OISD - 152

FOR RESTRICTED
CIRCULATION ONLY
NO.

SAFETY INSTRUMENTATION
FOR
PROCESS SYSTEM
IN
HYDROCARBON INDUSTRY

OISD - STANDARD - 152

First Edition, March, 1991

Oil Industry Safety Directorate

Government of India
Ministry of Petroleum & Natural Gas

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

OIL INDUSTRY SAFETY DIRECTORATE

KAILASH, 2ND FLOOR
26, K. G. MARG
NEW DELHI - 110 001.

NOTES
OIL INDUSTRY SAFETY DIRECTORATE publications
are prepared for use in the Oil and gas industry under Ministry
of Petroleum and Natural Gas. These are the property of
Ministry of Petroleum and Natural Gas and shall not be
reproduced or copied and loaned or exhibited to others without
written consent from OISD.
Though every effort has been made to assure the
accuracy and reliability of data contained in these documents,
OISD hereby expressly disclaims any liability or responsibility
for loss or damage resulting from their use.
These documents are intended only to supplement and
not replace the existing statutory requirements.

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.
Suggestions for amendments, if any, to this standard
should be addressed to:
The Co-ordinator,
Committee on
Process Instrumentation, Maintenance & Inspection
Oil Industry Safety Directorate,
Kailash, 2nd floor,
26, K. G. Marg,
New Delhi-110 001
.

COMMITTEE
ON
PROCESS INSTRUMENTATION, MAINTENANCE AND INSPECTION
LIST OF MEMBERS
-------------------------------------------------------------------------------------------------------------------------------------Name
Designation / Organisation
Status
-------------------------------------------------------------------------------------------------------------------------------------S/Shri
S. Raghuraman
K. G. Nair

Sr. Manager (Inst.), EIL

Ch. Inst. Manager, IOCL

Leader
Member

V.K. Agarwal

DGM (Tech.) BPCL

Member

C. S. Osman

Chief Manager (Inst.), MRL

Member

R. D. Shira

Sr. Maintenance Manager, BRPL

Member

A. Majumdar

DGM (Inst.), ONGC

Member

S. Rammohan

Sr. Manager (Inst.), GAIL

Member

R. Murlidharan

Manager (M & I), IOCL

Member

G. R. Rana
V. M. Ranalkar

Joint Director, OISD

Dy. Director, OISD

Member

Member
Co-ordinator.
-------------------------------------------------------------------------------------------------------------------------------------In addition to the above several experts from industry contributed in the preparation, review and
finalisation of the document.

SAFETY INSTRUMENTATION FOR

PROCESS SYSTEM IN HYDROCARBON INDUSTRY
CONTENTS
-----------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
PAGE NO.
-------------------------------------------------------------------------------------------------------------------------------------1.
INTRODUCTION
1
2.

SCOPE

3.

DEFINITIONS

4.

SAFETY INSTRUMENTATION
FOR PROCESS SYSTEMS

4.1

SEPARATORS

4.2

MAIN LINE PUMPS

4.3

GAS DEHYDRATOR

4.4

CROSS COUNTRY PIPE LINES

4.5

ELECTROSTATIC DESALTER

4.6

DISTILLATION COLUMN

4.7

PROCESS HEATERS

4.8

HDS REACTOR

4.9

PROCESS GAS COMPRESSOR

4.10

FCC REACTOR/REGENERATOR

4.11

FLARE GAS SYSTEM

4.12

ATMOSPHERIC STORAGE TANKS

4.13

AIR COMPRESSORS

4.14

TURBINES

4.15

LPG PRESSURE STORAGE AND BULK LOADING 9

4.16

COKE CHAMBERS

10

-----------------------------------------------------------------------------------------------------------------------

LIST OF THE FIGURES ATTACHED

-------------------------------------------------------------------------------------------------Figure No.
Description
Page No.
-------------------------------------------------------------------------------------------------4.1

Safety Instrumentation for Separator

12

4.2

Safety Instrumentation for Main Line Pumps

13

4.3

Safety Instrumentation for Gas Dehydrator

14

4.4.1

Safety Instrumentation for Pipeline System

15

4.4.2

Safety Instrumentation for Scrubber

16

4.4.3

Safety Instrumentation for Filter Separator

17

4.6

Safety Instrumentation for Crude Distillation Column

18

4.7.1

Safety Instrumentation for Process Heater

19

4.7.2

Safety Instrumentation for Combustion Air System

20

4.8

Safety Instrumentation for HDS Reactor

21

4.9

Safety Instrumentation for Process Gas Compressor

22

4.10

Safety Instrumentation for Fluidized Catalytic Cracker

23

4.11

Safety Instrumentation for Flare Gas System

24

4.15

Safety Instrumentation for L.P.G Sphere

25

4.16

Safety Instrumentation for Coke Chamber

26

----------------------------------------------------------------------------------------------

SAFETY INSTRUMENTATION FOR PROCESS SYSTEM

IN HYDROCARBON INDUSTRY
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

alarms and must be preceded by warning

alarms wherever applicable.
Details of individual processes in
brief have been included in the description
of each process.
Some mechanical items such as
flow safety valves have been included in
the scheme for the sake of completeness
even though they are not instrument items.
Some instrument items such as Restriction
Orifices and pressure control valves which
do not directly participate in the trip of
equipment have also been shown on the
sketches for the sake of completeness.

3.0

DEFINITIONS

3.1

EMERGENCY
SYSTEM(ESD)

SCOPE

This standard covers the onshore

production facilities excluding the well head,
gas and crude transportation facilities from
oil field, gas processing units and refinery
process plants. Offshore facilities have
been excluded.
Only selected process systems
have been considered in this standard.
Though it is possible that there are more
than one method of achieving a process
result (For example:-dehydration) only the
most widely used method has been
considered for each process.
This standard broadly follows the
guidelines of API-14C and considers only
the trips and alarms required for the
protection of the equipment. The level of
safety considered in the standard is for
adequate protection of the equipment
depending upon their criticality. For Trip
System the standard specifies that all trip
switches shall be direct mounted as far as
possible accompanied by audio visual

SHUTDOWN

A system of manual stations which,

when activated, initiate shutdown
operation.
3.2

FAILURE:
Improper performance of a device
or equipment item that prevents
completion of its
design
functions.

3.3

GAS DETECTION SYSTEM:

A system which monitors the
concentration of combustible and
toxic gases and initiates and /or
shutdown
functions
at
predetermined
level
of
concentrations.

3.4

HIGH LIQUID LEVEL:

Liquid level in a process system
above the highest operating level.

3.5

HIGH TEMPERATURE:

Temperature in a process system in

excess of the design operation
temperature.
3.6

3.7

The following safety instrumentation

shall be provided.(see Fig.4.1)

LEAK:

(i)

The accidental release of liquid

and/or gaseous hydrocarbon to
atmosphere from a process system.

High pressure switch shall be

provided to shut off inflow to the
vessel.

(ii)

Low pressure switch to shut off

inflow to the vessel.

(iii)

Safety/Relief
valve
shall
be
provided as per guidelines of OISD
Standard 106 on Pressure Relief
and Disposal System.

(iv)

High level switch to shut off inflow

to the vessel in case the down
stream component receiving the
gas cannot handle liquid.

(v)

Low level switch to shut off the

liquid outflow from the separator to
prevent gas blow by.

(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)

Automatic switching-off of the high

voltage transformer
used for
electrostatic separation in case of
abnormal conditions requiring feed
cut off and low level of the
separator.

LOW FLOW:
Flow in a process system less than
the minimum operation flow rate.

3.8

LOW LIQUID LEVEL:

Liquid level in a process system
below the lowest operating level.

3.9

LOW PRESSURE:
Pressure in a process system less
than
the
minimum
operating
pressure.

3.10

SAFETY DEVICE:
An instrument of control use for the
safety of the system.

3.11

SENSOR
A device which detects an abnormal
operating condition and transmits a
signal to perform a specific
shutdown function.

3.12

4.0

SHUTDOWN VALVE (SDV):

An automatically operated valve
used for the protection of a process
equipment in emergencies.

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.

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.

4.1.2

Safety Instrumentation

4.2.2

Safety Instrumentation

The following instrumentation shall

be provided for main-line pumps:(see Fig.4.2)
(I)

High pressure switch in the pump

discharge for tripping the pump.

(ii)

Low pressure switch in the pump

discharge for tripping the pump.

(iii)

Low pressure switch in the pump

suction to trip the pump.

(iv)

Vibration monitoring and trip shall

be
provided
as
per
pump
manufacturers recommendations.

(v)

Temperature sensors ( RTD/

Thermocouple type) for monitoring
of bearing temperatures and trip as
per recommendations of pump
manufacturers.

(vi)

Motor operated valves shall be

provided on upstream and down
stream of the pump which shall be
coupled to the operation of the
pump logic. In case of emergency
condition local operation shall be
considered.

(vii)

(viii)

(ix)

(x)

Check valves shall be provided in

the down stream of each pump in
order to minimize back flow.
Level switch shall be provided in
seal oil system to trip the pump in
the event of seal failure.
Motor
bearing
and
winding
temperature
indicators
with
alarms/trips as per manufacturers
recommendations.
Provision of Temperature Sensor
for tripping the mainline pump in
case of
high pump
casing
temperature
as
per
pump
Manufacturer's recommendation.

4.3

GAS DEHYDRATORS

4.3.1

Description
Liquid desiccant method is used in
the gas dehydrator considered here.

The desiccant considered is triethylene glycol.

The gas saturated with moisture but
free of entrained liquid particles is
brought into counter current contact
with concentrated triethylene glycol
in the contactor tower which has
bubble cap trays. The triethylene
glycol absorbs the water vapour
from the gas and passes out from
the bottom of the contactor. First it
cools the lean triethylene glycol
entering the contactor and then
partially condenses the top product
of the glycol still in the reflux
condenser. The gas then passes
through the overhead scrubber
where the entrained glycol is
knocked off and the dried gas is
sent to the pipeline. The bottom
stream is sent for glycol recovery
and reuse.
4.3.2

Safety Instrumentation:
The following instrumentation shall
be provided for gas dehydrators:(see Fig.4.3)

(I)

High pressure switch on the glycol

contactor to shut off inflow of gas.

(ii)

Low pressure switch on the glycol

contactor to shut off inflow of gas.

(iii)

Safety/Relief valve shall be

provided as per guidelines of OISD
Standard 106 on Pressure Relief
and Disposal System on the glycol
contactor.

(iv)

High level switch to trip the glycol

pump and inflow of the gas to the
contactor.

(v)

Low level switch to shut off the

glycol outlet line.

(vi)

Blow down valve shall be installed

for depressuring the vessel and
discharge to flare in case
of
emergency.

(vii)

Shutdown valves on the Gas inlet

and outlet line.

4.4

CROSS COUNTRY PIPELINES

Description

The pipeline system consists of gas

dispatch terminals, gas receiving
terminals and scrapper stations.

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 dispatch and receiver terminals

are provided with gas scrubbers,
filter separators drums, gas heaters,
flow
metering
and
pressure
regulating
equipment
and
condensate
handling
systems
(Fig.4.4.1)
(ii)

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

The scrubber is used for removal of

foreign particles and condensate
droplets.
Safety instrumentation provided
shall be (See Fig.4.4.2)

Oil Pipeline System

Major portion of the Oil pipeline
instrumentation is in the main oil
pumping station which has been
covered under section 4.2. Apart
from Electrical drives, Engines
using Crude Oil, Diesel or both as
fuels are also used to drive Main
Line Pumps. In addition to the
manufacturers
recommendations
on instrumentation, the following
safety instrumentation
shall be
provided for the Engine:

(I)

Low Pressure switch for instrument

air.

(ii)

Low pressure switch on fuel supply.

(iii)

High temperature switches on gear

box pinion bearing and wheel
bearing, engine
bearing,
engine jacket cooling water.

(iv)

Oil Mist detector.

4.4.2
(I)

Gas Pipeline System

Description
This chapter covers only pipeline
transporting gas and associated
facilities. Since major portion of oil
pipeline instrumentation is only at
the main oil pumping station, this
has been covered under section 4.2.

Scrubber

(iii)

(a)

Level indicator with low,

low-low and high alarms.

(b)

Separate shut off valve on

the condensate line to shut
the system in case of lowlow level alarm.

(c)

Safety/Relief valve shall be

provided as per guidelines
of OISD Standard 106 on
Pressure Relief and
Disposal System

(d)

Level control valve.

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)

Level indicator with low,

low-low and high alarms.

(b)

Separate shut off valve to

shut the system in case of
low-low level.

(c)

Safety/Relief valve shall be

provided as per guidelines
of OISD Standard 106 on

(d)

Differential pressure high

alarm across filter drum.

necessary pressure reduction by

pressure regulators.,
the skid
consists of filters, flow meters, flow
computers
and
associated
temperature and pressure correcting
instrument systems.

(e)

Low level tripping of

condensate SDV.

The safety instrumentation shall

be:-

Pressure Relief and

Disposal System.

(iv)

Condensate handling system.

The condensate handling system
consists of condensate flash drum,
underground
sump,
overhead
storage tank, loading station and
burn pits. The condensate flows by
gravity to a sump tank. The transfer
pump is started and stopped by high
and low level switches on the sump
tank. The liquid is sent either to the
overhead tank or to the burn pit by
operating a manual valve.

(a) Quick shut off valve to isolate

the installation from the main pipe
line in case of high pressure. The
quick shut valves shall be self
actuating type & shall be provided
with manual reset only.
(vii)

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.

The following safety instruments

shall be provided:
(a)

Low level of condensate in

the sump tank shall trip the
condensate pump.

(b)

High level alarm of the

condensate in the sump
tank.

(c)
(v)

The filtered gas is heated before

entering the metering system to
keep the gas temperature above its
dew point. The safety instruments
are:
(a)

(vi)

In all cases the resetting and

opening of the valve shall be
possible only locally and should be
done after investigation of the cause
of the trip.
Scrapper launcher and receiver
barrels shall be provided with
pressure relief valves.

High level alarm in the

overhead tank.

Gas heaters

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
under the influence of electrostatic
field.

Safety/Relief valve shall be

provided as per guidelines
of OISD Standard 106 on
Pressure Relief and
Disposal System

Gas metering /Pressure Reducing

Installation.
The clean filtered
through
metering

gas passes
skid
and

Scrapper
stations
and
Sectionalising valve stations.

4.5.2

Safety Instrumentation.
The
following
Safety
Instrumentation shall be provided:

(I)

High/low level interphase alarms.

(ii)

Low Oil level trip

(iii)

Desalter trip annunciation in the

control room.

(iv)

High and low pressure alarm.

(v)

Safety/Relief
valve
shall
be
provided as per guidelines of OISD
Standard 106 on Pressure Relief
and Disposal System.

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

(ii)

The column bottom level shall be

monitored
by
two
different
instruments with separate tappings.

(iii)

High level and low level switches at

column bottom shall be provided
independently. Both switches must
be
direct
operated
(without
air/power)

(iv)

There shall be minimum two

temperature points for column top
temperature, one for indication
and one for control with provision
for high alarm.

(v)

A high alarm shall be provided for

the column bottom temperature.

(vi)

High and low level alarm shall be

considered for overhead reflux
drum.

4.7

PROCESS HEATERS

4.7.1

Description
Process heaters are required to
raise the temperature of various
process fluids to achieve partial
vapourisation
of
fractionation
operation. The fluids enters the
heater in convection section in more
than one passes and after getting
heated passes through the radiant
section of tubes normally arranged
vertically and finally comes out in
one or tow stream. The burners are
normally combination type suitable
for oil or/and gas firing. In the
forced draft design of the furnace,
fans are provided to supply air for
burning which are associated with
drop out doors.
The furnaces
provided with ID fan and air
preheater (APH) will have stack
damper which is kept opened for
natural draft operation. The stack
damper remains closed in the
balanced draft operation.

Instrumentation

The following safety instrumentation shall

be provided in a distillation column:-(see
Fig.:4.6)
(I)

Safety/Relief valves shall be

provided as per guidelines of OISD
Standard 106 on Pressure Relief
and Disposal System.

4.7.2

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

Positive protection for mal

operation of ID fan shall be
provided by motor contact
closure and pressure switch.

Tripping/stopping of ID/FD
fan shall have provision to
automatically open the
stack damper.

Furnace trip due to high

pressure shall be preceded
by high pressure alarm.
This very high pressure
(PHH) trip shall be sensed
preferably by three directly
mounted pressure switches
and voting logic of two out
of three shall be used for
furnace tripping.

Necessary analysers shall

be provided to monitor CO,
Nox, SO2 and H2S on flue
gases.

(I) Feed Section

Low total feed flow switch to

bring the heater to a safe
minimum firing position.

Low low
total feed flow
switch to trip the heater.

High temperature alarm for

each pass and at the heater
outlet.

Skin
temperature
measurements at 3 locations
for each pass.

(ii)

Low Feed flow alarms for

each pass.

Automatic injection of coil

purging steam at the time of
furnace trip shall be
considered.

COMBUSTION AIR SYSTEMS

Running of FD fan shall be

verified in the circuit by
Motor
contactor
closure
discharge pressure low low
pressure switch. This will
ensure positive protection
against mal-operation of
guide van.

Low air flow alarm and low

air flow combined with motor
contactor to warn
mal
operation of FD fan.

Air storage tank to ensure

opening of drop out door in
case of air failure provision
for mechanically opening
shall be provided.

Provision shall be made to

check up operation of drop
out
door
in
running
condition. This is referred
as crack open test.

In the event of fuel oil and

fuel gas cut off to the
furnace, the
following
sequential
action
is
needed:(a) Stack Damper Shall
Open.
(b) ID Fan to trip
(c) FD Fan to trip
(iii)

Burner System.

Low pressure alarm and

very low pressure alarm for
pilot
gas
should
be
incorporated in the safety
inter lock system. of the
furnace.

A separate shut off valve

shall be provided on the
pilot gas header.

This shall be linked up with

push button trip or full
furnace trip.

Main FO/FG headers shall

be provided with shut off
valves operated by low
fuel pressure and other
reasons of furnace trip.

Shut down valve operated

by manual push button
switches
shall
be
considered for each fuel
gas burners, wherever
applicable.

The pressure switches

shall be directly mounted
on the FO/FG headers for
safety.

For dual firing the safety

interlock should take care
that no interruption in
furnace operation takes
place during change over
of fuel.

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.

4.8

HDS
REACTOR
(HYDRO
DESULPHURISATION)

4.8.1

Description
HDS Reactors are used to remove
sulphur from petroleum products
like Naphtha, Kerosene, diesel etc.
the product to be desulphurised is
mixed with Hydrogen and heated in
a furnace, the outlet temperature of
which is controlled. The outlet of
the
furnace
with
controlled
temperature enters into a reactor
filled with catalyst. In the reactor
the sulphur in the petroleum

products combine with hydrogen

and forms hydrogen sulphide. The
reaction product goes to a separator
where the gas is separated from the
desulphurised product.
4.8.2

Safety Instrumentation

The following safety instrumentation shall

be provided for HDS unit. (see Fig:4.8)
(I)

Reactor thermocouple assembly

consisting
of
number
of
thermocouples of different lengths
to measure and record reactor bed
temperature at different heights.
High temperature alarms also shall
be provided.

(ii)

Reactor inlet and outlet temperature

recorder with high alarms. Separate
sensors for recorders and alarms
shall be provided.

(iii) Reactor inlet temperature control to

be incorporated in the furnace outlet
temperature control scheme.
(iv) Safety/Relief valve shall be provided
as per guidelines of OISD Standard
106 on Pressure Relief and
Disposal System
(v) Safety interlock shall be provided for
low hydrogen flow or low feed or
high reactor temperature.

4.9

PROCESS GAS
COMPRESSORS

4.9.1

Description
Process gas compressors are used
in the petroleum processing and gas
pipeline processes to increase the
pressure of gas for handling and
transportation.

4.9.2

Safety Instrumentation
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)

Pressure safety valve on the

discharge line and K.O drum of
each stage.
A check valve (FSV) on the
discharge line.
Gas detection and fire detection
devices shall be provided if the
compressor is located inside
enclosed buildings totally covered
on all the sides. The protection
shall
also
include
turbine
enclosures.

Reactor
contains
hydrocarbon
vapour and regenerator contains hot
air. air should not enter the reactor
and hydrocarbon vapour should not
find entry into the regenerator.
Regenerator is kept at higher
pressure (0.5 Kg/CM2) more
compared to the reactor. Additional
heads due to spent catalyst level in
the reactor aids the transfer of spent
catalyst from reactor to regenerator.
During normal operation spent
catalyst slide +valve operation is
dependent on the LRC of reactor.
The reactor is maintained at a temp
around 490 Deg.C by the transfer of
hot regenerated catalyst from
regenerator.
During
normal
operation regenerator catalyst slide
valve opening is controlled by
reactor TRC (Fig.4.10)

An anti surge controller shall be

provided
for
centrifugal
compressors.

(vi)

Devices to monitor and trip in case

of excessive vibration, speed, low
lube oil pressure, seal oil low
differential pressure, high bearing
temperature and high discharge
temperature etc. in line with
manufacturers recommendations.

(vii)

High level switches on the suction

knockout drum shall trip the
compressor.

(viii) Automatically operated blow down

valve shall be provided on the
discharge line.
Note: Compressor trip shall mean shutting
down the drive unit and closing of
suction shut down valve.

4.10

to flow with the feed (HVGO) in the

riser pipe of the reactor. Carbon
particles are deposited on the
catalyst when the feed cracks into
lighter ends like Fuel Gas, LPG,
Naphtha, diesel and heavy oil. The
carbonized catalyst is called spent
catalyst and is then taken into the
regenerator for regeneration. In the
regenerator controlled air is blown
through the hot catalyst to convert
the carbon into carbon monoxide,
thereby
releasing
equilibrium
catalyst for use in the next cycle.

PSH and PSL on suction and

discharge
line
to
trip
the
compressor.

FLUIDISED
CATALYTIC
CRACKING UNIT REACTOR/
REGENERATOR

4.10.1 Description
Lighter products are obtained from
Heavy Vacuum Gas Oil (HVGO) by
Catalytic cracking in FCCU, Zeolite
catalyst is heated to a temperature
of 650 degree C and is then allowed

4.10.2 Safety Instrumentation

The following safety instrumentation
shall be provided:
(I) Three nos. of low differential
pressure switches in 2/3 voting logic
across the spent catalyst
slide
valve to shut off the slide valve
automatically in the event of low
differential pressure.
(ii)

Three nos. differential pressure

switches in 2/3 voting logic across
the regenerated catalyst slide valve
to shut off the valve automatically in
the event of low differential
pressure.

(iii)
Mechanical stopper shall be
provided for the double disc slide
valve to prevent closing of the
valve against over pressurisation of
regenerator.
(iv)

Reactor high temperature alarm.

(v)

Emergency feed by pass switch to

divert feed from the reactor.

(vi)

Hand jack for all slide valves for

manual operation. In addition local
electrical/hydraulic/pneumatic
operation shall also be provided.

(vii) Low flow alarm rate and emergency

cut in for steam and bypassing feed
to reactor may be considered.
(viii) Low temperature alarm for reactor
cyclone outlet temperature may be
considered
for
prevention
of
hydrocarbon
vapour
into
regenerator.

4.12.1 Description
In petroleum industries, there are usually
two types of storage tanks:
(I)

Cone Roof
products.

(ii)

Floating Roof
products.

for

lighter

tanks

(I)

Indicator with optional high level

alarm.

(ii)

Temperature indicator with optional

high temperature alarm.

(iii)

Pressure and vacuum Relief valves

in case of it is not freely vented to
atmosphere, with
a
flame
arrest on the downstream side.
AIR COMPRESSORS

4.13.1 Description
Air compressors are used in
hydrocarbon industry for supplying
air to pneumatic instruments and as
well as for process requirements.
The compressors considered here
are reciprocating type.

4.11.2 Safety Instrumentation

The following safety instrumentation
shall be provided (see Fig.4.11)

heavy

The following safety instrumentation shall

be provided:

4.13

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.

for

4.12.2 Safety Instrumentation

4.11.0 FLARE GAS SYSTEM

4.11.1 Description

tanks

4.13.2 The following safety instrumentation

shall be provided:

(I)

Low level alarm set at below the

pump auto stop.

(I)

Pressure safety valve

discharge of each stage.

(ii)

Knock out drum (K. O. D.) high

level alarms.
In case of gas
processing units a system trip to
restrict the liquid inflow to
K.O drum may be considered.

(ii)

Cooling water low flow trip.

(iii)

Discharge temp high trip.

(iv)

Frame oil low pressure trip.

(v)

Discharge pressure high trip.

(vi)

Automatic loading/unloading system

to be considered wherever possible.

(iii)

T.V. monitoring of the flame may be

considered.

4.12
ATMOSPHERIC
TANKS

STORAGE

at

the

4.4

TURBINES

through loading arms into truck

tankers or rail tankers.

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.

When LPG is received through road

or rail tankers, it is pumped into the
bullets or spheres by unloading
pumps.
4.15.2 Safety Instrumentation.

4.14.2 The following safety Instrumentation

shall be provided:
I)

Lube Oil pressure low trip.

ii)

Governor oil to pressure low trip.

iii)

Turbine exhaust pressure high trip.

iv)

Over speed trip.

v)

Axial displacement trip.

vi)

Vibration high trip.

vii)

Emergency trip.

viii)

Condensate level high alarm.

ix)

Exhaust
alarm.

x)

Operating temperature high Trip.

xi)

FG pressure low trip.

xii)

Exhaust
temp.(average
of
3
thermocouples in exhaust) high trip.

xiii)

Lube oil temp. high trip

xiv)

K.O drum level high trip.

xv)

Oil tank level alarms.

4.15

LPG PRESSURE STORAGE AND

BULK LOADING

hood

high

temperature

The following safety instrumentation

shall be provided for LPG Sphere
(Fig.4.15)
(I)

LPG sphere shall be provided with

Pressure Safety Valve as per
guidelines
of
OISD-106
on
Pressure Relief and Disposal
System

(ii)

Fire detection and protection system

It shall consist of fusible plugs on a
tubing system pressurised by
instrument air which shall be
provided on LPG spheres, LPG
pumps, compressor house etc. The
fusible plugs shall be designed to
blow at 80 Deg.C. If any of the plug
fuses and blows it will depressurise
the system. This is sensed by a
pressure switch which will activate
the security system.
The activation of the pressure
switch shall initiate the following
action.
Closure of remote operated
valves in the affected area.
Start up of fire water pump,
activation of deluge valve and
activation
of
the
sprinkler
system.
Activation of tone generator in
paging or a siren in the particular
area.

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

Tripping of LPG pumps and

compressors.
Emergency push buttons shall be
provided in the control panel and at
a safe place in the field to initiate
the above actions manually.

ROVS shall be provided with

open/close indications on the
control panel.
(iii)

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.

Gas Detection Systems

Gas detectors shall be provided at
all locations where possibility of
build up of LPG vapour exists,
which might lead to a fire.
Suggested locations are:
-

LPG Pump and compressor

house.

LPG Truck and rail loading

gantries

LPG Sampling Point.

Near ROVS.

Gas detectors shall have two levels

of alarms. Suggested values are
20% LEL and 60% LEL.
(iv)

4.16.2 Safety Instrumentation

The following safety instrumentation
shall be provided in a coke
chamber. (See Fig:4.16)
(I)

Level alarms at different locations

to avoid foam/coke carry over etc.

(ii)

High
pressure
alarm
independent impulse line.

(iii)

Temperature indication and high

temperature alarm at vapour outlet
(after HGO quench). Skin thermo
couple at top/middle/bottom of the
chamber.

(iv)

Coke cutting water pump trips for

following conditions:

Level gauging devices

LPG spheres shall be provided with
two independent indicators as a
minimum.

(v)

Level switches
A separate high level switch shall be
provided for alarm in the control
room.
A water seal pot shall be provided
on the low pressure side of the DP
type level transmitter if use, the seal
pot and the connecting pipe shall be
of the same rating as that of the
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

COKE CHAMBERS

4.16.1 Description

(a)

with

Low discharge pressure.

(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)

During coke cutting, when the

cutting/drilling tools need to be
brought out for the tool change etc.,
the coke cutting water pump
discharge shall automatically get
routed to storage tank.

Following legends are used in the figures

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
TEMPERATURE
TEMPERATURE
TEMPERATURE
TEMPERATURE

SDV
BDV
ROV
MOV
VSHH
FO
FG

:
:
:
:
:
:
:

SHUT DOWN VALVE

BLOW DOWN VALVE
REMOTE OPERATE VALVE
MOTOR OPERATED VALVE
VIBRATION SWITCH HIGH HIGH
FUEL OIL
FUEL GAS

SAFETY VALVE
SWITCH LOW
SWITCH LOW LOW
CONTROL VALVE
TRANSMETER
ELEMENT
CONTROL VALVE
SWITCH HIGH
SWITCH HIGH HIGH

NOTE