ESD System Operation

Yanbu Export Refinery Project
OPERATING INSTRUCTIONS FOR SP1 TANK FARM

EMERGENCY PROCEDURES
Document No.: 143-SP1-PE-OPM-0003
Revision No.: A Issue Date: 08 OCT 2013
TABLE OF CONTENTS
1.0
PURPOSE ................................................................................................................... 4
2.0
100 EMERGENCY SHUT DOWN ............................................................................... 4
3.0
200 LOSS OF UTILITIES .......................................................................................... 36
4.0
300 LOSS OF CRITICAL SYSTEMS/COMPONENTS ............................................. 45
5.0
400 UNUSUAL OCCURRENCES ............................................................................. 47
TABLES
Table 1 MOS and SUO requirement ....................................................................................... 7
Table 2 Non phenolic pumps shutdown signals ...................................................................... 9
Table 3 phenolic pumps shutdown signals ........................................................................... 10
Table 4 crude pumps shutdown signals ................................................................................ 11
Table 5 NHT pumps shutdown signals ................................................................................. 12
Table 6 NHT pumps shutdown signals ................................................................................. 12
Table 7 DCU pumps shutdown signals ................................................................................. 13
Table 8 DHT pumps shutdown signals ................................................................................. 14
Table 9 HCK pumps shutdown signals ................................................................................. 15
Table 10 heavy naphtha pumps shutdown signals ............................................................... 16
Table 11 off spec diesel pumps signals ................................................................................ 17
Table 12 Isomerate, Light reformate , NHT light naphtha pumps shutdown signals ............. 20
Table 13 BEU raffinate pumps shutdown signals ................................................................. 20
Table 14 Reformate pumps shutdown signals ...................................................................... 21
Table 15 Light naphtha pumps shutdown signals ................................................................. 22
Table 16 propane pumps shutdown signals.......................................................................... 23
Table 17 Coker LPG pumps shutdown signals ..................................................................... 24
General Confidential
Page 2 of 53

Table 18 Butane pumps shutdown signals ........................................................................... 27

Table 19 slop pumps shutdown signals ................................................................................ 27
Table 20 Desalter effluent shutdown signals ........................................................................ 27
Table 21 Benzene pumps shutdown signals......................................................................... 28
Table 22 BEU pumps shutdown signals ............................................................................... 28
Table 23 Sulfur pumps and cooler shutdown signals............................................................ 29
Table 24 Diesel pumps shutdown signals ............................................................................. 31
Table 25 Gasoline pumps shutdown signals......................................................................... 34
Table 26 Benzene pumps shutdown signals......................................................................... 35
Table 27 control valves fail action ......................................................................................... 36
Table 28 control valves fail action ......................................................................................... 40
Table 29 Shutdown valves fail action .................................................................................... 45
Table 30 Floating roof protected by foam system ................................................................. 48
Table 31 spheres and spheroids protected by water deluge system .................................... 50
Table 32 Fire and gas emergency table................................................................................ 53
Page 3 of 53

1.0 PURPOSE
This document covers step by step instructions for emergency procedure of SP1
scope of work (SWS-142, TKF-143, PBF-157, PSL-172).
2.0 100 EMERGENCY SHUT DOWN
The principal aims and objectives of a safety system are:
Protection of personnel.
Protection of facility and equipment.
Prevention of pollution to the environment.
The functions of the ESD shall include:
Automatically sense an abnormal operational or equipment condition.
React automatically to this condition by shutting down and/or isolating the

installation, preventing any consequential effects of the abnormal condition.
Provide additional manual facilities for the shutdown and/or isolation and blow
down of sections of the installation.
Provide audible and visual system status information for the operator and/or
other Personnel as appropriate.
Provide sequence of events recording.
Safety System Availability

The facility is designed for 92% Plant-wide uptime (availability) with 95% unit
availability for defined areas. The requirement for safety availability of safety systems
is as listed
below:
SIL3 applications: 99.9% to 99.99%
SIL2 applications: 99% to 99.9%
SIL1 applications: 90 to 99%
The parameters considered for calculations are listed below:
MTTR: 8 hours
Proof Test Interval: 10 years ( for Logic solver subsystem)
Proof Test interval for Analog ESD Inputs (Transmitters, Transducers and
Trip Amplifiers): 12 months
Proof Test Interval for Discrete ESD Inputs such as process switches: 6
months
Page 4 of 53

Proof Test Interval ( Full stroke test) for ZV (ESD Isolation Valves): 12
months (Note1)
Partial stroke test for ZV: 3 months
Plant Design Lifetime: 25 years
Note1:ZV assemblies shall be fully stroked on yearly basis when a full ZV bypass is
Available, the process or equipment is spared or the process operation can be
Maintained.
Equipment Location
The ProSafe-RS Safety System hardware, associated marshalling cabinets and
network equipment are installed in PIBs/ PIRs and in the CCB which are indoor safe
area locations, non-classified electrical area as per ANSI/ NFPA 70, NEC, Article
505. Saudi Aramco specifications require ESD system indoor equipment to be
suitable for installation in climate controlled buildings with the following environment
conditions:
Ambient temperature range: 10 oC to 35 oC
Ambient relative humidity: 20% to 80%
ESD Inputs
The input section of the ESD system shall be designed to receive input signals from
Non-Intrinsically safe analog (HART) field devices or process activated switch
contacts that are closed (i.e., normally energized) during healthy process conditions
(and will open when process variables exceed predetermined limits).
All shutdown inputs shall be configured with input validation logic to detect
transmitter failure. Input status shall be transmitted to the PAS for indication and
alarming.
ESD Inputs: Failsafe Operation
ESD transmitter failure mode and transmitter validation logic shall be applied
to minimize spurious trips and spurious alarms. Consequently, 1oo1 ESD
transmitters shall be configured to have a defined failure mode, in the
direction opposite to the trip setting. In case of a transmitter fault, a time
delayed shutdown is applied up to 30 minutes, if the fault is not rectified
within this time delay.
A single transmitter may be used to provide both Low-Low trip (LTRP) and
High-High trip (HTRP) ESD input signals if that the transmitter's calibrated
range spans both LTRP and HTRP trip settings, and that it is acceptable to
bypass both LTRP and HTRP inputs at the same time when performing
maintenance on the transmitter. For 1oo1 ESD transmitters used for both
HTRP and LTRP, the fail safe configuration shall be towards the HTRP by
default unless otherwise specified.
The digital input shall be validated upon any fault detection independently
depending on the fault detection design. The fail safe setting in input channel
Page 5 of 53

parameter and signal validation setting in application program shall be

configured independently accordingly.
All ESD digital input (trip initiators) shall be configured to failsafe to trip on
detection of a channel and/or line fault. Line monitoring (detect disconnection
and detect short circuit) are not provided for limit switches that are non-trip
initiator.
ESD Outputs
ESD outputs shall be designed to be Non- Intrinsically safe, normally energized
(when healthy) and de-energize upon the loss of appropriate input signals unless
otherwise specified.
However, alarm/ local indication lamp outputs from the ESD system shall be
configured to energize on trip.
ESD outputs shall go to de-energized state on occurrence of a channel fault or wire
Break. All ESD outputs to ZVs (ESD isolation valves) shall have line monitoring to
detect disconnection in case of a wire break.
Line monitoring for digital output channels are selected by channel parameter
settings in the ProSafe-RS software configuration. For details, refer to ESD
Software Design Specifications document [192-SP1-PE-ESD-1002].
ESD Reset
ESD logic shall be designed such that if it is de-energized for any reason, it can only
be reset or reenergized by deliberate, momentary actuation of a reset button.
ESD systems reset buttons shall be initiated from the PAS operator's workstation
(HIS) along with an event log, to time-tag the actuation of the reset by its specific tag
number and descriptor.
Resetting ESD system logic shall not cause a ZV (ESD isolation valve) or other
equipment to automatically return to its normal operating position or state. Manual
intervention by field operator is required to return a ZV to its normal state after a trip.
ESD Input & Output Bypasses
All shutdown sensing devices shall have an input bypass switch to facilitate
maintenance or testing. Bypass switches shall be software-configured with a
restrictive access mechanism using a MOS Enable Authentication Soft Switch and
password. The MOS Enable Authentication Switch will remain active after successful
password entry for a predetermined time period (presently set at 5 minutes). MOS
input bypasses are only required for input signals wired to the ESD system and used
for shutdown logic.
Input bypass switch implementation shall be software configured. Activation of an
input bypass switch shall confirm the bypass logic and cause an associated status
light or graphic window to be illuminated. Activation or deactivation of a bypass
switch shall initiate a system generated alarm in the DCS HIS and SOE event log
which archives the change of state of the bypass switch with its tag number and
descriptor.
Page 6 of 53

Input bypasses shall not result in the loss of measurement and/or annunciation of the
condition being monitored by the ESD.
Input bypass switches are not envisaged for ESD trip push/ pull buttons.
Start-up Bypasses
Timed automatic startup bypass shall be configured in ESD application software for
devices which would prevent the normal startup of plant equipment such as minimum
flow, level, pressure, temperature, motor load startup-current and vibration. Startup
bypasses shall be automatically reset when the plant or equipment reaches normal
operating parameters or when a prescribed time period has elapsed.
Activation or deactivation of an automatic startup bypass switch shall initiate an SOE
event log which archives the change of state of the bypass switch with its tag number
and descriptor.
Startup bypass timers shall be specified including a stabilization timer for operating
parameters to stabilize after the equipment has started up. The stabilization time
specified could be in the order of ten seconds or as per individual process
requirements.
Below table identifies types of signals that have MOS and / or SUO switches:
Signals that require Maintenance
Override Switches (MOS)
1
2.a
2.b
2.c
3
4
5
6
7
Signals that require Start Up Override

Switches (SUO)
Open Limit Switches (ZXSO) of normal

ZV's (111 off)
100% open (ZXSO) of Critical ZV's (16
off)
80% open (ZXSO) of Critical ZV's (16

off)
Close (ZXSC) of Critical ZV's (16 off)
Level Transmitters (LIT) connected to
ESD (13 off)
Open Limit Switches (ZXSO) of Discharge

ZV's (as per attached List)
Common SOU for Critical Discharge ZV's
Limit Switches (0%, 80%, 100%) (as per
attached List)
SP-7 Trip Signals (172-YS-G-1001/1002/1011)
All VMS Trip Signals (except for 2oo2

voting)
MOV's Open Limit Switches- XSO (from
DCS) as in ESD Logic Diagram
Level Switches (8 off) 143-LS0005A/B/C/D & 143-LS-0006A/B/C/D
Temperature Switches (7-off) (143-TS0062/64/67/87/56/57, 172-TS-0015) on
progressive cavity pumps.
SP-7 Trip Signals (172-YS-G1001/1002/1011)
Table 1 MOS and SUO requirement

Page 7 of 53

Alarm Annunciation and First Out Status

ESD input alarms shall be combined into first-out groups, within each ESD system,
to distinguish between initial and subsequent alarms. This information shall be
available on the DCS HMI.
First Out groups shall be configured based on logic groups or equipment basis as
applicable. Each first-out group shall have a separate reset faceplate button. Firstout status shall be reset when the trip initiators goes back to normal condition upon
activation of the First-out reset.
Architectural Design of the ESD System
The ProSafe-RS comprises Safety Control Station(s) (SCS), the Safety Engineering
PC (SENG), and the real-time control bus called Vnet/IP that connects the SCS and
the SENG and also integrates the ProSafe-RS with the PAS (Centum VP DCS). The
SCS performs safety control for ESD application, and the SENG is used for
engineering and maintenance of the SCS. The SCS can be operated and monitored
by the HIS (human interface station) of the PAS.
Fault Tolerant Design
The ESD system is a dedicated system using Yokogawa ProSafe RS Safety
Instrumented System incorporating a redundant architecture which is fault tolerant,
failsafe and fully integrated with the PAS via a redundant, common safety and control
bus (Vnet/IP).
Each ProSafe-RS CPU, input or output function module features a dual architecture,
providing SIL 3 level protection on a single card.
In case of a failure of one of the redundantly configured CPU or IO modules, the
system continues to operate without any degraded or crippled mode
Sequence of Events (SOE)
SOER (Sequence of Events Recorder) is a function for recording events detected by
an SCS so that these can be used in analysis. With SOER, changes in analog
inputs/outputs, discrete inputs/outputs and application logics can be collected/saved
as event information. Collected event information is displayed in the SOE Viewer.
Moreover, a function to synchronize to the standard time is provided in order to
maintain the accuracy of the time stamps attached to the events.
Sequence of Events Recording for ESD system includes:
ESD inputs and transition of analog/digital devices past shutdown limits
ESD pull/push buttons, Manual Reset buttons
ESD DI are time stamped at the Digital input module
ESD Analog Inputs are time stamped in the application logic scan cycle
MOS Enable/ Disable operation
The below tables shows the shutdown signals for SP1 scope.
Page 8 of 53

SWS-NP-3000
Non-Phenolic Sour Water Storage Tank
The shutdown of the non-phenolic system is carried out by the following signal:
Tag No.
Description
Interlock Action
Initiate an ESD:
Stop Non Phenolic SW Stripper Skim oil Pumps
142-G-0005A/B
Initiate an ESD:
142-G-0005A/B
Initiate an ESD:
142-G-0005A/B
Initiate an ESD:
142-G-0005A/B
Initiate an ESD:
142-G-0005A/B
Initiate an ESD:
142-G-0005A/B
142-ZXSC-0057
142- G-0005A/B discharge

header valve close
142-ZHS-0057D
15 m remote close 142-ZV-0057
142-ZIC-0057A
close 142-ZV-0057 from DCS
142-ZXSC-0056
142- G-0005A/B suction header

valve close
142-ZHS-0056D
142-ZIC-0056A
CLOSE 142-ZV-0056 from DCS
142-HS-0049A
142- G-0005A stop from DCS

142-G-0005A
142-HS-0050A
142- G-0005B stop from DCS

142-G-0005B
142-HS-0051A
Stop Non Phenolic SW Stripper Feed Pump

142-G-0002A
142-HS-0052A
142- G-0002Bstop from DCS
Stop Non Phenolic SW Stripper Feed Pump

142-G-0002B
Table 2 Non phenolic pumps shutdown signals
Page 9 of 53

Phenolic Sour Water Storage Tank

The shutdown of the phenolic system is carried out by the following signal:
Tag No.
Description
Interlock Action
142-ZXSC-0552
142- G-0025A/B Suction header

valve close
142-ZHS-0552D
142-ZIC-0552A
close 142-ZV-0552A from DCS
142-ZXSC-0553
142- G-0025A/B Discharge

header valve close
142-ZHS-0553D
142-ZIC-0553A
close 142-ZV-0553 from DCS
Initiate an ESD:
Stop Phenolic SW Skim Oil Pump 142-G-0025A/B
142-HS-0547A
Stop Phenolic SW Skim Oil Pump 142-G-0025A
142-HS-0548A
142- G-0025B stop from DCS

Stop Phenolic SW Skim Oil Pump 142-G-0025B
142-C-1022 Phenolic SW Stripper Stop Phenolic SW Stripper Feed Pumps Train
Level (By EPC-3) LAHH-1085
142-G-1022/0023
Stop Phenolic SW Stripper Feed Pumps Train
142- G-1022 stop from DCS
142-G-1022.
Stop Phenolic SW Stripper Feed Pumps Train
142-G-0023.
142-C-2022 Phenolic SW Stripper Stop Phenolic SW Stripper Feed Pumps Train
Level (By EPC-3)LAHH-2085
142-G-2022 /0023
Stop Phenolic SW Stripper Feed Pump Train
142-G-2022
142-LIT-1085
142-HS-1003A
142-HS-0546A
142-LIT-2085
142-HS-2003A
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Table 3 phenolic pumps shutdown signals
Page 10 of 53

TKF-NP-3000
Crude Storage
The shutdown of the crude oil system is carried out by the following process signals:
Tag No.
Description
Interlock Action
143-ZXSO-0557B
143-G-0001A/B/C suction valve

header (80% open)
Stop the crude charge pumps (143-G-0001A/B/C)
143-ZXSC-0557

header close
143-ZHS-0557D
143-ZXSO-0562B
143-ZXSC-0562
143-G-0001A/B/C discharge
header valve (80% open)
143-G-0001A/B/C discharge
header valve is closed

143-HS-0036A
143-G-0001A stop PB from DCS
Stop the crude charge pump (143-G-0001A)
143-HS-0037A
143-G-0001B stop PB from DCS
Stop the crude charge pump (143-G-0001B)
143-HS-0046A
143-G-0001C stop PB from DCS
Stop the crude charge pump (143-G-0001C)
143-YS-1001O
143-G-0001A HH Vibration
143-YS-2001O
143-G-0001A HH Temperature
143-YS-1101O
143-G-0001B HH Vibration
Stop the crude charge pump (143-G-0001B)
143-YS-2101O
143-G-0001B HH Temperature
Stop the crude charge pump (143-G-0001B).
143-YS-1201O
143-G-0001C HH Vibration
Stop the crude charge pump (143-G-0001C).
143-YS-2201O
143-G-0001C HH Temperature
Stop the crude charge pump (143-G-0001C).
Table 4 crude pumps shutdown signals
Page 11 of 53

Naphtha Hydrotreater (NHT) Feed Storage

The shutdown of the NHT system is carried out by the following process signals:
Tag No.
Description
143-ZHS-0107D
143-ZHS-0108D
143-HS-0103A
142-HS-0104A
143-YS-2003O
143-YS-2103O
143-G-0003B HH Temperature
Interlock Action
Initiate an ESD:
Stop the NHT feed pumps SGP Naphtha (143G-0003A/B).
Initiate an ESD:
Stop the NHT feed pumps SGP Naphtha (143G-0003A/B).
Stop the NHT feed pump SGP Naphtha (143-G0003A).
Stop the NHT feed pump SGP Naphtha (143-G0003B).
Initiate an ESD:
Stop the NHT feed pump SGP Naphtha (143-G0003A).
Initiate an ESD:
Stop the NHT feed pumps SGP Naphtha (143G-0003B).
Table 5 NHT pumps shutdown signals

Naphtha Hydrotreater Feed Tank (Coker Naphtha/ SGP Naphtha) (143-D-0004)
The shutdown of the NHT feed system (COKER NAPHTHA/SGP NAPHTHA) is
carried out by the following process signals:
Tag No.
143-ZHS-0530D
Description
Interlock Action
Initiate an ESD:
Stop the NHT feed pumps Coker Naphtha
(143-G-0023A/B).
Initiate an ESD:
(143-G-0023A/B).
Initiate an ESD:
(143-G-0023A/B).
143-ZHS-0533D
143-ZIC-0533A
Close 143-ZV-0533 from DCS
143-HS-0105A
Stop the NHT feed pump Coker Naphtha (143G-0023A).
143-HS-0106A
Stop the NHT feed pump Coker Naphtha (143G-0023B).
Table 6 NHT pumps shutdown signals
Page 12 of 53

DCU FEED STORAGE:

The shutdown of the DCU feed storage system is carried out by the following
process signals:
Tag No.
Description
Interlock Action
143-ZXSO-0424B
143-G-0004A/B suction header

valve (80% Open)
Initiate an ESD:
Stop the DCU feed pumps (143-G-0004A/B).
143-ZXSC-0424

valve close
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
143-ZHS-0424D
143-ZXSO-0425B
143-ZXSC-0425
142-ZHS-0425D
143-HS-0138A
143-HS-0139A
143-YS-1004O
143-G-0004A/B discharge
header valve (80% Open)
143-G-0004A/B discharge
header valve close
Initiate an ESD:
Stop the DCU feed pump (143-G-0004A).
Stop the DCU feed pump (143-G-0004B).
Initiate an ESD:
Initiate an ESD:
143-YS-2004O
Table 7 DCU pumps shutdown signals
Page 13 of 53

DHT FEED STORAGE:

The shutdown of the DHT FEED system is carried out by the following process
signals:
Tag No.
Description
Interlock Action
143-ZHS-0916D
143-ZHS-0917D
143-ZHS-0600D
143-ZHS-0610D
143-HS-0175A
143-G-0006 A stop PB from

DCS
143-HS-0176A
143-G-0006 B stop PB from

DCS
Stop the DHT feed pump (143-G-0006B).
143-HS-0177A
143-G-0006 C stop PB from DCS
Stop the DHT feed pump (143-G-0006C).
143-HS-0188A
143-G-0005 A stop PB from DCS
Stop the DHT feed pump-start-up (143-G0005A).
143-HS-0189A
143-G-0005 B stop PB from DCS
Stop the DHT feed pump-start-up (143-G0005B).
143-YS-1005O
143-G-0005A HH vibration
143-YS-2005O
143-YS-1105O
143-G-0005 B HH Vibration
143-YS-2105O
143-G-0005 B HH Temperature
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Stop the DHT feed pumps (143-G-0006 A/B) and
the DHT feed pumps start-up (143-G-0005A/B).
Initiate an ESD:
Stop the DHT feed pumps (143-G-0006 B/C).
Initiate an ESD:
Stop the DHT feed pumps (143-G-0006 A/B/C).
Initiate an ESD:
Stop the DHT feed pumps start-up (143-G0005A/B).
Stop the DHT feed pump (143-G-0006A).
Table 8 DHT pumps shutdown signals
Page 14 of 53

HCK FEED storage:

Tag No.
Description
Interlock Action
Initiate an ESD:
Stop the HCK feed pumps (143-G-0007 A/B) and
the HCK feed pumps start-up (143-G-0008A/B).
Initiate an ESD:
Stop the HCK feed pumps (143-G-0007 B/C).
Initiate an ESD:
Stop the HCK feed pumps (143-G-0007 A/B/C).
Initiate an ESD:
Stop the HCK feed pumps start-up (143-G0008A/B).
143-ZHS-0918D
143-ZHS-0919D
143-ZHS-0616D
143-ZHS-0636D
143-HS-0236A
Stop the HCK feed pump (143-G-0007A).
143-HS-0237A
Stop the HCK feed pump (143-G-0007B).
143-HS-0238A
143-G-0007 C stop PB from DCS
Stop the HCK feed pump (143-G-0007C).
143-HS-0248A
Stop the HCK feed pump-start-up (143-G-0008A).
143-HS-0249A
Stop the HCK feed pump-start-up (143-G-0008B).
143-YS-1008O
Initiate an ESD:
143-YS-2008O
Initiate an ESD:
143-YS-1108O
143-G-0008 B HH Vibration
Initiate an ESD:
143-YS-2108O
143-G-0008 B HH Temperature
Initiate an ESD:
Table 9 HCK pumps shutdown signals
Page 15 of 53

HEAVY NAPHTHA FEED STORAGE:

Tag No.
Description
143-ZHS-0585D
143-ZHS-0588D
143-HS-0278A
143-HS-0279A
143-YS-1009O
143-YS-2009O
143-G-0009A HH temperature
143-YS-1109O
143-YS-2109O
Interlock Action
Initiate an ESD:
Stop the heavy naphtha feed pumps (143-G0009A/B).
Initiate an ESD:
Stop the heavy naphtha feed pumps (143-G0009A/B).
Stop the heavy naphtha feed pump (143-G0009A).
Stop the heavy naphtha feed pump (143-G0009B).
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Table 10 heavy naphtha pumps shutdown signals
Page 16 of 53

OFF-SPEC DIESEL/FLUSH OIL TANK STORAGE:

The shutdown of the OFF-SPEC DIESEL/FLUSH OIL storage system is carried out
by the following process signals:
Tag No.
Description
Interlock Action
Initiate an ESD:
Stop the HCK Transfer pumps (143-G-0010)
and Flush oil pump (143-G-0043).
Initiate an ESD:
Stop the HCK Transfer pumps (143-G-0010).
143-ZHS-0880D
143-ZHS-0881D
143-HS-0364A
143-G-0010 stop PB from DCS
Stop the HCK Transfer pumps (143-G-0010).
143-ZHS-0887D
Initiate an ESD:
Stop Flush oil pump (143-G-0043).
143-HS-0888A
143-YS-1043O
143-G-0043 HH VIBRATION
143-YS-2043O
143-G-0043 HH Temperature
Table 11 off spec diesel pumps signals
Page 17 of 53

ISOMERATE/LIGHT REFORMATE AND NHT LIGHT NAPHTHA STORAGE

TANKS:
The shutdown of isomerate/light reformate storage system is carried out by the
following process signals:
Tag No.
143-LIT-0512
Description
143-D-0014 level low-low
143-LIT-0517
143-LIT-0522
143-ZHS-0503D
143- ZHS-0504D
143- ZHS-0506D
143- ZHS-0508D
143- ZHS-0509D
143- ZHS-0510D
143- ZHS-0511D

0506
0508
0509
0510
0511
Interlock Action
Initiate an ESD:
Stop the isomerate/light reformate pumps (143G-0011A/B).
Stop the NHT light naphtha pumps (143-G0026A/B)
Stop the HGU light naphtha HP pumps (143-G0030/0073A/B)
Stop the CCR Heavy Reformate Blending
pumps (143-G-0012A/B)
Stop the Boiler Fuel Light Naphta pump
143-G-0045
Initiate an ESD:
pumps (143-G-0012A/B)
143-G-0045
Initiate an ESD:
pumps (143-G-0012A/B)
143-G-0045
Initiate an ESD:
Close isomerate/light reformate 143-ZV-0503
inlet to 143-D-0014
Initiate an ESD:
Stop the HGU light naphtha HP pumps (143-G-
Page 18 of 53

Tag No.
Description
Interlock Action
0030/0073A/B)
pumps (143-G-0012A/B)
143-G-0045
143-ZHS-0540D
143- ZHS-0542D
143-ZHS-0620D
143- ZHS-0623D
143-ZHS-0637D
143- ZHS-0638D
143-ZHS-0660D
143- ZHS-0663D

143-HS-0548A
143-HS-0548A
143-HS-0628A
143-HS-0629A
143-HS-0645A
143-HS-0668A
143-HS-0670A
143-HS-0669A
143-HS-0671A
143-YS-1011O
143-YS-1111O
143-YS-1026O
143-YS-1126O
Initiate an ESD:
Initiate an ESD:
Stop the NHT light naphtha pumps (143-G0026A/B).
Initiate an ESD:
Stop the Boiler fuel naphtha pumps (143-G0045).
Initiate an ESD:
Stop the isomerate/light reformate pump (143G-0011A).
Stop the isomerate/light reformate pump (143G-0011B).
Stop the NHT light naphtha pumps (143-G0026A)
Stop the NHT light naphtha pumps (143-G0026B)
Stop the HGU light naphtha HP pumps (143-G0030A)
Stop the HGU light naphtha HP pumps (143-G0073A)
Stop the HGU light naphtha HP pumps (143-G0030B)
Stop the HGU light naphtha HP pumps (143-G0073B)
Initiate an ESD:
Stop the isomerate/light reformate pump (143G-0011A).
Initiate an ESD:
Stop the isomerate/light reformate pump (143G-0011B).
Initiate an ESD:
Stop the NHT light naphtha pumps (143-G0026A).
Initiate an ESD:
Stop the NHT light naphtha pumps (143-G0026A/B).
Page 19 of 53

Tag No.
Description
143-YS-1045O
143-G-0045 HH Vibration
Interlock Action
Initiate an ESD:
Table 12 Isomerate, Light reformate , NHT light naphtha pumps shutdown

signals
BEU RAFFINATE STORAGE TANK:
The shutdown of the BEU RAFFINATE pumps is carried out by the following process
signals:
Tag No.
Description
143-ZHS-0445D
143-ZHS-0448D
143-HS-0440A
142-HS-0438A
143-YS-1025O
143-G-0025A HH VIBRATION
143-YS-1125O
143-G-0025B HH VIBRATION
Interlock Action
Initiate an ESD:
Stop the BEU RAFFINATE PUMP (143-G0025A/B).
Initiate an ESD:
Stop the BEU RAFFINATE PUMP (143-G0025A/B).
Stop the BEU RAFFINATE PUMP (143-G0025A).
Stop the BEU RAFFINATE PUMP (143-G0025B).
Initiate an ESD:
Stop the BEU RAFFINATE PUMP (143-G0025A).
Initiate an ESD:
Stop the BEU RAFFINATE PUMP (143-G0025B).
Table 13 BEU raffinate pumps shutdown signals
Page 20 of 53

REFORMATE STORAGE TANK

The shutdown of CCR heavy reformate is carried out by the following process
signals:
Tag No.
Description
143-ZHS-0572D
143-ZHS-0575D
143-HS-0397A
143-HS-0398A
143-YS-1012O
43-YS-2012O
143-G-0012A HH TEMPERATURE
143-YS-1112O
43-YS-2112O
143-G-0012B HH TEMPERATURE
Interlock Action
Initiate an ESD:
Stop the CCR heavy reformate blending
pumps (143-G-0012A/B).
Initiate an ESD:
pumps (143-G-0012A/B).
pumps (143-G-0012A).
pumps (143-G-0012B).
Initiate an ESD:
pumps (143-G-0012A).
Initiate an ESD:
pumps (143-G-0012A).
Initiate an ESD:
pumps (143-G-0012B).
Initiate an ESD:
pumps (143-G-0012B).
Table 14 Reformate pumps shutdown signals
Page 21 of 53

LIGHT NAPHTHA TANK

The shutdown of CCR heavy reformate is carried out by the following process
signals:
Tag No.
Description
143-ZHS-0913D
143-ZHS-0914D
143-HS-0926A
143-HS-0927A
143-YS-1013O
143-YS-1113O
Interlock Action
Initiate an ESD:
Stop the HCK light naphtha pumps (143-G0013A/B).
Initiate an ESD:
Stop the HCK light naphtha pumps (143-G0013A/B).
Stop the HCK light naphtha pumps (143-G0013A).
Stop the HCK light naphtha pumps (143-G0013B).
Initiate an ESD:
Stop the HCK light naphtha pumps (143-G0013A).
Initiate an ESD:
Stop the HCK light naphtha pumps (143-G0013B).
Table 15 Light naphtha pumps shutdown signals

PROPANE SPHERES
The shutdown of Propane sphere system is carried out by the following process
signals:
Tag No.
Description
Interlock Action
143-LIT-0711
143-LIT-0717
143-LIT-0723
143-ZHS-0748D
143-ZHS-0749D

0749
143-ZHS-0701D
Initiate an ESD:
Stop the HP propane booster and transfer
pumps (143-G-0014A/B &143-G-0072A/B).
Stop the LP propane transfer pumps (143-G0015A/B).
Initiate an ESD:
pumps (143-G-0014A/B &143-G-0072A/B).
Initiate an ESD:
pumps (143-G-0014A/B &143-G-0072A/B).
Initiate an ESD:
pumps (143-G-0014A/B &143-G-0072A/B).
Initiate an ESD:
Page 22 of 53

Tag No.
Description
Interlock Action
143-ZHS-0706D
143-ZHS-0703D
143-ZHS-0707D
143-ZHS-0705D
143-ZHS-0708D
143-ZHS-0752D
143-ZHS-0756D
143-ZHS-0757D
0706
0703
0707
0705
0708
0756
0757

pumps (143-G-0014A/B &143-G-0072A/B).
143-HS-0732A
143-HS-0735A
143-HS-0736A
143-HS-0737A
143-HS-0741A
143-YS-1072O
Stop the HP propane booster pump (143-G0014A)

Stop the HP propane booster pump (143-G0014B)
Stop the HP propane transfer pump (143-G0072A)
Stop the HP propane transfer pump (143-G0072B)
Stop the LP propane transfer pump (143-G0015B)
Initiate an ESD:
pumps (143-G-0014A &143-G-0072A).
143-YS-1172O
143-G-0072B HH vibration
143-YS-1115O
Initiate an ESD:
Stop the LP propane transfer pumps (143-G0015B).
Initiate an ESD:
pumps (143-G-0014B &143-G-0072B).
Initiate an ESD:
Stop the LP propane transfer pumps (143-G0015B).
Table 16 propane pumps shutdown signals
Page 23 of 53

COKER LPG spheres (143-D-0031/0032)

The shutdown of Coker LPG sphere system is carried out by the following process
signals:
Tag No.
Description
143-LIT-0463
143-LIT-0859
143-ZHS-0479D
143-ZHS-0470D
143-ZHS-0477D
143-ZHS-0867D
143-ZHS-0869D

0470
0477
0867
0869
143-ZHS-0471D
143-ZHS-0478D
143-HS-0458A
143-HS-0461A
143-YS-1024O

143-YS-1124O
Interlock Action
Initiate an ESD:
Stop the Coker LPG pumps (143-G-0024A/B).
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Stop the Coker LPG pumps (143-G-0024A).
Initiate an ESD:
Stop the Coker LPG pumps (143-G-0024B).
Initiate an ESD:
Initiate an ESD:
Table 17 Coker LPG pumps shutdown signals

MIXED BUTANE SPHERES
The shutdown of Butane sphere system is carried out by the following process
signals:
Tag No.
Description
143-LIT-0824
143-LIT-0830
143-LIT-0836
Interlock Action
Initiate an ESD:
Stop the HP butane transfer pumps
(143-G-0016A/B).
Stop the LP butane transfer pumps
(143-G-0017A/B).
Initiate an ESD:
(143-G-0016A/B).
(143-G-0017A/B).
Stop export butane transfer pumps
(143-G-0068A/B).
Initiate an ESD:
Page 24 of 53

Tag No.
Description
143-LIT-0853
143-LIT-0859
143-ZHS-0842D
143-ZHS-0847D
143-ZHS-0867D
143-ZHS-0869D

0847
0867
0869
143-ZHS-0844D
143-ZHS-0848D
143-ZHS-0846D
143-ZHS-0849D
143-ZHS-0865D
143-ZHS-0868D

0848
0846
0849
0865
0868
143-ZHS-0920D
143-ZHS-0921D

0921
143-ZHS-0819D
143-ZHS-0400D

0400
143-ZHS-0403D
143-ZHS-0402D

0402
143-ZHS-0404D
143-ZHS-0401D
143-HS-0809A
143-HS-0812A
Interlock Action
(143-G-0016A/B).
(143-G-0017A/B).
(143-G-0068A/B).
Initiate an ESD:
(143-G-0016A/B).
(143-G-0017A/B).
(143-G-0068A/B).
Initiate an ESD:
(143-G-0016A/B).
(143-G-0017A/B).
Initiate an ESD:
(143-G-0016A/B).
(143-G-0017A/B).
Initiate an ESD:
(143-G-0016A/B).
(143-G-0017A/B).
(143-G-0068A/B).
Initiate an ESD:
(143-G-0068A/B).
Initiate an ESD:
(143-G-0016A/B).
Initiate an ESD:
(143-G-0017A/B).
Initiate an ESD:
(143-G-0017A).
Initiate an ESD:
(143-G-0017B).
(143-G-0016A).
Page 25 of 53

Tag No.
Description
Interlock Action
(143-G-0016B).
(143-G-0017A).
(143-G-0017B).
(143-G-0068A)
(143-G-0068B)
Initiate an ESD:
(143-G-0068A)
Initiate an ESD:
Stop export butane transfer pumps (143-G0068B)
Initiate an ESD:
Stop the LP butane transfer pumps (143-G0017A).
143-HS-0815A
143-HS-0818A
143-HS-0865A
143-HS-0866A
143-YS-1068O
143-YS-1168O
143-G-0068B HH vibration
143-YS-1017O
143-YS-1117O
Initiate an ESD:
Stop the LP butane transfer pumps (143-G0017B).
143-YS-2017O
143-G-0017A HH TEMPARTURE
Initiate an ESD:
Stop the LP butane transfer pumps (143-G0017A).
143-YS-2117O
143-G-0017B HH TEMPARTURE
Initiate an ESD:
Stop the LP butane transfer pumps (143-G0017B).
143-YS-1016O
Initiate an ESD:
Stop the HP butane transfer pumps (143-G0016A).
143-YS-1116O
Initiate an ESD:
Stop the HP butane transfer pumps (143-G0016B).
143-YS-2016O
143-G-0016A HH TEMPARTURE
Initiate an ESD:
Stop the HP butane transfer pumps (143-G0016A).
Page 26 of 53

Tag No.
143-YS-2116O
Description
143-G-0016B HH TEMPARTURE
Interlock Action
Initiate an ESD:
Stop the HP butane transfer pumps (143-G0016B).
Table 18 Butane pumps shutdown signals

SLOP OIL TANKS:
The shutdown of slop oil storage system is carried out by the following process
signals:
Tag No.
Description
143-LIT-0948
143-ZHS-0498D
143-ZHS-0496D
143-ZHS-0497D
143-ZHS-0785D
143-YS-1070O

0497
143-G-0070 HH VIBRATION
Interlock Action
Initiate an ESD:
Stop the slop oil pumps (143-G-0028A &
143-G-0070).
Initiate an ESD:
Stop the slop oil pumps (143-G-0028B).
Initiate an ESD:
Stop the slop oil pumps (143-G-0028A &
143-G-0070).
Initiate an ESD:
Stop the slop oil pumps (143-G-0028B &
143-G-0070).
Initiate an ESD:
Stop the slop oil pumps (143-G-0070).
Table 19 slop pumps shutdown signals

DESALTER EFFLUENT STORAGE TANK:
Tag No.
Description
Interlock Action
143-HS-0409A
Stop Desalter effluent oil pump

(143-G-0033).
143-HS-0412A
Stop Desalter rag layer to CDU pump

(143-G-0049).
143-HS-0415A
Stop Desalter Effluent water pump

(143-G-0034A).
143-HS-0418A
Stop Desalter Effluent water pump

(143-G-0034B).
Table 20 Desalter effluent shutdown signals
Page 27 of 53

BENZENE STORAGE TANK

Tag No.
Description
Interlock Action
Initiate an ESD:
Stop the benzene pumps (143-G-0027A/B).
Initiate an ESD:
Stop the benzene pumps (143-G-0027A/B).
143-ZHS-0474D
143-ZHS-0476D
143-HS-0962A
Stop the benzene pump (143-G-0027A).
143-HS-0965A
Stop the benzene pump (143-G-0027B).
143-LIC-0098
Low Liquid Level in Benzene

Sump (143-D-0061)
Stop the Benzene sump pump (143-G-0046)
143-HS-0098A
STOP Benzene sump Pump (143G-0046)
Stop the Benzene sump pump (143-G-0046)
Table 21 Benzene pumps shutdown signals

BEU FEED TANK
Tag No.
Description
Interlock Action
Initiate an ESD:
Stop the BEU FEED pumps (143-G-0035A/B).
Initiate an ESD:
Stop the BEU FEED pumps (143-G-0035A/B).
143-ZHS-0915D
143-ZHS-0925D
143-HS-0972A
Stop the BEU FEED pumps (143-G-0035A).
143-HS-0973A
Stop the BEU FEED pumps (143-G-0035B).
143-YS-1035O
Stop the BEU FEED pumps (143-G-0035A).
143-YS-1135O
Stop the BEU FEED pumps (143-G-0035B).
Table 22 BEU pumps shutdown signals
Page 28 of 53

SULFUR STORAGE TANKS

Tag No.
Description
Interlock Action
143-HS-0606A
Stop Sulfur condenate pump (143-G-0050A)
143-HS-0607A
Stop Sulfur condenate pump (143-G-0050B)
143-HS-0611A
Stop Sulfur Transfer pump (143-G-0051A)
143-HS-0612A
Stop Sulfur Transfer pump (143-G-0051B)
143-HS-0601A
Stop Sulfur Transfer pump (143-G-0047A)
143-HS-0602A
143-G-0047Bstop PB from DCS
Stop Sulfur Transfer pump (143-G-0047B)
143-HS-0608A
143-E-0007A Fan stop PB from

DCS
Stop Condensate cooler (143-G-0007A)
143-VAH-0601

DCS
Stop Condensate cooler (143-G-0007A)
143-HS-0090A

DCS
STOP pump auxillary fan (143-E-0011A)
143-HS-0090B
143-E-0011B Fan stop PB from

DCS
STOP pump auxillary fan (143-E-0011B)
Table 23 Sulfur pumps and cooler shutdown signals
Page 29 of 53

PSL-NP-3000 Diesel Export Storage Tanks

Tag No.
172-ZXSO0090B
Description
header (80% Open)
172-ZXSC-0090

header close
172-ZXSO0099B
172-G-0001A/B/C discharge valve

header open (80% Open)
172-ZXSC-0099

header close
172-ZHS-0099D
172-HS-0088A
172-HS-0089A
172-HS-0090A
172-VSA-0001A
15 m Remote Close 172-ZV-0099

STOP Diesel Export Pump 172-G0001A from DCS
STOP Diesel Export Pump 172-G0001B from DCS
STOP Diesel Export Pump 172-G0001C from DCS
172-G-0001A High High Vibration
(Main)
Interlock Action
Initiate an ESD:
Stop the Diesel export pumps (172-G0001A/B/C).
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Stop the Diesel export pumps (172-G-0001A).
Stop the Diesel export pumps (172-G-0001B).
Stop the Diesel export pumps (172-G-0001C).
172-VSB-0001A

(Redundant)
172-TSA-0001A
172-G-0001A High High

Temperature (Main)
172-TSB-0001A

Temperature (Redundant)
172-VSA-0001B
172-G-0001B High High Vibration

(Main)
172-VSB-0001B

(Redundant)
172-TSA-0001B
172-G-0001B High High

Temperature (Main)
172-TSB-0001B

172-VSA-0001C
172-G-0001C High High Vibration

(Main)
172-VSB-0001C

(Redundant)
Page 30 of 53

Tag No.
172-XSC-0099
(FF)
172-TSA-0001C
172-TSB-0001C
Description
172-G-0001A suction valve close
(FF Limit Switch)
172-G-0001C High High
Temperature (Main)
172-ZHS-0091D
172-ZXSC-0092
172-G-0003 discharge header valve

close
172-ZHS-0092D
172-HS-0124A
172-VSA-0003
172-VSB-0003
172-XSC-0122
(FF)
172-XSC-0123
(FF)
STOP Diesel Export Circulation

Pump 172-G-0003
from DCS
172-G-0003 High High
Vibration/Temperature (Main)
Vibration/Temperature
(Redundant)
172-G-0003 suction valve close (FF
Limit Switch)
172-G-0003 discharge valve close
(FF Limit Switch)
Interlock Action
Initiate an ESD:
Stop the Diesel export circulation pump (172G-0003).
Initiate an ESD:
Initiate an ESD:
Table 24 Diesel pumps shutdown signals
Page 31 of 53

Gasoline storage tank

Tag no.
Description
Interlock Action
Stop Gasoline Export Pump 172-G0002A from DCS

Stop Gasoline Export Pump 172-G0002B from DCS
STOP Gasoline Export Pump 172G-0002C from DCS
Initiate an ESD:
Stop the gasoline export pumps (172-G0002A/B/C).
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
Stop the gasoline export pumps (172-G0002A).
Stop the gasoline export pumps (172-G0002B).
Stop the gasoline export pumps (172-G0002C).
172-VSA-0002A

(Main)
172-VSB-0002A

(Redundant)
172-TSA-0002A

Temperature (Main)
172-TSB-0002A

172-VSA-0002B

(Main)
172-VSB-0002B

(Redundant)
172-TSA-0002B

Temperature (Main)
172-TSB-0002B

172-VSA-0002C

(Main)
Stop the gasoline export pumps (172-G0002C).
172-ZXSO-0259B
172-G-0002A/B/C suction header

valve open (80% Open)
172-ZXSC-0259
172-G-0002A/B/C suction header

valve close
172-ZHS-0259D
172-ZXSO-0260B

header open (80% Open)
172-ZXSC-0260

header close
172-ZHS-0260D
172-HS-0252A
172-HS-0253A
172-HS-0254A
Page 32 of 53

Tag No.
Description
Interlock Action
172-VSB-0002C

(Redundant)
Stop the gasoline export pumps

(172-G-0002C).
172-TSA-0002C

Temperature (Main)

(172-G-0002C).
172-TSB-0002C


(172-G-0002C).
172-XSC-0261
(FF)

(FF Limit Switch)

(172-G-0002A).
172-XSC-0263
(FF)
172-G-0002B suction valve close

(FF Limit Switch)

(172-G-0002B).
172-XSC-0265
(FF)
172-G-0002C suction valve close

(FF Limit Switch)

(172-G-0002C).
172-ZXSC-0093
172-G-0005 suction header valve

close
172-ZHS-0093D
172-ZXSC-0094

close
172-ZHS-0094D
172-HS-0286A

Pump 172-G-0005
from DCS
Stop the gasoline export circulation pump

(172-G-0005).
172-VSA-0005


(172-G-0005).
172-VSB-0005

(Redundant)

(172-G-0005).
172-XSC-0288
(FF)

Limit Switch)

(172-G-0005).
172-XSC-0289
(FF)

(FF Limit Switch)

(172-G-0005).
172-ZXSC-0095
172-G-0006 suction header valve

close
Initiate ESD:
(172-G-0006).
Initiate ESD:
(172-G-0005).
Initiate ESD:
(172-G-0005).
Initiate ESD:
(172-G-0005).
Initiate ESD:
(172-G-0005).
Page 33 of 53

Tag No.
Description
172-ZHS-0095D
172-ZXSC-0096

close
172-ZHS-0096D
172-HS-0287A
172-VSA-0006
172-VSB-0006
172-XSC-0290
(FF)
172-XSC-0291
(FF)

Pump 172-G-0006 from DCS
Vibration/Temperature (Redundant)
Limit Switch)
(FF Limit Switch)
Interlock Action
Initiate ESD:
(172-G-0006).
Initiate ESD:
(172-G-0006).
Initiate ESD:
(172-G-0006).
(172-G-0006).
(172-G-0006).
(172-G-0006).
(172-G-0006).
(172-G-0006).
Table 25 Gasoline pumps shutdown signals
Page 34 of 53

Benzene Export Storage Tank

Tag No.
172-ZXSC-0445
Description
valve close
172-ZHS-0445D
172-ZXSC-0450
172-G-0011A/B discharge header

valve close
172-ZHS-0450D
Interlock Action
Initiate an ESD:
Stop Benzene export pumps 172-G-0011A/B
Initiate an ESD:
Initiate an ESD:
Initiate an ESD:
172-HS-0491A
STOP Benzene Export Pump 172G-0011A from DCS
Stop Benzene export pumps 172-G-0011A
172-HS-0492A
STOP Benzene Export Pump 172G-0011B from DCS
Stop Benzene export pumps 172-G-0011B
172-VSA-0011A

172-VSB-0011A

(Redundant)
172-VSA-0011B

172-VSB-0011B
142- G-0002Bstop from DCS
172-XSC-0475
(FF)

(FF Limit Switch)
172-XSC-0480
(FF)
172-G-0011A discharge valve

close (FF Limit Switch)
172-XSC-0490
(FF)
172-G-0011B suction valve close

(FF Limit Switch)
172-XSC-0485
(FF)
172-G-0011B discharge valve

close (FF Limit Switch)
Table 26 Benzene pumps shutdown signals
Page 35 of 53

3.0 200 LOSS OF UTILITIES
201 Power Outage with Emergency Generator On

Each substation 12 and 13 are feed from 34.5 KV normal feeders through
substation 4 and substation 2 respectively and one emergency feeder
through substation 15 (SP4 contractor). During normal operation all normal
loads are feed from normal supply and all essential loads are fed from
emergency supply where emergency diesel generators are working
continuously. Power outage with emergency generator on, Electrical power
shall be lost for normal loads & essential loads shall be still fed from
emergency feeder.
202 Power Outage with Emergency Generator Out of Service

Electrical power shall be lost for normal & essential loads except for critical
loads fed from AC UPS shall have back up batteries for 15 minutes & loads
fed from battery charger shall have back up batteries for 2 hours. These back
up batteries shall be utilized for safe shutdown of the plant.
203 Instrument Air Failure
204 Instrument Electrical Failure

Below table indicates control valves fail action based on air and electrical
failure
Table 27 control valves fail action

Control valve tag
Fail action (air failure)
Fail action (electric failure)
142-PCV-0032A
FO
FO
142-PCV -0532A
FO
FO
142-PCV-0032B
FO
FO
142-PCV-0532B
FO
FO
143-FCV -0043
FO
FO
143-FCV -0044
FO
FO
143-FCV -0045
FO
FO
143-FCV -0090
FO
FO
143-FCV -0096
FO
FO
143-FCV -0133
FO
FO
143-FCV -0160
FO
FO
Page 36 of 53

Control valve tag
143-FCV -0161
FO
FO
143-FCV -0162
FO
FO
143-FCV -0163
FO
FO
143-FCV -0180
FO
FO
143-FCV -0220
FO
FO
143-FCV -0221
FO
FO
143-FCV -0222
FO
FO
143-FCV -0227
FO
FO
143-FCV -0240
FO
FO
143-FCV -0270
FO
FO
43-FCV -0358
FO
FO
143-FCV -0359
FC
FC
143-FCV -0390
FO
FO
143-FCV -0419
FO
FO
143-FCV -0429
FO
FO
143-FCV -0452
FO
FO
143-FCV -0453
FO
FO
143-FCV -0498A
FO
FO
143-FCV -0498B
FO
FO
143-FCV -0498C
FO
FO
143-FCV -0553
FO
FO
143-FCV -0630
FO
FO
143-FCV -0631
FO
FO
143-FCV -0670
FO
FO
143-FCV -0742
FO
FO
143-FCV -0745
FO
FO
Page 37 of 53

Control valve tag
143-FCV -0747
FO
FO
143-FCV -0801
FO
FO
143-FCV -0806
FO
FO
14:1-FCV -0807
FO
FO
143-FCV -0808
FO
FO
143-FCV -0888
FO
FO
143-FCV -0908
FO
FO
143-FCV -0919
FO
FO
143-FCV -0920
FO
FO
143-FCV -0921
FO
FO
143-FCV -0966
FO
FO
143-LCV -0603
FLC
FC
143-LCV -0997
FC
FC
143-PCV -0116A
FO
FO
143-PCV -0116B
FO
FO
143-PCV -0124A
FO
FO
143-PCV -0124B
FO
FO
143-PCV -0134A
FO
FO
143-PCV -0134B
FO
FO
143-PCV -0181
FC
FC
143-PCV -0241
FO
FO
143-PCV -0271
FC
FC
143-PCV -0430
FC
FC
143-PCV -0450
FO
FO
143-PCV -0527A
FO
FO
143-PCV -0527B
FO
FO
Page 38 of 53

Control valve tag
143-PCV -0528A
FO
FO
143-PCV -0528B
FO
FO
143-PCV -0529A
FO
FO
143-PCV -0529B
FO
FO
143-PCV -0550
FC
FC
143-PCV -0608
FC
FC
143-PCV -0633
FC
FC
143-PCV -0706
FO
FO
143-PCV -0707
FO
FO
143-PCV -0708
FO
FO
143-PCV -0820
FO
FO
143-PCV -0821
FO
FO
143-PCV -0822
FO
FO
143-PCV -0850
FO
FO
143-PCV -0851
FO
FO
143-PCV -0852A
FO
FO
143-PCV -0852B
FO
FO
143-PCV -0909
FC
FC
143-TCV -0605
FC
FC
157-FCV -0007A
FC
FC
157-FCV -0007B
FC
FC
157-FCV -0013A
FC
FC
157-FCV -0013B
FC
FC
157-FCV -0019A
FC
FC
157-FCV -0019B
FC
FC
157-FCV -0046
FC
FC
Page 39 of 53

Control valve tag
157-FCV -0048A
FC
FC
157-FCV -0048B
FC
FC
157-FCV -0054A
FC
FC
157-FCV -0054B
FC
FC
172-FCV -0091
FO
FO
172-FCV -0092
FO
FO
172-FCV -0093
FO
FO
172-FCV -0255
FO
FO
172-FCV -0256
FO
FO
172-FCV -0257
FO
FO
172-FCV -0440
FO
FO
143-PCV-0576
FC
FC
Table 28 control valves fail action

Below table indicates shutdown valves fail action based on air failure
Tag Number
142-ZV-0056
FC
FC
142-ZV -0057
FC
FC
142-ZV -0552
FC
FC
142-ZV -0553
FC
FC
143-ZV -0107
FC
FC
143-ZV -0108
FC
FC
143-ZV -0400
FC
FC
143-ZV -0401
FC
FC
143-ZV -0402
FC
FC
143-ZV -0403
FC
FC
Page 40 of 53

Tag Number
143-ZV -0404
FC
FC
143-ZV -0424
FC
FC
143-ZV -0425
FC
FC
143-ZV -0445
FC
FC
143-ZV -0448
FC
FC
143-ZV -0470
FC
FC
143-ZV -0471
FC
FC
143-ZV -0472
FC
FC
143-ZV -0473
FC
FC
143-ZV -0474
FC
FC
143-ZV -0476
FC
FC
143-ZV -0477
FC
FC
143-ZV -0478
FC
FC
143-ZV -0479
FC
FC
143-ZV -0496
FC
FC
143-ZV -0497
FC
FC
143-ZV -0498
FC
FC
143-ZV -0503
FC
FC
143-ZV -0504
FC
FC
143-ZV -0505
FC
FC
143-ZV -0506
FC
FC
143-ZV -0507
FC
FC
143-ZV -0508
FC
FC
143-ZV -0509
FC
FC
143-ZV -0510
FC
FC
143-ZV -0511
FC
FC
Page 41 of 53

Tag Number
143-ZV -0530
FC
FC
143-ZV -0533
FC
FC
143-ZV -0540
FC
FC
143-ZV -0542
FC
FC
143-ZV -0557
FC
FC
143-ZV -0562
FC
FC
143-ZV -0572
FC
FC
143-ZV -0575
FC
FC
143-ZV -0585
FC
FC
143-ZV -0588
FC
FC
143-ZV -0600
FC
FC
143-ZV -0610
FC
FC
143-ZV -0616
FC
FC
143-ZV -0620
FC
FC
143-ZV -0623
FC
FC
143-ZV -0636
FC
FC
143-ZV -0637
FC
FC
143-ZV -0638
FC
FC
143-ZV -0660
FC
FC
143-ZV -0663
FC
FC
143-ZV -0700
FC
FC
143-ZV -0701
FC
FC
143-ZV -0702
FC
FC
143-ZV -0703
FC
FC
143-ZV -0704
FC
FC
143-ZV -0705
FC
FC
Page 42 of 53

Tag Number
143-ZV -0706
FC
FC
143-ZV -0707
FC
FC
143-ZV -0708
FC
FC
143-ZV -0709
FC
FC
143-ZV -0748
FC
FC
143-ZV -0749
FC
FC
143-ZV -0752
FC
FC
143-ZV -0753
FC
FC
143-ZV -0754
FC
FC
143-ZV -0756
FC
FC
143-ZV -0757
FC
FC
143-ZV -0785
FC
FC
143-ZV -0819
FC
FC
143-ZV -0841
FC
FC
143-ZV -0842
FC
FC
143-ZV -0843
FC
FC
143-ZV -0844
FC
FC
143-ZV -0845
FC
FC
143-ZV -0846
FC
FC
143-ZV -0847
FC
FC
143-ZV -0848
FC
FC
143-ZV -0849
FC
FC
143-ZV -0850
FC
FC
143-ZV -0851
FC
FC
143-ZV -0864
FC
FC
143-ZV -0865
FC
FC
Page 43 of 53

Tag Number
143-ZV -0866
FC
FC
143-ZV -0867
FC
FC
143-ZV -0868
FC
FC
143-ZV -0869
FC
FC
143-ZV -0880
FC
FC
143-ZV -0881
FC
FC
143-ZV -0887
FC
FC
143-ZV -0913
FC
FC
143-ZV -0914
FC
FC
143-ZV -0915
FC
FC
143-ZV -0916
FC
FC
143-ZV -0917
FC
FC
143-ZV -0918
FC
FC
143-ZV -0919
FC
FC
143-ZV -0920
FC
FC
143-ZV -0921
FC
FC
143-ZV -0925
FC
FC
172-ZV -0090
FC
FC
172-ZV -0091
FC
FC
172-ZV -0092
FC
FC
172-ZV -0093
FC
FC
172-ZV -0094
FC
FC
172-ZV -0095
FC
FC
172-ZV -0096
FC
FC
172-ZV -0099
FC
FC
172-ZV -0259
FC
FC
Page 44 of 53

Tag Number
172-ZV -0260
FC
FC
172-ZV -0445
FC
FC
172-ZV -0450
FC
FC
Table 29 Shutdown valves fail action
205 Loss of Cooling Water

SP1 uses of cooling water are limited to pumps cooling, the below is the list
of pumps that utilize cooling water:
1. 143-G-0015A, refer to table 16 for propane shutdown signals.
2. 172-G-0001A/B/C, refer to table 24 for diesel shutdown signals.
3. 172-G-0002A/B/C, refer to table 25 for gasoline shutdown signals.
SP1 receive cooling water from SP4, any emergency cases shall be handled
by SP4.
206 Loss of MP Steam

SP1 uses of MP steam in the following:
1. Steam tracing for DCU lines.
2. Steam turbine for pump 143-G-0015A
3. Steam for controtrace of sulfur lines and for tanks heating system. A
temperature high, low alarms 143-TAH-0605 & 143-TAL-0605 are
provided to warn the operator from high or low temperature of steam used
for sulfur system.
Also a pressure high and low alarms 143-PAH-0608 &143-PAL-0608 are
provided to warn the operator from high pressure of steam used for sulfur
system.
4.0 300 LOSS OF CRITICAL SYSTEMS/COMPONENTS
302 Loss of Makeup

Make up loss will occur only in caustic scrubber package
As the caustic solution reacts with the H2S gas, the pH of the caustic solution will
begin to drop. The Caustic control valve 143-ACV-0100 will modulate continuously to
add fresh make-up caustic to the Caustic Circulating Drum in order to maintain a
constant pH.
Page 45 of 53

Based on 4000 ppmW inlet H2S loading from each Vacuum Residue Tank, the
minimum theoretical 20% make up caustic rate will normally be about 0.084 gpm
total, while both Vacuum Residue Tanks are venting. The minimum caustic
concentration in the recycle liquid should not fall below 0.5% (equivalent to pH 13.1)
During normal operation, the Circulating Caustic pH should be maintained above
12.5. The intermediate product - NaHS - can gas off a rotten egg odor if pH falls
below 12.5.
CAUTION: It is critical that the Na2S concentration in the liquid shall not exceed 5
wt% to minimize precipitation.
NOTE: operator should periodically analyze the recycle solution for Na2S content, to
ensure it does not exceed the 5 w% Na2S in solution.
If, however, the Na2S concentration does increase, then the tank will need to be
manually purged or dumped and refilled with fresh caustic solution.
Also Make-up water is added to caustic scrubber drum 143-D-0098 on level control
to compensate for water loss due to purge from the oil skimmer and evaporation.
The normal make-up water rate is expected to be about 0.5 gpm (minimum purge
rate to maintain less than 5 wt% Na2S, plus water loss in exhaust gas due to
evaporation). However, water will be lost with the skimmed oil, hence the make-up
water level control valve (143-LCV-0002) is sized to accommodate a higher inlet
make up water flow rate (2-5 gpm).
Page 46 of 53

5.0 400 UNUSUAL OCCURRENCES
403 Fire Near High Pressure Equipment

Foam Protection System
Foam protection system will be installed on all Open Floating roof tanks
storing flammable liquids. Foam system shall be provided for rim-seal fire
protection. Foam system shall be capable of controlling and extinguishing the
largest single rim-seal fire.
The foam system will comprise the piping, fittings, valves and equipment that
provides foam to the protected tank and notification of plant personnel of
such an event though MAC,horn and speakers shall be activated. The
purpose of foam system will be to extinguish fires in the rim-seal area of a
floating roof storage tank located in the YERP facilities.
Each protected tank will have permanently installed foam pourers specifically
designed for rim-seal application. These devices will be designed per NFPA
11 and YERP-SEAS-B-018.
The foam pourer assembly complete with foam ring supply and foam riser will
be included in scope the tank manufacture
Semi-fixed system shall be utilized. Sufficient valved hose connections (hose
manifold) shall be provided and connected to foam fire truck.
The foam concentration shall be designed for 3% ARAFFF proportioning. The
foam truck will be availed by client
(See table 29) for list of protected tanks with associated number of hose
connections, number of foam chambers, foam demand and water demand.
(See Dwg. 160-SP1-PE-PID-0018, 0019, 0020,0021, 0022, 0023, 0024,
0025,0026 for Foam system)
Page 47 of 53

Dia
(m)
Foam
No. of
Foam
No. of
application
hose
solution foam
rate
connect
(l/min) pourer
(l/min/m2)
ions
Water
demand
(l/min)
Item
Service
143-D-0001
CRUDE OIL
TANK (FROM
YCOT)
110
20.4
4205
15
4079
143-D-0002
CRUDE OIL
TANK (FROM
YCOT)
110
20.4
4205
15
4079
143-D-0003
NHT FEED
TANK (SGP
NAPHTHA)
74.5
20.4
2841
10
2756
143-D-0007
DHT FEED
TANK
(KEROAND
DIESEL)
102.5
20.4
3917
14
3800
143-D-0009
HCK FEED
TANK
(AGO/VGO)
109
20.4
4167
15
4042
143-D-0016
REFORMATE
STORAGE
TANK
45
20.4
1707
1656
143-D-0017
REFORMATE
STORAGE
TANK
45
20.4
1707
1656
172-D-0005
GASOLINE
EXPORT
TANK
88
20.4
3360
12
3260
172-D-0006
GASOLINE
EXPORT
TANK
88
20.4
3360
12
3260
172-D-0007
GASOLINE
EXPORT
TANK
88
20.4
3360
12
3260
Table 30 Floating roof protected by foam system
Page 48 of 53

Fixed Water Deluge System

Fixed water deluge system shall be provided to protect spheres and
spheroids containing flammable liquids. The minimum protected area for
spheres and spheroids shall be the surface area above the maximum
diameter of the vessel tank. Where liquid level is under normal operating
conditions but is below the maximum diameter of the vessel/tank, the
protected area shall include the surface area between the top of the
vessel/tank and normal liquid level. In this case, a ring of water sprays shall
be added to protect the area of the shell that is not wetted by the spray
system due to interference by the legs.The minimum protected area for
hemispheroids shall be the roof area.
Design of the fire water deluge system shall follow requirements of YERPSAESB-017 Total calculated flow rate should not exceed 238.2 m3/hr (1048
GPM).
The deluge valves shall be skid mounted and installed in a readily accessible
position, with access from the plant road and at least 15m from the protected
item.
System shall be activated automatically and manually as follows:
1- Automatic through fusible link.
2- Remote Manually through push buttons located in CCB room
3- Manually from manual valve located on deluge skid.
4- Manually through pneumatic manual valve located near to deluge skid
5- Remote DCS soft switch.
Actuation of the deluge skids shall be as per control system /instrumentation
design basis doc.no. 100-YER-PE-PDB-0001
Branch piping to spray heads shall be connected on the top of the distribution
piping or supply ring to minimize clogging of the heads.
(See table #30 for list of protected items with associated number of deluge
valve sizes, application rates and water demand
Page 49 of 53

Water deluge
application rate
(l/min/m2)
Water
deluge
flow rate
(l/min)
Deluge
valve size
(in)
Item
Service
Dia
(m)
143-D-0024
Propane sphere
20
10.2
3970
143-D-0025
Propane sphere
20
10.2
3970
143-D-0026
Propane sphere
20
10.2
3970
143-D-0027
Mixed Butane
20
10.2
3970
143-D-0028
Mixed Butane
20
10.2
3970
143-D-0029
Mixed Butane
20
10.2
3970
143-D-0030
Mixed Butane
20
10.2
3970
143-D-0031
Coker LPG/Mixed
butane
20
10.2
3970
143-D-0032
Mixed Butane
20
10.2
3970
143-D-0014
Isomerate and
CCR light
reformate
88
10.2
9060
143-D-0015
Isomerate and
CCR light
reformate
33.94
10.2
9060
143-D-0044
NHT light
naphtha
33.94
10.2
9060
143-D-0047
Light slop tank
31
10.2
7360
Table 31 spheres and spheroids protected by water deluge system
Page 50 of 53

Fire and gas emergency

Sphere 143-D-0024 fire fighting
Tag No.
Description
143-PIT-1140
Heat detection
143-HS-1000
Deluge hand switch located in

CCR
Interlock Action
Initiate an alarm :
Open deluge valve 143-ZXV-0975 for sphere
143-D-0024
Initiate an alarm :
143-D-0024

Tag No.
Description
143-PIT-1143
Heat detection
143-HS-1001

CCR
Interlock Action
Initiate an alarm :
143-D-0025
Initiate an alarm :
143-D-0025

Tag No.
Description
143-PIT-1146
Heat detection
143-HS-1002

CCR
Interlock Action
Initiate an alarm :
143-D-0026
Initiate an alarm :
143-D-0026

Tag No.
Description
143-PIT-1149
Heat detection
143-HS-1003

CCR
Interlock Action
Initiate an alarm :
143-D-0027
Initiate an alarm :
143-D-0027

Tag No.
Description
143-PIT-1152
Heat detection
143-HS-1004

CCR
Interlock Action
Initiate an alarm :
143-D-0028
Initiate an alarm :
143-D-0028
Page 51 of 53


Tag No.
Description
143-PIT-1155
Heat detection
143-HS-1005

CCR
Interlock Action
Initiate an alarm :
143-D-0029
Initiate an alarm :
Open deluge valve 143-ZXV-0980for sphere
143-D-0029

Tag No.
Description
143-PIT-1158
Heat detection
143-HS-1006

CCR
Interlock Action
Initiate an alarm :
143-D-0030
Initiate an alarm :
143-D-0030

Tag No.
Description
143-PIT-1161
Heat detection
143-HS-1007

CCR
Interlock Action
Initiate an alarm :
143-D-0031
Initiate an alarm :
143-D-0031

Tag No.
Description
143-PIT-1164
Heat detection
143-HS-1008

CCR
Interlock Action
Initiate an alarm :
143-D-0032
Initiate an alarm :
143-D-0032
Spheroid 143-D-0014 fire fighting

Tag No.
Description
143-PIT-1167
Heat detection
143-HS-1009

CCR
Interlock Action
Initiate an alarm :
Open deluge valve 143-ZXV-0984for spheroid
143-D-0014
Initiate an alarm :
143-D-0014
Page 52 of 53


Tag No.
Description
143-PIT-1170
Heat detection
143-HS-1010

CCR
Interlock Action
Initiate an alarm :
143-D-0015
Initiate an alarm :
143-D-0015

Tag No.
Description
143-PIT-1173
Heat detection
143-HS-1011

CCR
Interlock Action
Initiate an alarm :
143-D-0044
Initiate an alarm :
143-D-0044

Tag No.
Description
143-PIT-1176
Heat detection
143-HS-1012

CCR
Interlock Action
Initiate an alarm :
143-D-0047
Initiate an alarm :
143-D-0047
Table 32 Fire and gas emergency table
Page 53 of 53

ESD System Operation

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ESD System Operation

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Yanbu Export Refinery Project

OPERATING INSTRUCTIONS FOR SP1 TANK FARM

100 EMERGENCY SHUT DOWN ............................................................................... 4

200 LOSS OF UTILITIES .......................................................................................... 36

300 LOSS OF CRITICAL SYSTEMS/COMPONENTS ............................................. 45

400 UNUSUAL OCCURRENCES ............................................................................. 47

Yanbu Export Refinery Project

Table 18 Butane pumps shutdown signals ........................................................................... 27

Yanbu Export Refinery Project

Protection of facility and equipment.

Prevention of pollution to the environment.

The functions of the ESD shall include:

Automatically sense an abnormal operational or equipment condition.

React automatically to this condition by shutting down and/or isolating the

Provide sequence of events recording.

Safety System Availability

SIL3 applications: 99.9% to 99.99%

SIL2 applications: 99% to 99.9%

SIL1 applications: 90 to 99%

The parameters considered for calculations are listed below:

Proof Test Interval: 10 years ( for Logic solver subsystem)

Yanbu Export Refinery Project

Partial stroke test for ZV: 3 months

Plant Design Lifetime: 25 years

Ambient temperature range: 10 oC to 35 oC

Ambient relative humidity: 20% to 80%

Yanbu Export Refinery Project

parameter and signal validation setting in application program shall be

Yanbu Export Refinery Project

Signals that require Start Up Override

Open Limit Switches (ZXSO) of normal

80% open (ZXSO) of Critical ZV's (16

Open Limit Switches (ZXSO) of Discharge

All VMS Trip Signals (except for 2oo2

Table 1 MOS and SUO requirement

Yanbu Export Refinery Project

Alarm Annunciation and First Out Status

ESD inputs and transition of analog/digital devices past shutdown limits

ESD pull/push buttons, Manual Reset buttons

ESD DI are time stamped at the Digital input module

MOS Enable/ Disable operation

Yanbu Export Refinery Project

142- G-0005A/B discharge

15 m remote close 142-ZV-0057

close 142-ZV-0057 from DCS

142- G-0005A/B suction header

15 m remote close 142-ZV-0056

CLOSE 142-ZV-0056 from DCS

142- G-0005A stop from DCS

Stop Non Phenolic SW Stripper Skim oil Pumps

142- G-0005B stop from DCS

Stop Non Phenolic SW Stripper Skim oil Pumps

142- G-0002A stop from DCS

Stop Non Phenolic SW Stripper Feed Pump

142- G-0002Bstop from DCS

Stop Non Phenolic SW Stripper Feed Pump

Table 2 Non phenolic pumps shutdown signals

Yanbu Export Refinery Project

Phenolic Sour Water Storage Tank

142- G-0025A/B Suction header

15 m remote close 142-ZV-0552

close 142-ZV-0552A from DCS

142- G-0025A/B Discharge

15 m remote close 142-ZV-0553