switch for Pit Level Detection LS02
Make/Model: Flygt 'ENM-10EX' (supplied by
Ultraspin)
Analogue 4-20 mA output
Ex e
Level Transmitter for Tank Loadout Pump LT01
Make/Model: Rosemount ‘3300’ (or equivalent,
supplied by Ultraspin)
Actuated Valves
24 VDC
¼ turn actuator
Ex d
Recycle/Discharge Valve (Electrically Actuated) XV01
IECEx/ATEX certified
Make/Model: Noah 'SA-009X' (or equivalent,
supplied by Ultraspin)
Electrical Control Panel
415 VAC / 3~ / 50Hz
Min. IP65
Main Panel PN01
Cast alloy, SS316 or Powder-coated mild steel
Ex d – Flameproof
Main Isolator Switch 415 VAC / 3~ / 50Hz
Motor Overload for Separator Pump (PP01) 415 VAC / 3~ / 50Hz
Motor Contactor for Separator Pump (PP01) 415 VAC / 3~ / 50Hz
Motor Overload for Tank Loadout Pump (PP02) 415 VAC / 3~ / 50Hz
Motor Contactor for Tank Loadout Pump (PP02) 415 VAC / 3~ / 50Hz
24 VDC
Audible / Visual Combination Alarm EX ia
IECEx certified
Make/Model: Schneider Zelio ‘SR3B261BD’ (or
equivalent)
Programable Logic Controller 24 VDC
Include Ethernet Interface to enable Modbus
TCP “SR3NET01BD’
Schneider Electric Zelio Analog RM Series
Analogue Converter Analogue Converter, IECEx, converting 4-20 mA
to 0-10 VDC for Zelio SR3B261BD
Power Supply 240 VAC x 24 VDC

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Control Panel Interface
Operator Inputs
Main Isolator Switch Lockable toggle switch
Emergency Stop Push Button Latching push button, twist to release
Separator Reset Momentary push button, blue
Alarm Mute Momentary push button, black
Tank Loadout Pump On Momentary push button, green
Tank Loadout Pump Off Momentary push button, red
Indication Lights
Separator Operating Indicator light, LED, green
Discharge Mode Indicator light, LED, amber
Separator Fault Indicator light, LED, red
Oil Storage Tank Full Indicator light, LED, red

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D CONTROL SYSTEM FUNCTIONAL DESCRIPTION

Control of the various functions is provided by the Schneider Zelio PLC located in the Electrical Panel.
The timer settings and alarm points are listed in the tables at the end of this specification.
Note that both the transmitters output 4 – 20 mA which are then converted by the Analogue Converter
to 0-10 V signal which are readable by the PLC. The PLC coding has to be done accordingly.

D.1 SAFETY RESET

The function of the Safety Reset is to provide fail safe operation to the panel to ensure that a conscious
action has taken place to restart the device as per AS/NZS 4024.1503:2014 Section 5.2.2.

If the system has been turned off or stopped for any of the following reasons, then it should revert to
fail-safe mode:
• Power supply to the electrical panel is interrupted.
• Pressure fault alarm
• Motor fault alarm
• Emergency stop being activated

In fail-safe mode the Separator Pump (PP01) Tank Loadout Pump (PP02) and Actuators (XV01) cannot
be activated until the system is taken out of fail-safe mode.

When the Separator is powered up via the Main Isolator to remove the fail-safe mode, the blue Safety
Reset push-button must be pressed.

D.2 LEVEL SWITCH OPERATION (LS01 AND LS02)

The signals from either float level switch must be present for longer than the delay time listed in Section
E.1 before any action is taken.

• When the low-level switch (LS01) is activated (float in up position) the low level switch circuit
will be closed
• When the high-level switch (LS02) float is activated (float in up position) the high level switch
circuit will be closed

D.3 STARTING OPERATION

Prior to the Oily Water Separator starting operation the homing sequence below should be completed
prior to starting the Separator Pump (PP01):
• Recycle/discharge Actuator (XV01) set to ‘recycle’ position.
• All timers reset to zero

D.3.1 Automatic Starting

The Separator pump (PP01) will automatically start if all the following conditions are met:
• System is not in fail-safe mode
• Low-level switch (LS01) is activated (up)
• High-level switch (LS02) is activated (up)
• ‘Level switch delay’ time listed in Section E.1 has elapsed.
• No alarm conditions are present (refer to Section 0 for alarm conditions)

Once the Separator Pump (PP01) starts:

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• ‘Separator Operating’ light will illuminate.

D.4 OPERATING FUNCTIONS

D.4.1 Recycle/Discharge Function

After the separator has continuously run for the ‘Recycle time’ specified in Section E.1:
• Recycle/discharge Actuator (XV01) will switch to ‘discharge’ position
• ‘Discharge Mode’ light will illuminate.

D.5 NORMAL SHUTDOWN SEQUENCE

The Separator Pump (PP01) will stop if any of the following conditions are met:
• The ‘Emergency Stop’ button is pressed (this will also trigger an alarm, see Section 0)
• Any alarm conditions listed in Section 0 are triggered
• The Low-level switch (LS01) is de-activated (down)

If the Separator stop is triggered by the low-level switch (LS01), then:

• The pump will continue to run on for the ‘Recycle run-on’ specified in Section E.1.
• The Recycle/discharge Actuator (XV01) will immediately return to ‘recycle’ position.
• Once the run on time has elapsed then Separator Pump (PP01) will stop.

Once the Separator Pump (PP01) stops:

• ‘Separator Operating’ light will switch off.

D.6 ALARM FAULT CONDITIONS

Any of the following conditions will activate an alarm on the Electrical Control Panel, then the
corresponding red indication light will illuminate, to advise the nature of the alarm condition.
In addition, the audible alarm sounder and visual flashing alarm beacon will trigger to provide an
additional signal to indicate an alarm condition to the operator.

Alarm modes are listed in Section E.2

D.6.1 High/Low Pressure Protection

The Separator Pump (PP01) will stop operating if the Pressure Transmitter senses lower or higher than
normal pressure.
In cases of both low or high pressure, the ‘Separator Fault’ light will illuminate and the system will stop
operating. The safety reset (D.5) will need to be activated to resume normal operation of the system.

This pressure protection will prevent overpressure in the case of discharge blockages and minimise
pump damage in the case of suction blockages.

D.6.2 Motor Fault

A motor overload condition from either pump motor will illuminate ‘Separator Fault’ light on the Electrical
Control Panel. This will also trip the pump motor which triggered the fault, if only one of the motors
faults the other can continue to operate if no other fault conditions exist.

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D.6.3 Actuator Fault

If any electrical actuator fails to reach its open or closed position within the expected time, the ‘Separator
Fault’ light on the Electrical Control Panel will be illuminated. The valve actuation sequence of the
corresponding actuator will be stopped. The system can continue to run if no other faults conditions
exist.

On system restart the actuators will attempt to home again, if they are successful then the fault will clear
if they still cannot turn freely then the actuator fault condition will persist.

D.6.4 Separator Package Emergency Stop

Pressing the Separator Package Emergency Stop Button on the Electrical Control Panel will electrically
isolate all equipment, valves and instrumentation that form part of the oil water separator package.
All motors, electrically actuated valves, instrumentation, and control functions within the electrical
panels will be de-energized at their current position, when the Emergency Stop is pressed. The items
will remain in this position even after the Emergency stop is dis-engaged. All functions will return to
their default starting position once the Safety Reset is pressed.

D.6.5 Alarm Mute

If an alarm is triggered, then pressing the ‘Alarm mute’ button will:

• Silence the audible alarm.
• Visual alarm flashing beacon will remain activated.
• The panel indicator light corresponding to the alarm that was triggered will remain illuminated.
• This button won’t reset the alarm condition.

D.7 OSD TANK PUMP OUT

The Oil Storage Tank level transmitter will have two set points: a high-level set point to indicate the tank
is full and needs to be emptied and a low level cut off to prevent pump dry running.

When the Oil Storage Tank level transmitter reaches high level the ‘Oil Storage Tank Full’ indicator light
will come on.

Any time the Oil Storage Tank level transmitter is detecting level above the low level cut off then the
Tank Loadout Pump out can be activated by pressing the ‘Tank Loadout Pump start’ button on the
Control Panel manually.
The Tank Loadout Pump will then continue to operate until any of the two following occurs.
• Level transmitter LT01 detects low level
• Or an operator manually presses ‘‘Tank Loadout Pump Stop’ button.

If an operator continues to manually press ‘Tank Loadout Pump start’ despite LT01 detecting low level,
the pump should not start. LT01 should be priority control parameter in pump start/stop.

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E SETTINGS

E.1 TIMER SETTINGS

# Item Timer Name Description Setting

• LS01 de-energised for this time before sending signal to

1 LS01 Low Level Switch (down) Recycle run-on 120 seconds
Separator Pump PP01

• LS01 energised for this time before sending signal to Separator

2 LS01 Low Level Switch (up) Level switch delay 10 seconds
Pump PP01

• LS02 de-energised for this time before sending signal to

3 LS02 High Level Switch (down) Level switch delay 10 seconds
Separator Pump PP01

• LS02 energised for this time before sending signal to Separator

4 LS02 High Level Switch (up) Level switch delay 10 seconds
Pump PP01

PS01 High/Low Pressure • Delay timer on start-up for PT01, so that signals will be de-
5 Transmitter - output delay on PT01 Start-up delay activated for this time period before sending stop signal to 20 seconds
start-up Separator Pump PP01, (at every start-up only)

PS01 High/Low Pressure • Delay timer during operation for PT01, so must show an
6 Transmitter - output delay during PT01 Operation delay unhealthy signal for this time period before sending stop signal 10 seconds
operation to Separator Pump PP01

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 XV01 Recycle/Discharge • Time from starting of Separator Pump (PP01) until
7 Recycle timer 30 minutes
Actuator Recycle/Discharge Actuator (XV01) energised.

XV01 Recycle/Discharge • Actuator fault alarm sequence will be energised if actuator has
8 Actuator - fail to turn alarm (open XV01 actuator limit delay not reached the limits (open or closed) when this timer times 60 seconds
or closed limits not reached) out.

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E.2 ALARM TABLE

# Alarm Name Alarm Description Trigger Action

Stop the equipment in an • Electrically Isolate all equipment, valves, lights and
1 Emergency Stop emergency with manual Emergency Stop button is manually pressed instrumentation
operator intervention • Stop all pumps and actuators in their current position.

The pump discharge • Stop Separator Pump (PP01)

Low/High Pressure Transmitter (PT01) signal open:
pressure measured by
2 Pressure Low pressure: <250kPa • Illuminate ‘Separator Fault’ light.
Pressure Transmitter (PS01)
Protection
is too high or too low.
High pressure: >600kPa • Audible and visual alarm activated

• Trip pump overload.

Motor current draw is too Motor current draw exceeds full load amps set on
3 Motor Fault • Illuminate ‘Separator Fault’ Light
high (PP01 or PP02) TOL
• Audible and visual alarm.

• Stop the actuator which has not reached its limit

Actuator doesn’t fully rotate Actuator faults to reach limit switch (open or closed)
4 Actuator Fault • Illuminate ‘Separator Fault’ Light
in the time required within the timer as per Section E.1

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