TSD -Job No.
18240
Executive Summary
The purpose of this report is to clarify the design and engineering of instrumentation
and control system for project of unloading and pumping naphtha to RASCO
Ethylene plant existing facilities, as a temporary solution.
Standard & Code:
GNS, SP-2000-EE &SP-2000-II &SP-2000-W6 & SP-2000-E6
API 610 / 670
BS 7671, BS 6121 / BS 8608
IEC 60423 / 60228 /
ATEX approval Motor for hazards area.
Abbreviations:
A: Active
S: Standby
P: Pump
C: Cable
LSL: Level Switch Low
PSH: Pressure Switch High
XS: Alarm Contact
TTS: Telemetry Transmission System
MCC: Motor Control Central
JB: Junction Box
TB: Terminal Block
SOA: Send Out Area
IS: Intrinsically Safe
SB: Substation
HR: Harbour
I/C: Instrument & Control
1. List of Engineering Drawings:
PE/I/6550 – Sheet 1 of 2 Pump Run /Stop Alarm of 40-P-2827A/S
PE/I/6550 – Sheet 2 of 2
PE/I/6551 – Sheet 1 of 2 Seal Pump Common Protection Alarm.
PE/I/6551 – Sheet 2 of 2
PE/I/6514 – Sheet 1 of 2 Pump Run Dry Protection by LZA168-LL
PE/I/6514 – Sheet 2 of 2
2. Design & Engineering.
We are responding to the project team to produce tangible engineering deliverables
based on modification of project scope.
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TSD -Job No. 18240
The modification strategy is focus on deliver the function of the pumps system to be
fit to the required purpose stated in scope of work and safety rules, as well as
keeping the basic design of the instrument & control loops and its equipment in
parallel with new signals (see attached Drawings.).
2.1 Pumps 40-P-2827A/S Discharge pressure gauge.
2.2 Pumps 40-P-2827A/S Run dry Protection & Tank Level indication.
2.3 Pumps 40-P-2827A/S Running /Stop Connections.
2.4 Mechanical Seal Alarm Signals Connection.
2.5 Transfer All Instrument & Control data to S.O.A Control Room via
Telemetry Transmission System.
3. Phase II Marine Loading Arm Jetty 2A/2B.
The proposal of utilize the Phase II, Marine Loading arms of Jetty 2A/2B for
modification of unloading Naphtha to supply ethylene plant facilities require to relying
on loading arm systems which is not tested and maintained since its commissioning
in 2001, making the possibility of its operation questionable and unreliable.
so that require to examine the whole system to be able to identify any issue for jetty
loading arms at the earliest stage to work out a solution or mitigate expected
unforeseen risk if any.
In brief, a successful comprehensive maintenance of the whole system and function
test of Loading arms in local and remote mode has been accomplished, as well as
operation special procedure is prepared for HR operators due to software control
system amendment that required to override some of the process or protection
conditions to be operatable, i.e. to employ arms for unloading function instead of
basic design for exporting function of benzene product (See attached function test
report & Temporary Loading Arms 2A/2B operation procedure).
4. Test & Inspection Procedures.
The work of Test & check procedure of instrumentation and control equipment and
related loops during modification commissioning to be undertaken in accordance the
relevant and professionalism safety rules to prove that they will effectively prevent
risk of dangers on people, plant and environment.
The test and inspection shall carry out to all loops and alarm panel indications to:
4.2 Level Control Loop for Pump 40-P-2827 A/S.
Tag No.
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TSD -Job No. 18240
4.3 Pump Mechanical Seal Common Alarm Loops.
Tag No.
4.4 Pump Running Contact Alarm Test.
Tag No.
4.5 Loading Arm 2A/2B Operation & Performance Function Test.
Tag No.
5. Recommendations
Recommendations as to future management plan and actions are made based on
the findings of issues and obstacles of this project, but the most concern problems
might be faced plant operation system are:
Phase I Telemetry Transmission System:
This system is made and set up by C.S.I vender and the system are responsible for
transfer the data, alarms and information among phase I plants and control rooms
using telecommunications technology, and most of the signals are tank levels,
pressures, temperatures alarms and analysers information, roughly estimated
transferring 120 Control process signals.
The Control Unit (Outstation) system are located mainly in S.O.A, ethylene and
Utilities control rooms as follows:
Outstation No.1 Tankage Area.
Outstation No.2 Ethylene plant.
Outstation No.3 Utility
Outstation No.4 Sea Water Intake.
Outstation No.5 S.O.A.
The main problematic issue that the system is already in obsolesces phase since its
installed in the beginning of RASCO Complex in1980s, so the system technology
spares and technical support are no longer available in such technology markets.
In addition, the responsibility of maintenance and follow up of this system also is not
clear whether if instrumentation or electrical duty, whereas the communication
technology skilful technicians are more appropriate.
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TSD -Job No. 18240
Based on the above findings, I/C plant engineer recommend you that, maintenance
Department should organise a team work from concerned departments, to survey &
review the system and its problems, documentation, prepare of preventive &
corrective maintenance procedures, as well as give an advice report to upgrade or
replace the system with estimation budget.
6. Appendices
1. Engineering drawings documents.
2. Temporary Loading Arms 2A/2B operation procedure.
3. Loading arms jetty 2A/2B function performance test report.
4. Jetty Arms maintenance Flowchart.
5. Bill of Materials B.M.O.
Prepared By
Ahmed A. Elhoni
I/C Senior Engineer
