CLIENT NAME INDIAN OIL CORPORATION LTD (IOCL)

PROJECT TITLE PARADIP REFINERY PROJECT (PDRP)

PROJECT LOCATION PARADIP, ORISSA, INDIA

VENDOR NAME PETRON ENGINEERING CONSTRUCTION LIMITED

CONTRACT NO. 14-420/ 4399

IOCL ORDER NO.

CONSULTANT (FW)
0459/ 4200 REQ NO.: DSN – 15562
P.O. NO.

REQ ITEM NO.: TAG NO.:

CAUSE & EEFECT TABLE FOR HEATER & AIR PREHEATING

DOCUMENT TITLE
SYSTEM FOR CRUDE CHARGE HEATER 010-F-101

VENDOR DOC NO.: PECL/C-908/1145/ AVU/C-1021 VENDOR REV. S1 A

DOC TYPE CODE &  CONSULTANT

7
SEQUENCE NO. (FW) REV. NO.

STATUS CODE: BY: DEPT: DATE:

4 Suresh K D153(PE) 28 Sept 2012
 PECL/C-908/1145/AVU/C-1021
Revision No: S1
Revision Date: 22-Aug-12
Document Category: Class 3
Sheet: 1 of 3

CAUSE AND EFFECTS

CRUDE CHARGE HEATER 010-F-101
UNIT 010

 
 
 
 
 
 

REVIEWED
 

             

NEERAV CHAUDHARY   

Indian Oil Corporation Limited (IOCL)

Paradip Refinery Project (PDRP)
Paradip, Orissa State, India
Contract No: 1-14-4200/ 399

S1 22-Aug-12 Revised & Re-Issued VKJ AKJ SKS

S 22-Feb-12 Issued for Construction VKJ AKJ SKS
A2 01-Dec-11 Revised & Re-Issued VKJ AKJ SKS
A1 21-Mar-11 Revised & Re-Issued VKJ RKT SKS
A 25-Oct-10 Issued for Design VKJ RKT SKS
H 22-Sep-10 Issued for Hazop NK VKJ SKS
O1 04-Aug-10 Issued for Comments NK VKJ SKS
Rev Date Description Orig By Checked By Approved
DSN: 18139
 PECL/C-908/1145/AVU/C-1021
CAUSE AND EFFECTS Revision No: S1
NOTES SHEET Revision Date: 22-Aug-12
Sheet: 2 of 3
Rev
GENERAL NOTES:
1. Unless otherwise noted, shutdown/ trip switch contacts are normally closed, open on trip condition.

2. Unless otherwise noted, outputs shall be de-energized to trip.

3. Unless otherwise stated, a two-second time delay shall be provided for each analog input signal to
avoid nuisance trips.
4 As a general rule, each Interlock will have a soft 'logic' reset. Any ESD valves shall also have
individual field reset. The system design shall prevent valve reset, unless the interlock has been
reset. Reset of the interlock shall be permissive only and shall not open / close the valve. Valve
opening / closing shall only be possible by subsequent local reset.
5. For detailed description of Interlocks refer P&ID No: PECL/C-908/1145/AVU/C-1020.

LIST OF INTERLOCKS

010-IZ-0631 : ACTIVATION OF EMERGENCY PUSH BUTTON

010-IZ-0644 : LOW LOW / HIGH HIGH PILOT GAS PRESSURE
010-IZ-0645 : TRIPPING OF HEATER 010-F-201 OTHER THAN EMERGENCY & PILOT SHUTDOWN
010-IZ-0106 : HIGH HIGH FURNACE ARCH PRESSURE
010-IZ-0106 : FAILURE OF BOTH ID FANS
010-IZ-0107 : HIGH HIGH PROCESS OUTLET TEMPERATURE
010-IZ-0107 : LOW LOW PROCESS FEED FLOW AT COMBINED INLET OR ANY PASS
010-IZ-0107 : FAILURE OF BOTH FD FANS
010-IZ-0107 : LOW LOW COMBUSTION AIR FLOW & PRESSURE
010-IZ-0633 : HIGH HIGH OR LOW LOW FLUE GAS TEMPERATURE AT APH OUTLET
010-IZ-0118 : HIGH HIGH OR LOW LOW MAIN FUEL GAS PRESSURE
010-IZ-0119 : HIGH HIGH OR LOW LOW MAIN FUEL OIL PRESSURE
010-IZ-0119 : LOW LOW DIFFERNTIAL PRESSURE BETWEEN ATOMISING STEAM & FUEL OIL
010-IZ-0121 : LOW LOW MPSH STEAM TEMPERATURE FROM DESUPERHEATER
010-IZ-0122 : LOW LOW LPSH STEAM TEMPERATURE FROM CONVECTION SECTION
010-IZ-0640 : LOW LOW STEAM DRUM LEVEL
010-IZ-0634 : CONSEQUENCE OF IZ 0106, 0107, (0118 & 0119), 0633, 0640 & 0644
010-IZ-0635 : FAILURE OF SINGLE FD FAN
010-IZ-0642 : ID FAN SAFEGUARDING ACTIVATION OF IZ 0633 & 0640 AT A TIME
010-IZ-0643 : SINGLE ID FAN FAILURE DURING WHB/ APH BYPASS
010-I-0632 : SOOT BLOWER OPERATION IN PROGRESS
010-IZ-0646 : LOSS OF MAIN FLAME
010-IZ-0638 : PERMISSIVE FOR PILOT BURNER IGNITION S1
010-IZ-0639 : PERMISSIVE FOR MAIN BURNER IGNITION S1
 LEGEND

LSTK-A P&ID
P&ID NO.

010-1014
C-1016

C-1016

C-1012

C-1012
C-1012

C-1014

C-1014

C-1014

C-1014

C-1014

C-1014

C-1014

C-1014

C-1014

C-1014
C-1014

C-1014

C-1014

C-1014

C-1014

C-1014

C-1014

C-1015

C-1016

C-1011

C-1016

C-1016

C-1016

C-1013

C-1013

C-1013

C-1016

C-1016

C-1015

C-1015
Index of IZ Safety Instrumented Functions

-
010-IZ-0631 : ACTIVATION OF EMERGENCY PUSH BUTTON Actions:

BOILER FEED WATER DOWNSTREAM SHUT OFF VALVE

010-IZ-0644 : LOW LOW / HIGH HIGH PILOT GAS PRESSURE OP = Open

PILOT FUEL GAS DOWNSTREAM SHUT OFF VALVE

PILOT FUEL GAS DOWNSTREAM SHUT OFF VALVE
010-IZ-0645 : TRIPPING OF HEATER 010-F-201 OTHER THAN EMERGENCY & PILOT SHUTDOWN CL = Close

MAIN FUEL GAS DOWNSTREAM SHUT OFF VALVE

MAIN FUEL GAS DOWNSTREAM SHUT OFF VALVE
PILOT GAS CHARGE HEATER SHUT OFF VALVE
010-IZ-0106 : HIGH HIGH FURNACE ARCH PRESSURE

LPSH STEAM DOWNSTREAM SHUT OFF VALVE

PILOT FUEL GAS UPSTREAM SHUT OFF VALVE

PILOT FUEL GAS UPSTREAM SHUT OFF VALVE

ST = Start

MAIN FUEL GAS UPSTREAM SHUT OFF VALVE

MAIN FUEL GAS UPSTREAM SHUT OFF VALVE

FUEL OIL LINE TO BURNER SHUT OFF VALVE

010-IZ-0106 : FAILURE OF BOTH ID FANS

HEATER FLUE GAS OUTLET DUCT DAMPER

SP = Stop

CRUDE CHARGE HEATER STACK DAMPER

SOOT BLOWER DRAIN SHUTDOWN VALVE

OIL GUN STEAM PURGE SHUT OFF VALVE

SOOT BLOWER INLET SHUTDOWN VALVE

FUEL OIL RETURN LINE SHUT OFF VALVE
010-IZ-0107 : HIGH HIGH PROCESS OUTLET TEMPERATURE EN = Enabled

COIL PURGE STEAM SHUTDOWN VALVE

FUEL OIL UPSTREAM SHUT OFF VALVE
010-IZ-0107 : LOW LOW PROCESS FEED FLOW AT COMBINED INLET & INDIVIDUAL PASS

LPSH STEAM VENT SHUT OFF VALVE

NOT EN = Not Enabled

CRUDE CHARGE HEATER 010-F-201

DESCRIPTION
010-IZ-0107 : FAILURE OF BOTH FD FANS ACT = Active

APH FLUE GAS BY-PASS DAMPER

APH FLUE GAS BY-PASS DAMPER

WHB FLUE GAS INLET DAMPER

010-IZ-0107 : LOW LOW COMBUSTION AIR FLOW & PRESSURE

PILOT FUEL GAS BLEED VALVE

PILOT FUEL GAS BLEED VALVE

INH = Inhibit

APH FLUE GAS INLET DAMPER

MAIN FUEL GAS BLEED VALVE

MAIN FUEL GAS BLEED VALVE

FD FAN DISCHARGE DAMPER

FD FAN DISCHARGE DAMPER

010-IZ-0633 : HIGH HIGH OR LOW LOW FLUE GAS TEMPERATURE AT APH OUTLET MAN = Controller into Manual & ramp output to 0%
010-IZ-0118 : HIGH HIGH OR LOW LOW MAIN FUEL GAS PRESSURE TRIP

WHB BY-PASS DAMPER

WHB BY-PASS DAMPER

010-IZ-0119 : HIGH HIGH OR LOW LOW MAIN FUEL OIL PRESSURE
010-IZ-0119 : LOW LOW DIFFERENTIAL PRESSURE BETWEEN ATOMISING STEAM & FUEL OIL

EFFECT

FEED TO HEATER
010-IZ-0121 : LOW LOW MPSH STEAM TEMPERATURE FROM DESUPERHEATER X = Direct Actions
010-IZ-0122 : LOW LOW LPSH STEAM TEMPERATURE FROM CONVECTION SECTION T = Time Delayed Actions
010-IZ-0640 : LOW LOW STEAM DRUM LEVEL

FD FANS
R = Reset Action

ID FANS
010-IZ-0634 : CONSEQUENCE OF IZ 0106, 0107, (0118 & 0119), 0633, 0640 & 0644 Z = Inhibit
010-IZ-0635 : FAILURE OF SINGLE FD FAN P = Permissive
010-IZ-0642 : ID FAN SAFEGUARDING ACTIVATION OF IZ 0633 & 0640 AT A TIME

ACTION

TRIP

TRIP

TRIP

TRIP
010-IZ-0643 : SINGLE ID FAN FAILURE DURING WHB/ APH BYPASS

OP

OP

OP

OP

OP

OP
OP

OP

OP

OP

OP

OP

OP

OP
CL

CL

CL

CL

CL

CL

CL

CL

CL
CL

CL

CL

CL

CL

CL

CL

CL

CL

CL
010-I-0632 : SOOT BLOWER OPERATION IN PROGRESS
010-IZ-0646 : LOSS OF MAIN FLAME

HZS-9302 A
HZS-9302 A

HZS-93111
HZS-1805
HZS-1098

HZS-1802

HZS-1802

HZS-1802

HZS-1804

HZS-1804

HZS-1804

HZS-9301

HZS-1028

HZS-1028

HZS-9308

HZS-9307

HZS-9304

HZS-9304

HZS-9305

HZS-1802

HZS-1802

HZS-1802

HZS-1804

HZS-1804

HZS-1804
HZS-1035

HZS-9301

HZS-1001

HZS-9309

HZS-9306

HZS-9306
TO 1820
RESET
010-IZ-0638 : PERMISSIVE FOR PILOT BURNER IGNITION

TO P
TO P
-

-
-
010-IZ-0646 : PERMISSIVE FOR MAIN BURNER IGNITION

XZV-1045 A TO P

XZV-1046 A TO P

XZV-1057 A TO P

XZV-1001 ATO H
TAG NO.

P-003A/B/C
K-001 A/B

K-002 A/B
XZV-1023

XZV-1053

XZV-1054

XZV-1030

XZV-1025

XZV-1029

XZV-1043

XZV-1042

XZV-1023

XZV-1053

XZV-1054

XZV-1022

XZV-1049

XZV-1050
XZV-1022

XZV-1049

XZV-1050

XZV-1024

XZV-1026

XZV-1031

XZV-1030

XZV-9301

XZV-9302

XZV-1028

XZV-1029

XZV-1037

XZV-1038
PV-1098

PV-1035
F-201
CAUSE

NOTES
VOTING
No. TAG NO. SENSE DESCRIPTION SIL P&ID NO.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37
1

9
1 010-IZ-0631 : ACTIVATION OF EMERGENCY PUSH BUTTON NOTES:
HZS-3000 A Open EMERGENCY PUSH BUTTON IN AUXILLARY HARDWIRED PANEL - C-1014 1oo1 X X X X X X X X X X X X X X X X X X 1) ALL TAG NOS ARE PREFIXED BY UNIT NUMBER 010.
HZS-3000 BA Open EMERGENCY PUSH BUTTON IN FIELD - C-1014 1oo1 X X X X X X X X X X X X X X X X X X 2) START TIMER FOR 30 SECS.
010-IZ-0631_R Interlock Reset in ESD HMI 3) APH BYPASS & WHB BY PASS SENSED BY INLET DAMPER
2 010-IZ-0644 : LOW LOW / HIGH HIGH PILOT GAS PRESSURE POSITION LIMIT SWITCHES (XZSL-1031 & XZSL-1028
PZT-1167A/ B/ C HH / LL LOW LOW / HIGH HIGH PILOT GAS PRESSURE 2 C-1014 2oo3 8 T T T T T T T T T T T T RESPECTIVELY)
010-IZ-0644_R Interlock Reset in ESD HMI 4) THIS INTERLOCK SHALL BE IMPLEMENTED IN THE DCS
3 010-IZ-0645 : TRIPPING OF HEATER 010-F-201, CONSEQUENCE OF IZ 0506, 0507, (0518 & 0519) 5) BASED ON THE INDIVIDUAL FLAME SCANNER INPUT,
- - TRIPPING OF HEATER 010-F-201 - - - X X X X X X X X X RESPECTIVE FUEL OIL SHUTDOWN VALVES SHALL CLOSE &
010-IZ-0645_R Interlock Reset OIL GUN STEAM PURGE SHUTDOWN VALVES SHALL OPEN.
4 010-IZ-0106: HIGH HIGH FURNACE ARCH PRESSURE OR FAILURE OF BOTH ID FANS 6) PILOT GAS BLOCK & BLEED VALVES TO OPERATE ONLY
PZT-1124A/ B/ C HH HIGH HIGH ARCH PRESSURE 2 C-1012 2oo3 X X WHEN ALL PILOT GAS BURNER SHUTOFF VALVES ARE
MZL-1018C & MZL-1019C Open FAILURE OF BOTH ID FANS - C-1016 2oo2 X X CLOSED AND PILOT & MAIN LEAK TEST CLEARED
PSH-1035/ PSH-1098 Open HEATER FLUE GAS DAMPER OPEN/ STACK DAMPER OPEN 2 C-1012/1016 1oo1 2 T T T T T T T T 7) MAIN FUEL GAS BLOCK & BLEED VALVES TO OPERATE ONLY
010-IZ-0106_R Interlock Reset in ESD HMI WHEN BURNER LEAK TEST CLEARED AND AT LEAST ONE
5 010-IZ-0107 : HH PROCESS OUTLET TEMP. / LL PROCESS FEED FLOW / FAILURE OF BOTH FD FANS / LL COMB. AIR FLOW OF THE PILOT IS ON
TZT-1123A/ B/ C HH HIGH HIGH PROCESS OUTLET TEMPERATURE 0 C-1011 2oo3 X X X X X X X X 8) START TIMER FOR 5 SECS.
FZT-1016A/ B/ C LL LOW LOW PROCESS FEED FLOW 2 C-1011 2oo3 X X X X X X X X 9) DURING START UP INDIVIDUAL VALVE ON PILOT GAS LINE
FZT-9307A TO H A/ B/ C LL LOW LOW PROCESS FEED FLOW FOR ANY PASS 2 C-1011 2oo3 X X X X X X X X TO BURNER 010-XZV-1045A TO P IS OPENED BY PRESSING
MZL-1020AC & MZL-1020BC Open FAILURE OF BOTH FD FANS - C-1015 2oo2 X X X X X X X X SWITCH 010-HZS-1805 TO 1820 ON THE LOCAL PANEL. IF THE
FZT-1084A/ B/ C LL LOW LOW COMBUSTION AIR FLOW 2 C-1012 2oo3 X X X X X X X X RESPECTIVE BURNER FLAME IS NOT DETECTED AS SENSED BY
PZT-9319A/ B/ C LL LOW LOW COMBUSTION AIR PRESSURE 2 C-1015 2oo3 X X X X X X X X 010-BZSLL-1001 A TO P, WITHIN 10 SEC THE SHUTDOWN
010-IZ-0107_R Interlock Reset in ESD HMI VALVE ON INDIVIDUAL PILOT GAS LINE TO BURNER
6 010-IZ-0633 : HIGH HIGH OR LOW LOW FLUE GAS TEMPERATURE AT APH OUTLET 010-XZV-1045A TO P SHALL CLOSE AUTOMATICALLY.
TZT-1212A/ B/ C HH / LL HIGH HIGH OR LOW LOW FLUE GAS TEMPERATURE AT APH OUTLET 0 C-1016 2oo3 X X 10) DURING START UP, AFTER OPENING/ CLOSING OF BLOCK AND
XZSL-1031/XZSH-1030 Open/ Close APH INLET DAMPER CLOSE/ APH BYPASS DAMPER OPEN 0 C-1016 1oo1 2 T T T T T T T T T BLEED VALVES ON PILOT GAS LINE 010-XZV-1023, 1053 /
010-IZ-0633_R Interlock Reset in ESD HMI 1054 BY PRESSING SWITCH 010-HZS-1802 ON THE LOCAL
7 010-IZ-0118 : HIGH HIGH OR LOW LOW MAIN FUEL GAS PRESSURE PANEL, IF ANY THE BURNER PILOT FLAME IS NOT DETECTED
PZT-1165A/ B/ C HH / LL HIGH HIGH OR LOW LOW MAIN FUEL GAS PRESSURE 2 C-1014 2oo3 X X X AS SENSED BY 010-BZSLL-1001 A TO P WITHIN 10 MIN.,
010-IZ-0118_R Interlock Reset in ESD HMI THE BLOCK & BLEED VALVES ON PILOT GAS LINE
8 010-IZ-0119 : HH OR LL MAIN FUEL OIL PRESSURE OR LL DIFF. PRESSURE B/W ATOMISING STEAM & FUEL OIL 010-XZV-1023, 1053 / 1054 SHALL TRIP AND A FRESH LEAK
PZT-1172A/ B/ C HH / LL HIGH HIGH OR LOW LOW MAIN FUEL OIL PRESSURE 2 C-1014 2oo3 X X X X TEST HAS TO BE CARRIED OUT.
PDZT-1083A/ B/ C LL LOW LOW DIFFERNTIAL PRESSURE BETWEEN ATOMISING STEAM & FUEL OIL 2 C-1014 2oo3 X X X X
010-IZ-0119_R Interlock Reset in ESD HMI
9 010-IZ-0121 : LOW LOW MPSH STEAM TEMPERATURE FROM DESUPERHEATER
TZT-1136 LL LOW LOW MPSH STEAM TEMPERATURE FROM DESUPERHEATER 0 C-1013 1oo1 X
010-IZ-0121_R Interlock Reset in ESD HMI
10 010-IZ-0122 : LOW LOW LPSH STEAM TEMPERATURE FROM CONVECTION SECTION S1 22-Aug-12 VKJ AKJ SKS
TZT-1137 LL LOW LOW LPSH STEAM TEMPERATURE FROM CONVECTION SECTION 0 C-1013 1oo1 X X S 22-Feb-12 VKJ AKJ SKS
010-IZ-0122_R Interlock Reset in ESD HMI A2 01-Dec-11 VKJ AKJ SKS
11 010-IZ-0640 : LOW LOW STEAM DRUM LEVEL A1 21-Mar-11 VKJ RKT SKS
LZT-1055 LL LOW LOW STEAM DRUM LEVEL - C-1017 1oo1 X X A 25-Oct-10 VKJ RKT SKS
XZSL-1028/XZSH-1029 Open/ Close WHB INLET DAMPER CLOSE/ WHB BYPASS DAMPER OPEN 0 C-1016 1oo1 2 T T T T T T T T T H 22-Sep-10 NK VKJ SKS
010-IZ-0640_R Interlock Reset in ESD HMI O1 04-Aug-10 NK VKJ SKS
12 010-IZ-0634 : CONSEQUENCE OF IZ 0106, 0107, (0118 & 0119), 0633, 0640 & 0644 REV DATE PRPD CHKD APPD
- - CONSEQUENCE OF IZ 0106, 0107, (0118 & 0119), 0633 & 0640 - - - 2 X X T T
010-IZ-0634_R Interlock Reset in ESD HMI
13 010-IZ-0635 : FAILURE OF SINGLE FD FAN
MZL-1020AC Open FAILURE OF SINGLE FD FAN - C-1015 1oo1 X
MZL-1020BC Open FAILURE OF SINGLE FD FAN - C-1015 1oo1 X
010-IZ-0635_R Interlock Reset in ESD HMI
14 010-IZ-0642 : ID FAN SAFEGUARDING ACTIVATION OF IZ 0633 & 0640 AT A TIME
- - ID FAN SAFEGUARDING ACTIVATION OF IZ 0633 & 0640 AT A TIME - - - X X X X X PARADIP REFINERY PROJECT
010-IZ-0642_R Interlock Reset in ESD HMI Paradip, Orissa State, India
15 010-IZ-0643 : ONE ID FAN FAILURE DURING WHB/ APH BYPASS AS SENSED BY (XZSL-1028 & XZSL-1031 RESPECTIVELY)
MZL-1018C OR MZL-1019C Open ONE ID FAN FAILURE DURING WHB/ APH BYPASS - C-1016 1oo1 3 X X X X X X
010-IZ-0643_R Interlock Reset in ESD HMI
16 010-I-0632 : SOOT BLOWER OPERATION IN PROGRESS This Drawing is the Property of INDIAN OIL CORPORATION LTD
TT-1125 LL SOOT BLOWER OPERATION IN PROGRESS - C-1012 1oo1 4 X and is lent without consideration other than the Borrower's agreement that it
shall not be reproduced, copied lent or disposed of directly or indirectly, nor
PT-1006 LL SOOT BLOWER OPERATION IN PROGRESS - C-1012 1oo1 4 X
used for any purpose other than that for which it is specifically furnished.
010-I-0632_R Interlock Reset in DCS HMI
The apparatus shown in the drawing is covered by patents. Information
17 010-IZ-0646 : LOSS OF MAIN FLAME contained in this drawing may be proprietary to Indian Oil Corporation Ltd
BZE-1002 A TO P LL LOSS OF MAIN FLAME - C-1014 1oo1 5 X X and/or licensors, and issued subject to obligations of confidentiality.
010-IZ-0646_R Interlock Reset
18 010-IZ-0638 : PERMISSIVE FOR PILOT BURNER IGNITION -
XZSL-1045 A TO P Close PILOT GAS BURNER SHUT OFF VALVES - C-1014 - 6 P P P
XZL-1006 True PILOT GAS HEADER LEAK TEST CLEARED - C-1020 - 6 P P P TITLE: INSTRUMENT CAUSE AND EFFECTS
XZL-1027 True MAIN FUEL GAS HEADER LEAK TEST CLEARED - C-1020 - 6 P P P CRUDE CHARGE HEATER 010-F-101
19 010-IZ-0639 : PERMISSIVE FOR MAIN BURNER IGNITION SHEET REV
DOC. No.: PECL/C-908/1145/AVU/C-1021
XZL-1027 True MAIN FUEL GAS HEADER LEAK TEST CLEARED - C-1020 - 7 P P P 3 of 3 S1

BZE-1001 A TO P True PILOT FLAME SCANNER ON (AT LEAST ONE) - C-1020 - 7 P P P CONTRACT No. 1-14-4200/4399 Doc Class 3 DSN 18139