PROCESS CONTROL SYSTEM AUTOMATION STANDARD (PL723). C1 PL723 Rev 4.0... · Process Control System Automation Standard PL723 04 [DRAFT ... Process Control System Automation Standard

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Document Name Document Number Revision Number Page

Process Control System Automation Standard PL723 04 [DRAFT] 1 of 363

PROCESS CONTROL SYSTEM

AUTOMATION STANDARD

(PL723)

Rev 04

[DRAFT]

DOCUMENT APPROVAL PROCESS

NAME POSITION/MEETING NO. SIGNATURE DATE

Originator: Chris Murray TPL MC&I Dept.

Approver: Alan R Parsons MC&I Manager

Original date: 01 April 2017

Effective date: 01 April 2017

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Page 2 of 326 Originator: TPL MC&I Dept. Original date: 01/04/2017

Copyright © Transnet Pipelines, All rights reserved, including rights to amendments

APPROVAL

RESPONSIBILITY DESIGNATION SIGNATURE DATE

Designation :

COMPILED BY

(Latest Amendment)

MC&I Dept 1 Feb 2017

Name :

C Murray

ACCEPTED BY

Designation :

MC&I Specialist

Name:

Emmanuel Khangale

Designation :

MC&I Specialist

Name:

Edwin Narothan

Designation :

MC&I Specialist

Name:

Vasu Govender

APPROVED BY

Designation :

MC&I Manager

Name:

Alan Parsons

Designation :

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DOCUMENT CHANGE HISTORY:

The owner of this document is responsible for the revision and control of the document, including

updating of the table below, which contains the history of the document with details of each revision.

Date Previous

Rev No.

New

Rev No.

Details of Revision

3 July 1999 - 0.0 Document distributed for comment.

3 Aug 1999 0.0 0.1 Document distributed for approval.

10 Mar 2002 0.1 0.8 SCADA section added, document reformatted and submitted to Transnet Pipelines for comment.

1 Sep 2002 0.8 1.0 Document approved by Transnet Pipelines.

1 Jun 2003 1.0 1.1 Document reformatted. Cross Reference added to end of document.

20 Feb 2005 1.1 1.2 Launcher & LP Routing Group Description expanded.

3 Apr 2006 1.2 2.0

Document separated into an Automation Standard, defining Transnet Pipelines requirements, and an LSX Automation EDS, which details the practical implementation of the LSX Control System.

18 Jun 2007 2.0 2.1 Detail amended to reflect current practise. Mainline VSD device/groups added. Line Control and Reporting sections added.

22 Jul 2008 2.1 2.2 MCC Reporting section updated. Issued as a FEED Document for the NMPP Project.

4 Dec 2008 2.2 2.3a NMPP requirements added. Submitted for TPL Approval.

4 Mar 2009 2.3a 2.3b Data from Part 1Rev 1.2 added.

Comments received for Rev 2.3a added.

26 Mar 2009 2.3b 2.3c Update to include ABB ACS1000 detail, Machine Monitoring detail.

31 Mar 2009 2.3c 2.3d Review Workshop: TPL, Uhde, Siemens.

1 Dec 2009 2.3d 3.0 Issued as baseline document for NMPP Project.

1 Sep 2014 3.0 3.1 Document formatting revised. PCS7 Requirements added.

1 Mar 2017 3.1 4.0 Document revised in accordance with TPL-TECH-I-C-STD-014 Rev 03 (Segregated Process Control & Custody Metering

Systems – Requirements Concept) Philosophies.

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TABLE OF CONTENTS

1 INTRODUCTION ................................................................................................................... 18

1.1 Purpose ....................................................................................................................... 18 1.2 Scope .......................................................................................................................... 18

1.2.1 Requirements Included............................................................................................ 18

1.2.2 Requirements Excluded ........................................................................................... 18 1.2.3 Process Control System Constraints .......................................................................... 19

1.3 Document Usage .......................................................................................................... 19

1.4 Abbreviations ............................................................................................................... 19 1.5 Station Abbreviations .................................................................................................... 22

2 APPLICABLE DOCUMENTS .................................................................................................... 23

2.1 TPL Applicable Specifications and Standards .................................................................. 23

2.2 Other Applicable Specifications and Standards ............................................................... 23 2.3 Reference Documentation ............................................................................................. 23

3 PROCESS CONTROL OVERVIEW ............................................................................................ 25

3.1 Stations ....................................................................................................................... 25

3.1.1 Intake stations ........................................................................................................ 25 3.1.2 Pump stations ......................................................................................................... 25

3.1.3 Delivery stations ..................................................................................................... 25

3.1.4 Terminal Facilities ................................................................................................... 25

3.1.5 Remote Block Valve Chambers ................................................................................. 26

3.2 Tele-Control Facilities ................................................................................................... 26

3.2.1 Mainline Pump and Motor Sets (HP Manifold) ............................................................ 26 3.2.2 Receivers (HP Manifold) .......................................................................................... 26

3.2.3 Launchers (HP Manifold) ......................................................................................... 27

3.2.4 Sump Injection Facilities (HP Manifold) ..................................................................... 27

3.2.5 Interface Handling Control Facilities (HP Manifold) .................................................... 27

3.2.6 Lube Oil Facilities. ................................................................................................... 27

3.2.7 Purge Air Facilities................................................................................................... 27

3.2.8 Pressurisation Facilities ............................................................................................ 28

3.2.9 Delivery Facilities (LP Manifold) ................................................................................ 28

3.2.10 Intake Facilities (LP Manifold) .................................................................................. 28

3.2.11 Prover Loop Facilities (LP Manifold) .......................................................................... 28

3.2.12 Intermixture Handling Facilities (LP Manifold) ........................................................... 28

3.2.13 Accumulator Tank Facilities (LP Manifold) ................................................................. 28 3.2.14 Booster Pump Spillback Control facilities ................................................................... 29

4 DEFINITIONS AND CONCEPTS .............................................................................................. 30

4.1 Typographic Conventions .............................................................................................. 30

4.2 Device ......................................................................................................................... 30

4.2.1 Device Fault............................................................................................................ 30

4.2.2 Device Available ...................................................................................................... 30

4.2.3 Open OR Wirebreak ................................................................................................ 31 4.2.4 Closed OR Wirebreak .............................................................................................. 31

4.3 Device Group ............................................................................................................... 31

4.3.1 Group Available ...................................................................................................... 31

4.3.2 Group Ready .......................................................................................................... 31 4.3.3 Sequence Fault ....................................................................................................... 31

4.3.4 Group Flow-path ..................................................................................................... 32

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4.3.5 Group Flushing ....................................................................................................... 32

4.4 Control Modes (Overview) ............................................................................................. 32

4.4.1 Modes of Control ..................................................................................................... 33 4.4.2 Mode of Operation .................................................................................................. 33

4.5 Route Definitions .......................................................................................................... 34

4.6 Interlocks .................................................................................................................... 35 4.7 Switching definitions ..................................................................................................... 36

4.8 General........................................................................................................................ 36

4.9 Sequence Control ......................................................................................................... 36

4.9.1 Sequence Control Matrix .......................................................................................... 36

4.9.2 Sequences .............................................................................................................. 37

5 GENERAL CONTROL PHILOSOPHY - DEVICES ........................................................................ 42

6 GENERAL CONTROL PHILOSOPHY – DEVICE GROUPS ............................................................ 43

6.1 Introduction ................................................................................................................. 43

6.2 Receiver Device Group .................................................................................................. 44

6.2.1 Group Description ................................................................................................... 44

6.2.2 Modes of Control ..................................................................................................... 45

6.2.3 Modes of Operation ................................................................................................. 46

6.2.4 Group Functionality ................................................................................................. 46

6.2.5 Group Availability .................................................................................................... 51

6.2.6 Group Status .......................................................................................................... 52

6.2.7 Group Interlocks ..................................................................................................... 53

6.2.8 Failure Modes ......................................................................................................... 53

6.2.9 Graphic Representation ........................................................................................... 53 6.3 Launcher ..................................................................................................................... 54


6.3.2 Modes of Control ..................................................................................................... 55




6.3.6 Group Status .......................................................................................................... 61

6.3.7 Additional Device Alarms ......................................................................................... 62

6.3.8 Group Interlocks ..................................................................................................... 62 6.3.9 Failure modes ......................................................................................................... 63

6.3.10 Graphic Representation ........................................................................................... 63

6.4 Launcher Interface Handling ......................................................................................... 64


6.4.2 Modes of Control ..................................................................................................... 64


6.4.4 Group Functionality ................................................................................................. 64 6.4.5 Group Availability .................................................................................................... 67

6.4.6 Group Status .......................................................................................................... 67

6.4.7 Group Interlocks ..................................................................................................... 67 6.4.8 Failure modes ......................................................................................................... 67


6.5 MV Booster Pump Sets – DOL ....................................................................................... 69 6.5.1 Group Description ................................................................................................... 69

6.5.2 Modes of Control ..................................................................................................... 71

6.5.3 Modes of Operation ................................................................................................. 71 6.5.4 Group Functionality ................................................................................................. 71

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6.5.6 Group Status .......................................................................................................... 74

6.5.7 Additional Device Alarms ......................................................................................... 75 6.5.8 Group Interlocks ..................................................................................................... 75

6.5.9 Failure Modes ......................................................................................................... 76

6.5.10 Graphic Representation ........................................................................................... 76 6.6 Booster Pump Bxx Flow Control ..................................................................................... 77


6.6.2 Modes of Control ..................................................................................................... 77



6.6.5 Spillback control ...................................................................................................... 77 6.6.6 Group Availability .................................................................................................... 78

6.6.7 Group Status .......................................................................................................... 79



6.6.10 Failure Modes ......................................................................................................... 79


6.7 MV Mainline Pump Sets – DOL (Series Configuration) ..................................................... 80


6.7.2 Modes of Control ..................................................................................................... 81



6.7.5 Group Availability .................................................................................................... 85 6.7.6 Group Status .......................................................................................................... 86



6.7.9 Failure Modes ......................................................................................................... 89


6.8 MV Mainline Pump Sets – VSD (Parallel Configuration) .................................................... 90 6.8.1 Group Description ................................................................................................... 90

6.8.2 Modes of Control ..................................................................................................... 93

6.8.3 Modes of Operation ................................................................................................. 93 6.8.4 Group Functionality ................................................................................................. 93


6.8.6 Group Status .......................................................................................................... 98


6.8.8 Failure Modes ....................................................................................................... 101

6.8.9 Graphic Representation ......................................................................................... 101

6.9 MV Mainline Pump Sets – VSD (Crude Booster Stations) ............................................... 102 6.9.1 Group Description ................................................................................................. 102

6.9.2 Modes of Control ................................................................................................... 103

6.9.3 Modes of Operation ............................................................................................... 103

6.9.4 Group Functionality ............................................................................................... 103

6.9.5 Group Availability .................................................................................................. 106

6.9.6 Group Status ........................................................................................................ 107 6.9.7 Group Interlocks ................................................................................................... 107

6.9.8 Failure Modes ....................................................................................................... 109

6.9.9 Graphic Representation ......................................................................................... 109 6.10 Lube Oil System – 24” MPP Stations ............................................................................ 110

6.10.1 Group Description ................................................................................................. 110

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6.10.2 Modes of Control ................................................................................................... 110


6.10.4 Group Functionality ............................................................................................... 111 6.10.5 Group Availability .................................................................................................. 115

6.10.6 Group Status ........................................................................................................ 115

6.10.7 Group Interlocks ................................................................................................... 116 6.10.8 Failure Modes ....................................................................................................... 117


6.11 Lube Oil System – RPP & COP Stations ........................................................................ 118


6.11.2 Modes of Control ................................................................................................... 118

6.11.3 Modes of Operation ............................................................................................... 118 6.11.4 Group Functionality ............................................................................................... 118


6.11.6 Group Status ........................................................................................................ 119

6.11.7 Additional Device Alarms ....................................................................................... 119

6.11.8 Group Interlocks ................................................................................................... 119


6.12 HP Routing ................................................................................................................ 121


6.12.2 Modes of Control ................................................................................................... 121



6.12.5 Group Availability .................................................................................................. 127 6.12.6 Group Status ........................................................................................................ 127



6.12.9 Failure Modes ....................................................................................................... 128

6.12.10 Graphic Representation ...................................................................................... 128

6.13 Dual Strainers ............................................................................................................ 129 6.13.1 Group Description ................................................................................................. 129

6.13.2 Modes of Control ................................................................................................... 129



6.13.6 Group Status ........................................................................................................ 134


6.13.8 Failure modes ....................................................................................................... 135


6.14 Flow Control – HP Application ..................................................................................... 136 6.14.1 Group Description ................................................................................................. 136

6.14.2 Modes of Control ................................................................................................... 136




6.14.6 Group Status ........................................................................................................ 138 6.14.7 Additional Device Alarms ....................................................................................... 138


6.14.9 Failure Modes ....................................................................................................... 138 6.14.10 Graphic Representation ...................................................................................... 138

6.15 Duty and Speed Control .............................................................................................. 139

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6.15.2 Modes of Control ................................................................................................... 140


6.15.5 Device Group Availability ....................................................................................... 153

6.15.6 Inter-PLC Communication ...................................................................................... 153 6.15.7 Actions in Event of Communication Failure ............................................................. 154

6.15.8 Event Strategies .................................................................................................... 154

6.15.9 Alarm Strategies ................................................................................................... 156

6.15.10 Interlocking Strategies ....................................................................................... 157


6.16 Safety Instrumented System (Line Over-pressure Protection) ........................................ 159 6.16.1 Group Description ................................................................................................. 159

6.16.2 Modes of Control ................................................................................................... 160




6.16.6 Group Status ........................................................................................................ 162


6.16.8 Failure Modes ....................................................................................................... 164


6.17 Sumps and Intermix Transfer ...................................................................................... 165


6.17.2 Modes of Control ................................................................................................... 165 6.17.3 Modes of Operation ............................................................................................... 165



6.17.6 Route availability................................................................................................... 167

6.17.7 Group Status ........................................................................................................ 167

6.17.8 Additional Device Alarms ....................................................................................... 167 6.17.9 Group Interlocks ................................................................................................... 168


6.18 Road Loading ............................................................................................................. 169 6.18.1 Group Description ................................................................................................. 169

6.18.2 Modes of Control ................................................................................................... 169




6.18.6 Group Status ........................................................................................................ 170



6.19 Road & Rail Loading ................................................................................................... 172


6.19.2 Modes of Control ................................................................................................... 174




6.19.8 Failure Modes ....................................................................................................... 177

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6.20 Sump Injection (Venturi) ............................................................................................ 178

6.20.1 Group Description ................................................................................................. 178 6.20.2 Modes of Control ................................................................................................... 178



6.20.6 Group Status ........................................................................................................ 180




6.21 Purge Air Fans – RPP & COP Stations .......................................................................... 182 6.21.1 Group Description ................................................................................................. 182

6.21.2 Modes of Control ................................................................................................... 182




6.21.6 Group Status ........................................................................................................ 183




6.22 Ventilation Fans – 24” MPP Stations ............................................................................ 185





6.22.6 Group Status ........................................................................................................ 187


6.22.8 Failure Modes ....................................................................................................... 188 6.22.9 Inter-PLC Communications Interface ...................................................................... 188


6.23 Pressurisation Fans - RPP Stations ............................................................................... 189 6.23.1 Group Description ................................................................................................. 189

6.23.2 Modes of Control ................................................................................................... 189




6.23.6 Group Status ........................................................................................................ 190



6.24 Inhibitor & DRA Injection ............................................................................................ 192


6.24.2 Modes of Control ................................................................................................... 192



6.24.6 Group Status ........................................................................................................ 194 6.24.7 Additional Device Alarms ....................................................................................... 195


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6.25 General...................................................................................................................... 196

6.25.1 Group Description ................................................................................................. 196 6.25.2 Modes of Control ................................................................................................... 197



6.25.6 Group Status ........................................................................................................ 198


6.25.8 Failure Modes ....................................................................................................... 199


6.26 Electrical Distribution .................................................................................................. 200 6.26.1 Group Description ................................................................................................. 200

6.26.2 Modes of Control ................................................................................................... 202




6.26.6 Group Status ........................................................................................................ 202



6.27 MV Generator Sets ..................................................................................................... 204


6.27.2 Modes of Control ................................................................................................... 204



6.27.6 Group Status ........................................................................................................ 207



6.28 MV Generator Diesel Supply ........................................................................................ 208 6.28.1 Group Description ................................................................................................. 208

6.28.2 Modes of Control ................................................................................................... 208



6.28.6 Group Status ........................................................................................................ 212


6.28.8 Failure Modes ....................................................................................................... 213


6.29 MV Generator Diesel Offloading ................................................................................... 214 6.29.1 Group Description ................................................................................................. 214

6.29.2 Modes of Control ................................................................................................... 214






6.30 LP Routing – General .................................................................................................. 218 6.30.1 Group Description ................................................................................................. 218

6.30.2 Modes of Control ................................................................................................... 218

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6.30.8 Graphic Representation ......................................................................................... 220 6.31 LP Routing - Product .................................................................................................. 221


6.31.2 Modes of Control ................................................................................................... 223



6.31.5 Route Availability .................................................................................................. 231 6.31.6 Group Status ........................................................................................................ 231


6.31.8 Failure Modes ....................................................................................................... 233


6.33 Flow Control – LP Application ...................................................................................... 234


6.33.2 Modes of Control ................................................................................................... 234




6.33.6 Group Status ........................................................................................................ 236


6.33.9 Failure Modes ....................................................................................................... 236


6.34 Tank Farms ................................................................................................................ 237








6.35 Safety Instrumented System (Tank Overfill Protection) ................................................. 245





6.35.6 Group Status ........................................................................................................ 248




6.36 Prover ....................................................................................................................... 251 6.36.1 Group Description ................................................................................................. 251

6.36.2 Modes of Control ................................................................................................... 252

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6.36.8 Interlocking Strategies .......................................................................................... 261 6.36.9 Graphic Representation ......................................................................................... 261

6.37 Intermix Blend Control ................................................................................................ 262


6.37.2 Modes of Control ................................................................................................... 262



6.37.6 Group Status Indications ....................................................................................... 269


6.37.8 Failure Modes ....................................................................................................... 269


6.38 System Diagnostics .................................................................................................... 270


6.38.2 Modes of Control ................................................................................................... 271



6.38.5 Device Group Availability ....................................................................................... 275

6.38.6 Group Status ........................................................................................................ 275 6.38.7 Group Events ........................................................................................................ 275

6.38.8 Group Alarms ........................................................................................................ 276

6.38.9 Interlocking Strategies .......................................................................................... 276


6.39 Station Sequences ...................................................................................................... 277

6.39.1 Introduction.......................................................................................................... 277 6.39.2 Modes of Control ................................................................................................... 278



6.39.6 Station Offline Sequence Availability ....................................................................... 282

6.39.7 Station Isolation Sequence Availability .................................................................... 283

6.39.8 Station Flush Sequence Availability ......................................................................... 283

6.39.9 Pump Set P01-P03 Flush Sequence Availability ........................................................ 283

6.39.10 Group Status ..................................................................................................... 284

6.39.11 Interlocking Strategies ....................................................................................... 284

7 APPENDICES ...................................................................................................................... 285

7.1 Appendix A: Flow Compensation ................................................................................. 285

7.1.1 Description ........................................................................................................... 285

7.1.2 Graphic Representation ......................................................................................... 286 7.2 Appendix B: Sequence Flowcharts & Tables ................................................................. 287

7.2.1 Receiver Device Group .......................................................................................... 288

7.2.2 Launcher Device Group ......................................................................................... 289 7.2.3 MV Booster Pump Device Group ............................................................................. 290

7.2.4 MV Mainline Pump Set Device Group - DOL ............................................................ 291

7.2.5 MV Mainline Pump Set Device Group – VSD (24” MPP) ............................................ 293

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7.2.6 MV Mainline Pump Set Device Group – VSD (Crude) ................................................ 296

7.2.7 Lube Oil Device Group (24” MPP Stations) .............................................................. 298

7.2.8 HP Routing Device Group ...................................................................................... 300 7.2.9 Sump & Intermix Transfer Device Group ................................................................ 301

7.2.10 Sump Injection Device Group (Venturi) .................................................................. 302

7.2.11 Inhibitor/DRA Injection Device Group ..................................................................... 303 7.2.12 LP Routing – Product Device Group ........................................................................ 304

7.2.13 Prover Device Group ............................................................................................. 315

7.2.14 Intermix Blend Device Group ................................................................................. 319

7.2.15 Station Sequences................................................................................................. 321

7.3 Comment Resolution .................................................................................................. 325

7.4 DOCUMENT CHANGE HISTORY: .................................................................................. 326 Total Pages 326

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Table of Figures

Figure 4.3-1: Group Flow-path logic ..................................................................................................... 32 Figure 4.9-1: Typical Matrix Status Indications ..................................................................................... 37 Figure 4.9-2: Typical Sequence Matrix for Intermix Blend & Transfer .................................................. 37 Figure 4.9-3: SFC Legend..................................................................................................................... 38 Figure 4.9-4: Alternative Branch ........................................................................................................... 39 Figure 4.9-5: Simultaneous Branch ...................................................................................................... 40 Figure 4.9-6: Abort on error................................................................................................................... 40 Figure 4.9-7: Continue on Error ............................................................................................................ 41 Figure 6.2-1: Functional Layout of the Receiver R01 ........................................................................... 45 Figure 6.3-1: Functional Layout of the Launcher .................................................................................. 55 Figure 6.6-1: Booster pump Bxx spillback - Flow Control Schematic ................................................... 78 Figure 6.13-1: Dual Strainer (LP Intake) Control Logic ....................................................................... 133 Figure 6.14-1: Flow Control – HP Application ..................................................................................... 137 Figure 6.15-1: Control Methodology ................................................................................................... 139 Figure 6.15-2: Simplified Pump Station Control Methodology ............................................................ 140 Figure 6.15-3: Duty Controller Loop .................................................................................................... 142 Figure 6.15-4: Duty Controller Faceplate ............................................................................................ 143 Figure 6.15-5: Duty Controller Faceplate ............................................................................................ 144 Figure 6.15-6: Speed Controller Loop ................................................................................................. 147 Figure 6.15-7 Drive Controller Loop .................................................................................................... 151 Figure 9.2.1 – Road and Rail Loading (Diesel) ................................................................................... 174 Figure 6.29-1: Typical LP Product Routing Manifold Layout (Intake Station) ..................................... 222 Figure 6.29-2: Typical LP Product Routing Manifold Layout (Delivery Station) .................................. 222 Figure 6.31-1: Flow Control – LP Application ..................................................................................... 235 Figure 7.2-1 – Receiver R01 Online Sequence .................................................................................. 288 Figure 7.2-2: Receiver R01 Offline Sequence .................................................................................... 288 Figure 7.2-3: Launcher L01 Online Sequence .................................................................................... 289 Figure 7.2-4: Launcher L01 Offline Sequence .................................................................................... 289 Figure 7.2-5: Booster Pump Set B01 Online sequence ...................................................................... 290 Figure 7.2-6: Booster Pump Set B01 Offline sequence ...................................................................... 291 Figure 7.2-7: MV Mainline Pump Set P01 Online Sequence .............................................................. 291 Figure 7.2-8: MV Mainline Pump Set P01 Set Offline Sequence ....................................................... 292 Figure 7.2-9: MV Mainline Pump Set P01 Flush Sequence ............................................................... 292 Figure 7.2-10: MV Mainline Pump Set P01 Line-Up Sequence.......................................................... 293 Figure 7.2-11: MV Mainline Pump Set P01 Online Sequence ............................................................ 294 Figure 7.2-12: MV Mainline Pump Set P01 Offline Sequence ............................................................ 294 Figure 7.2-13: MV Mainline Pump Set P01 Flush Sequence ............................................................. 295 Figure 7.2-14: MV Mainline Pump Set P01 Line-Up Sequence.......................................................... 296 Figure 7.2-15: MV Mainline Pump Set P01 Online Sequence ............................................................ 296 Figure 7.2-16: MV Mainline Pump Set P01 Set Offline Sequence ..................................................... 297 Figure 7.2-17: Lube Oil Online Sequence ........................................................................................... 298 Figure 7.2-18: Lube Oil Offline Sequence ........................................................................................... 298 Figure 7.2-19: HP Routing Isolation Online Sequence (TNI) .............................................................. 300 Figure 7.2-20: HP Routing Isolation Offline Sequence (TNI) .............................................................. 300 Figure 7.2-21: Intermix Transfer Online Sequence ............................................................................. 301 Figure 7.2-22: Intermix Transfer Offline Sequence ............................................................................. 302 Figure 7.2-23: Sump Injection Online Sequence ................................................................................ 302 Figure 7.2-24: Sump Injection Offline Sequence ................................................................................ 303 Figure 7.2-25: Inhibitor/DRA Online Sequence................................................................................... 303 Figure 7.2-26: LP Routing Intake Manifold Layout (Example) ............................................................ 304 Figure 7.2-27: LP Routing – PRDx Open Route Sequence (Intake) .................................................. 306

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Figure 7.2-28: LP Routing – PRDx Start Intake Sequence ................................................................. 307 Figure 7.2-29: LP Routing – PRDx Stop Intake Sequence ................................................................. 308 Figure 7.2-30: LP Routing Delivery Manifold Layout (Example) ......................................................... 309 Figure 7.2-31: LP Routing – PRDx Open Route Sequence (Delivery) ............................................... 312 Figure 7.2-32: LP Routing – PRDx Start Delivery Sequence ............................................................. 313 Figure 7.2-33: LP Routing – PRDx Stop Delivery Sequence .............................................................. 314 Figure 7.2-34: Prover Y01 Online Sequence ...................................................................................... 315 Figure 7.2-35: Prover Y01 Offline Sequence ...................................................................................... 316 Figure 7.2-36: Prover Y01 Fill Sequence ............................................................................................ 317 Figure 7.2-37: Prover Y01 Drain Sequence ........................................................................................ 318 Figure 7.2-38: Intermix Blend Online Sequence (WAO) ..................................................................... 319 Figure 7.2-39: Intermix Blend Offline Sequence (WAO) ..................................................................... 320 Figure 7.2-40: Station Line-Up Sequence (TNI) ................................................................................. 321 Figure 7.2-41: Station Online Sequence (TNI).................................................................................... 321 Figure 7.2-42: Station Offline Sequence (TNI).................................................................................... 321 Figure 7.2-43: Station Isolation Sequence (TNI) ................................................................................ 322 Figure 7.2-44: Station Flush Sequence (TNI) ..................................................................................... 323 Figure 7.2-45: MV Mainline Pump P01-P03 Flush Sequence (TNI) ................................................... 324

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Table of Tables

Table 6.2-1: Receiver Availability .......................................................................................................... 52 Table 6.2-2: Receiver Group Alarm Status ........................................................................................... 52 Table 6.2-3: Receiver Group Error Status ............................................................................................ 52 Table 6.2-4: Receiver Group Information Status .................................................................................. 53 Table 6.3-1: Launcher Availability .................................................................................................... 61 Table 6.3-2: Launcher Group Alarm Status ..................................................................................... 61 Table 6.3-3: Launcher Group Error Status ....................................................................................... 62 Table 6.3-4: Launcher Group Information Status ............................................................................ 62 Table 6.4-1: Density Hut Launch Availability ........................................................................................ 67 Table 6.5-1: Booster Pump Set Bxx Availability.................................................................................... 74 Table 6.5-2: Booster Pump Set Bxx Group Alarm Status ..................................................................... 74 Table 6.5-3: Booster Pump Set Bxx Group Error Status ...................................................................... 75 Table 6.7-1: Mainline Pump Set Pxx Availability.............................................................................. 86 Table 6.7-2: Mainline Pump Set Pxx Group Alarm Status ............................................................... 86 Table 6.7-3: Mainline Pump Set Pxx Group Error Status ................................................................ 86 Table 6.8-1: Mainline VSD Pump Set P0x Line-up Availability ............................................................. 98 Table 6.8-2: Mainline VSD Pump Set P0x Online, Offline and Flush Availability ................................. 98 Table 6.8-3: Mainline VSD Pump Set P0x Group Alarm Status ...................................................... 99 Table 6.8-4: Mainline VSD Pump Set P0x Group Error Status ........................................................ 99 Table 6.9-1: Mainline VSD Pump Set P0x Online, Offline and Flush Availability .......................... 107 Table 6.9-2: Mainline VSD Pump Set P0x Group Alarm Status .................................................... 107 Table 6.9-3: Mainline VSD Pump Set P0x Group Error Status ...................................................... 107 Table 6.10-1: P0x Lube Oil Ready Status ........................................................................................ 114 Table 6.10-2: P0x Lube Oil Availability ............................................................................................... 115 Table 6.11-1: Lube Oil DuC Availability ........................................................................................... 119 Table 6.12-1: HP Routing Flow compensation ................................................................................ 124 Table 6.12-2: HP Routing Group Alarm Status ................................................................................ 127 Table 6.12-3: HP Routing Group Error Status ................................................................................. 128 Table 6.12-4: HP Routing Group Information Status ....................................................................... 128 Table 6.13-1: Strainer (LP Intake) Group Alarm Status ................................................................... 134 Table 6.13-2: Strainer (LP Intake) Group Error Status .................................................................... 135 Table 6.15-1: PID Controller Modes of Operation .............................................................................. 151 Table 6.16-1: SIS Group – Group Alarm Status .............................................................................. 163 Table 6.17-1: Intermix Transfer Sequence Availability .................................................................... 167 Table 6.17-2: Sump Additional Device Alarm .................................................................................. 167 Table 6.18-1: Road Loading Availability .......................................................................................... 170 Table 6.19-1: Sump Injection Availability ........................................................................................ 180 Table 6.20-1: Purge Air DuC Availability .......................................................................................... 183 Table 7.19-1: Pumphouse Ventilation Fans Availability ...................................................................... 187 Table 7.19-2: Pumphouse Ventilation Fans Group Alarm Status ....................................................... 187 Table 6.21-1: Pressurisation DuC Availability .................................................................................. 190 Table 6.22-1: Inhibitor/DRA Injection Availability ............................................................................ 194 Table 6.22-2: Inhibitor/DRA Injection Group Alarm Status ............................................................. 195 Table 6.23-1: General - LP Station Statuses ................................................................................... 197 Table 6.23-2: General - HP Station Statuses................................................................................... 198 Table 6.24-1: Electrical Group Alarm Status .................................................................................... 203 Table 6.26-1: Diesel Supply Availability ........................................................................................... 211 Table 6.27-1: MV Generator Diesel Offloading Availability .............................................................. 216 Table 6.28-1: LP Routing Group Alarm Status ................................................................................ 219 Table 6.29-1: LP Routing Tables (Intake Manifold) ......................................................................... 226 Table 6.29-2: LP Routing Tables (Delivery Manifold) ...................................................................... 226

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Table 6.29-3: LP Routing Tables (Intake Manifold) ......................................................................... 228 Table 6.29-4: LP Routing Tables (Delivery Manifold) ...................................................................... 228 Table 6.29-5: LP Routing - Group Error Status................................................................................ 232 Table 6.32-1: Tank Farm TGS OPC Tag Descriptors ...................................................................... 241 Table 6.32-2: Tank Farm TGS OPC Global Alarm Acknowledge .................................................... 241 Table 6.32-3: Tank Farm TGS OPC Watchdog ............................................................................... 241 Table 6.32-4: Tank Farm TGS OPC Qualities ................................................................................. 242 Table 6.32-5: Tank Farm Group Alarm Status Indication ................................................................ 242 Table 6.32-6: Tank Farm Additional Device Alarm .......................................................................... 243 Table 6.33-1: SIS Group Alarm Status ............................................................................................ 249 Table 6.34-1: Prover Diesel Level Indication ................................................................................... 254 Table 6.34-2: Prover Online Availability ........................................................................................... 258 Table 6.34-3: Prover Offline Availability ........................................................................................... 258 Table 6.34-4: Prover Fill Availability ................................................................................................. 259 Table 6.34-5: Prover Drain Availability ........................................................................................ 260 Table 6.34-6: Prover Group Alarm Status ....................................................................................... 260 Table 6.34-7: Prover Group Error Status ........................................................................................ 260 Table 6.34-8: Prover Group Information Status ............................................................................... 261 Table 6.36-1: PLC Status Monitoring ............................................................................................... 271 Table 6.36-2: OS Server Status Monitoring ..................................................................................... 272 Table 6.36-3: Network Switch Status Monitoring ............................................................................. 273 Table 6.36-4: PC Hardware Status Monitoring ................................................................................ 273 Table 6.36-5: TGS Status Monitoring .............................................................................................. 274 Table 6.36-6: MMS Status Monitoring ............................................................................................. 274 Table 6.36-7: Inter PLC Communications Status Monitoring ........................................................... 275 Table 6.37-1: Station Line-Up Sequence Availability ....................................................................... 282 Table 6.37-2: Station Online Sequence Availability ......................................................................... 282 Table 6.37-3: Station Offline Sequence Availability ......................................................................... 282 Table 6.37-4: Station Isolation Sequence Availability ...................................................................... 283 Table 6.37-5: Station Flush Sequence Availability........................................................................... 283 Table 6.37-6: P01-P03 Flush Sequence Availability ........................................................................ 283 Table 7.2-1: LP Routing - PRDx Intake Route Tables ................................................................... 305 Table 7.2-2: LP Routing - PRDx Delivery Route Tables ................................................................ 310 Table 7.2-3: Prover Y01 Availability ............................................................................................... 315

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1 INTRODUCTION

1.1 Purpose

The purpose of this document is to specify the core automation requirements that are

required to be complied with in the design of a process control system for the Transnet

Pipeline’s pipeline infrastructure.

This document should be read in conjunction with its applicable references, as invoked

throughout the document, and listed in Section [2.1]. The PCS Software Control Module

Standard [3] defines the core control and HMI requirements pertaining to software control

module development (devices). The Alarm Configuration Database [6] defines alarms and

event messages associated with the PCS.

These three documents specify the end-user requirements regarding process control system

automation requirements. These three documents are primarily used by the Main Automation

Contractor to engineer the Process Control System software.

This document does not detail control to be implemented in other systems (e.g. the safety

instrumented systems, machine monitoring systems, etc.).

This document also forms an input for the development of Transnet Pipelines System

Operating Procedures.

This document contains all the high level user requirements. Station specific requirements are

included in the Station specific documentation and will be developed in conjunction with the

Contractor.

The requirements specified herein are system independent.

1.2 Scope

1.2.1 Requirements Included

This document includes control system device\instrument requirements relating to,

HMI Interface

Device Control

Sequence Control

Error handling

Alarming and messaging

Framework and device groups

1.2.2 Requirements Excluded

This document does not define requirements relating to,

Process Control System (PCS) software control modules (devices)

Metering Systems (MDS)

Tank Gauging Systems (TGS)

Pipeline Monitoring Systems (PLMS)

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Systems Application Products (SAP)

WAN Communication (WAN)

1.2.3 Process Control System Constraints

1.2.3.1 Performance Criteria

Performance criteria that need to be complied with when developing a process control

system can be found in the Process Control System User Requirement Specification [2].

1.2.3.2 Communication Constraints

The PCS WAN to the various stations within the Transnet Pipelines pipeline infrastructure are

via FOC and Microwave links. Bandwidth and latency specifications can be found in Tele-

control Communication Standard [8].

1.3 Document Usage

This document is intended to convey core requirements for the PCS.

All requirements included herein should be traceable to lower level documents to ensure

compliance.

In this specification,

the word shall is to be understood as a mandatory requirement,

the word should as a preference,

the word may as a permissive (i.e. neither mandatory nor necessarily

recommended),

and the word will as a declaration on behalf of something/ someone else.

The word ‘should’ shall be treated as a requirement, although it is acknowledged that it may

be negotiated based on appropriate justification.

Text indicated as 'Note' does not form part of this specification. Notes aid the reader's

understanding of the associated requirements.

1.4 Abbreviations

ACDB Alarm Configuration Database

ASCII American Standard Code for Information Interchange

CN Control Narrative

CO Co-ordinating Officer

DDF Detected Dangerous Failure

DH Density Hut

DIE Diesel

DSF SIF Diagnostic Failure

CP Effluent Control Panel

EDS Engineering Design Specification

EPV Expanding Plug Valve

ET Remote IO station

ETF Remote IO station in metering panel

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ETL Remote IO station in LV room

ETM Remote IO station in MV room

ETP Effluent Treatment Package

F&G Fire and Gas

FC Flow Computer

FDS Functional Design Specification

FP Flow-path

HP High Pressure

HVAC Heating, Ventilation and Air Conditioning System

I/O Input/Output

ICP Station Inlet Pressure (Incoming Pressure)

IFC Internal Floating Cover

IN Inland Network

JP Jameson Park Pump Station

JP0 Jameson Park Dispatch Manifold

KEN Kendal

LAN Local Area Network

LDS Leak Detection System

LOP Line Over-pressure Protection

LOPA Layer of Protection Analysis

LP Low Pressure

LPF Low Pass Filter

LRP Lead Replacement Petrol

LSD Low Sulphur Diesel

LV Low Voltage

LWC Line Wide Control

MAOP Maximum Allowable Operating Pressure

MBV Motorised Block Valve

MCC Master Control Centre

MDS Metering Database System

MES Manufacturing Execution System

MMS Machine Monitoring System

MoC Mode of Control

MoO Mode of Operation

MPP Multi-Product Pipeline

MTTR Mean Time to Repair

MV Medium Voltage

NMPP New Multi-Product Pipeline

NOC National Operating Centre (MCC)

OID Optical Interface Detector

OLE Object Linking and Embedding

OMS Operations Management System (Transnet Pipelines)

OPC OLE for Process Control

OS Operating System

OSI Open System Interconnection

P&ID Piping and Instrumentation Drawing

PCN Process Control Network

PCS Process Control System

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PCS7 Siemens PCS7 Process Control system (integrated PLC

and SCADA)

PET Petrol

PID Proportional, Integral, Derivative (controller)

PL1 Pipeline One (IVW to JMP - 24” Trunk Line)

PL2 Pipeline Two (JMP to ALR2 - 16” New)

PLC Programmable Logic Controller

PLCpm PLC product metering

PSD Pipeline Shutdown

PSx Pump Station x

QC Quality Control

RAT Process Range, Alarm and Trip Schedule

RTU Remote Termination Unit

S7 SIMATIC S7 Automation Equipment

SCADA Supervisory Control and Data Acquisition

SCC Secondary Control Centre

SDP Station Discharge Pressure

SIF Safety Instrumented Function

SIL Safety Integrity Level

SIS Safety Instrumented System

SO Station Operator

STA Station “Refer to Local Station Control”

SWCP Storm Water Control Panel

TA Trip Amplifier

TBA To be Advised

TBC To be Confirmed

TBD To be Defined

TCP Transmission Control Protocol

TCT Tank Capacity Table

TGS Tank Gauging System

TOP Tank Overfill Protection

TM1 Coastal Terminal (Terminal 1)

TM2 Inland Terminal (Terminal 2)

TMS Terminal Management System

TSM Tank State Machine

ULP Unleaded Petrol

ULSD Ultra Low Sulphur Diesel

VCF Volume Correction Factor

VSD Variable Speed Drive

WAN Wide Area Network

WB Wire Break

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1.5 Station Abbreviations

ALR Alrode

JMP Jameson Park (NMPP TM2)

KEN Kendal

APT Airport

BEM Bethlehem

CBK Coalbrook

DNR Durban

DUZ Duzi

EDP Elardus Park

FTM Fort Mistake

FYN Fynnlands

HLR Hillcrest

HTP Hilltop (NMPP PS3)

HWR Howick

IRP Intermix Refractionator Plant (Tarlton Refractionator)

IVW Island View (NMPP TM1)

KRO Kroonstad

KRP Klerksdorp

LAY Ladysmith

LLA Langlaagte

LRV Lions River (NMPP PS4)

MBT Mnambithi (NMPP PS5)

MGA Magdala

MGN Mngeni

MRR Mooi River

MTN Meyerton

NCS Newcastle

PWT Pretoria West

QGA Quaggasnek

RTR Rustenburg

SBG Sasolburg

SEC Secunda

TLR Tarlton

TNI Twini (NMPP PS1)

UBB Umbumbulu (NMPP PS2)

VDE Vrede

VLR Villiers (NMPP PS8)

VNN Van Reenen (NMPP PS6)

VRN Van Reenen

WAO Waltloo

WDN Warden (NMPP PS7)

WIL Wilge

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2 APPLICABLE DOCUMENTS

All documents of the exact revision cited in the Applicable Documents form part of this

specification to the extent specified. In the event of conflict between the text of this

specification and the documents invoked herein, the text of this specification shall take

precedence.

However, nothing in this specification supersedes applicable laws and regulations.

2.1 TPL Applicable Specifications and Standards

No. and Title Doc. No. Rev.

[1] Control System Policy TPL-TECH-I-

POL-001

03

[2] Process Control System User Requirements Specification

TPL-TECH-I-C-

SPEC-012

02

[3] Process Control System Software Control Module

Standard

TPL-TECH-I-C-

STD-013

01c

[4] Metering Policy TPL-TECH-I-

POL-002

03

[5] Metering Standard PL709 1.1

[6] Alarm Configuration Database 2684358-J-A00-

CS-DS-001

XX

[7] Segregated Process Control Metering Systems – Operational Implications

TPL-TECH-I-C-

SPEC-015

03

[8] Tele-control Communication Standard PL703 Latest

[9] Framework for Minimum Controls for Security in the

Process Control Environment

TPL-TECH-I-

PCE-006

02

[10] Transnet Group Legal: Intellectual Property Policy TG/GL 4/14/4 P 01

2.2 Other Applicable Specifications and Standards

The following national and international standards are required to be complied with and shall

be read in conjunction with this Specification.

No. and Title Doc. No. Rev.

[11] Quality Management Systems SABS ISO 9000 2015

2.3 Reference Documentation

The documents included in this section do not form part of the specification, but are included

for background and context.

No. Doc. No. Rev.

[12] Standard for Information Technology – Software IEEE 12207.0 1996

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Lifecycle Processes

[13] Custody Metering System User Requirements

Specification

TPL-TECH-I-M-

SPEC-011

02

[14] Plant & Equipment Tag Numbering Standards PL101 03

[15] General Drawing Standards PL103 03

[16] Safety and Environmental Standards for Fuel

Storage Sites – Final Report

Buncefield

Standards Task

Group

24 July

2007

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3 PROCESS CONTROL OVERVIEW

3.1 Stations

Stations (or depots as they are often referred to) are located at various points along the

various pipelines owned and operated by Transnet Pipelines and consist of the following

types:

3.1.1 Intake stations

These stations are used to introduce product into the pipelines and as such are fed from

client storage facilities via dedicated feeder lines. In order to accurately meter the volume of

product intake as well as to establish the quality of product taken in (used to establish both

accurate mass balances as well as percentage product degradation during product transfer)

the volume of product received is metered to API Standards.

Spheres and pigs may be introduced into the line for the purposes of cleaning of the pipeline

or separation of products. Pressure head is provided by means of multiple stage mainline

pump and motor sets.

3.1.2 Pump stations

These pump stations are used to maintain pressure head and each station consists of

multiple stage centrifugal mainline pump and motor sets.

Depending on pressure head requirements and in order to optimise both flow and pressure

requirements, various combinations of stages are run, usually with stages in reserve/backup

should a pump set fail.

Facilities included at these pump stations also include receivers to remove spheres from the

pipelines prior to product entering the mainline pump sets, launchers to re-introduce spheres

into the pipelines after the mainline pump sets in order to separate products, density

monitoring facilities to enable accurate sphere launch/transmix control and Intermixture

injection facilities to enable the injection of sump tank contents back into the mainlines.

3.1.3 Delivery stations

These stations are used to deliver product to clients at various stages along the pipelines, via

dedicated consignee feeder lines. To accurately establish the volume of product delivered,

the volume is metered to API Standards, via interface to a custody metering system.

Facilities at these delivery stations include intermix tank storage and blending facilities to

enable the re-introduction of intermixture from the intermix tanks back into the manifold as

well as storage facilities in the form of accumulator tanks. Introduction of intermixture

(consisting of transmix product) is accurately controlled in order to ensure that the quality of

product being transferred is not downgraded to fall outside of pre-arranged quality target set

points.

3.1.4 Terminal Facilities

Terminals receive, distribute and accumulate multiple products, usually on a per grade basis.

Products are usually custody transfer metered into Tankage. Tank Overfill Protection is

provided in accordance with “Safety and Environmental Standards for Fuel Storage Sites –

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Final Report’ as compiled by the Buncefield Standards Task Group dated 24 July 2007 and

API 2350 recommendations.

Product distribution out of the product dedicated accumulator tanks is accomplished by

accumulator / booster pumps, the purpose of which is to increase the product pressure to an

acceptable inlet pressure required by the mainline pumps. Outloading facilities are also used

to transfer product to rail and road tankers using batch controllers for measuring product to

these tankers.

3.1.5 Remote Block Valve Chambers

MBV Valve chambers are located along pipeline infrastructure between pump stations and are

used to isolate pipelines for maintenance and emergency shutdown purposes. Pressure and

temperature instrumentation installed in these chambers form an integral part of Pipeline

Monitoring Systems (PLMS) installed.

These sites are in most cases remote from stable power supplies, regular maintenance and

operational teams. All Automation and Communications equipment at MBV chambers are

backed up via UPS equipment, to increase the availability of the pipeline process control

signals transmitted to the Control System during local power failure conditions.

3.2 Tele-Control Facilities

The following facilities are available at the remote stations and are monitored and/or

controlled from the master control centre. It should be noted that tele-control facilities are

divided into two categories: facilities concerned with high pressure manifold control and

product transfer and those facilities concerned with low pressure manifold control and

product intake or delivery.

Detailed Functional Design Specifications detailing the control methodology to be adopted in

controlling these facilities/devices have been included in this Automation Standard.

3.2.1 Mainline Pump and Motor Sets (HP Manifold)

These mainline pump and motor sets consist of multiple stage centrifugal pump and motor

sets and are used to introduce additional pressure head into the pipeline.

Control of the mainline pump and motor sets requires interface and control of not only the

pump set itself but also the suction/inlet valve (hand operated), bypass and outlet/discharge

valves (motorised actuated). Indication of pump suction and discharge pressure is achieved

via means of pressure transmitters installed on the pump inlet and outlet lines respectively.

3.2.2 Receivers (HP Manifold)

Receivers are used to remove incoming spheres and pigs from the pipeline and comprise

mechanically of a receiving barrel, kicker and bypass line. The receiver is placed on and off

line by means of inlet, discharge and bypass valves (motorised actuated).

Imminent arrival and receipt of incoming spheres and pigs are indicated by sphere detector

switches mounted remotely on the pipeline and locally on the receiver barrel, with the primed

status of the receiver being indicated by low and high level switches mounted on the receiver

itself.

Draining and filling of the receiver is required to be performed manually.

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3.2.3 Launchers (HP Manifold)

Launchers are used to introduce spheres, batching pigs and scraper pigs into the pipeline and

mechanically consist of a launcher barrel, magazine, kicker and bypass line and either an

open cage basket valve or launcher pins for release of spheres into the main flow path.

The launcher is placed on and off line by means of inlet, discharge and bypass valves

(motorised actuated).

A sphere detector switch located downstream of the launcher discharge valve indicates

successful launching of spheres. Primed status of the launcher is indicated by feedback from

low and high level switches mounted on the launcher barrel and magazine respectively.

Draining and filling of the launcher is required to be manually done.

3.2.4 Sump Injection Facilities (HP Manifold)

Intermixture injection facilities at the remote stations comprise of sump tanks, used to collect

product from sources (typically when the receiver and launchers are drained of product or for

maintenance purposes and from thermal relief valves), and injection facilities used to re-

introduce product back into the line.

Sump injection may be controlled by means of an injector and venturi, with intermixture flow

rate being controlled indirectly using a control valve (motorised actuated) located in the high

pressure line, upstream of the venturi (controlling differential pressure across the venturi and

hence the intermixture flow rate).

At some stations the sump injection is implemented by pumping the product via sump pump

through the sump injection valve into the mainline.

3.2.5 Interface Handling Control Facilities (HP Manifold)

Interface Handling control facilities at remote stations comprise of instrumentation located on

the pipeline as follows: -

Remotely upstream of the station, in order to indicate the imminent arrival of an

interface.

Locally on the manifold, in order to give the operator a continuous indication of

product quality in order to assist in sphere launching and interface control.

Locally after the launcher in order to indicate quality of product leaving the station.

Launch control facilities in the form of a density hut, hydrometer and launch control panel are

also provided in order that the operator may perform manual launching.

3.2.6 Lube Oil Facilities.

Associated with the operation of some mainline pump and motor sets, forced lube oil control

may be required in order to provide a steady flow of lubrication oil to the pump and motor

bearings.

3.2.7 Purge Air Facilities.

Associated with the operation of some mainline motors, purge air control may be required in

order to comply with safety regulations and cooling requirements.

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3.2.8 Pressurisation Facilities

Associated with the operation of some remote stations, purging and pressurisation of control

rooms may be required in order to comply with Hazardous Area safety regulations.

3.2.9 Delivery Facilities (LP Manifold)

Delivery of product to a client is achieved via control system interface to both a delivery

manifold and metering system, with the flow rate being controlled by a flow control valve

located upstream of the delivery manifold.

3.2.10 Intake Facilities (LP Manifold)

Intake of product from a client is achieved via control system interface to both an intake

manifold and metering system, with the flow rate being controlled by a flow control valve

located downstream of the intake manifold.

3.2.11 Prover Loop Facilities (LP Manifold)

Prover loop facilities at delivery and intake stations are utilised to accurately establish meter

factors to be used in the metering of product to API Standards.

Control of the Prover loop operation consists of the transfer of a fixed volume of metered

product, for a specified number of cycles in order to establish a meter factor.

Facilities to fill and empty the Prover may be provided and consist of dedicated transfer tanks,

transfer pumps and associated inlet and outlet piping. Control of the filling and draining of

Provers may be effected by interface to the control system requiring the automatic or manual

control of all associated inlet and outlet valves, as well as the continuous level measurement

of the transfer tanks.

3.2.12 Intermixture Handling Facilities (LP Manifold)

Intermixture handling and injection facilities at the remote stations may comprise of intermix

tanks used to accumulate intermix product and pumping facilities used to re-introduce product

back into the line.

Accurate control of intermixture blending into product being delivered is required in order to

ensure that the product is not delivered out of specification.

Tanker Loading facilities may also be provided to transfer product via road tankers to the IRP

Plant (Refractionator). Intermix may also be transferred to the IRP Plant via pipeline in some

instances.

3.2.13 Accumulator Tank Facilities (LP Manifold)

Accumulator Tank facilities in the form of dedicated accumulator tanks are provided at

delivery/intake stations for the purposes of accumulating product. Facilities may include

transfer pumps; inlet and outlet valves (motorised actuators), level measurement and

independent overfill protection systems.

Product transfer to and from accumulator tanks are considered to form part of consignee

deliveries and is thus metered to API Standards.

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3.2.14 Booster Pump Spillback Control facilities

Booster pumps may require minimum flow spillback facilities, to ensure minimum flow

requirements. These facilities may also be used for inter-tank transfer.

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4 DEFINITIONS AND CONCEPTS

The purpose of this section is to clarify definitions and concepts that are applied throughout

the rest of this document.

4.1 Typographic Conventions

The terms "Latch" and "Unlatched" implies the use of "Set" and "Reset".

Binary operators are indicated in capital letters (e.g. AND, OR, NOT).

Note that for confident disambiguation, De Morgan's' theorem is applied to logical constructs

when converting between the positive and negative senses of the binary statement. e.g.

NOT(A AND B) = NOT(A) OR NOT(B).

Device States are denoted in Title Case (example valve Not Closed).

4.2 Device

Devices are defined as any field equipment that is monitored / controlled by the PLC System.

Controllable devices include the following:

Actuated valves

Control valves

Drives (Auxiliary pumps, fans, motors, etc.)

Mainline pumps (DOL, VSD, etc.)

Monitoring devices include the following:

Hand valves (ZV)

Analog instrumentation

Digital instrumentation

4.2.1 Device Fault

A detailed list of device faults is indicated in the Process Control System Software Control

Module Standard [3].

A device fault is any condition which indicates that the device is not operating correctly. For

example:

For actuated valves: Device Fault = Wire Break OR Control Error.

For ZV valves: Device Fault = Wire Break.

For 400V Aux Motors: Device Fault = Thermal Overload OR Soft Start Fault OR VSD

Fault OR Control Error.

For Analogs: Device Fault = Hardware Fault.

4.2.2 Device Available

A device is defined as being Available if the device is not in local and has no fault condition

and is not in Commissioning Mode.

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4.2.3 Open OR Wirebreak

The valve is Open OR in Wirebreak. This condition is typically used for the following:

Determination of a flow-path

Sequence availability in certain specific instances (for example HP isolation valve and

LP routing ZV's).

4.2.4 Closed OR Wirebreak

The valve is Closed OR in Wirebreak.

4.3 Device Group

A Device Group is defined as a collection of devices, grouped both logically and functionally

for the purposes of control and monitoring e.g. Receivers and Launchers.

4.3.1 Group Available

A device group is defined as being Available when all devices associated with a group are

available and all associated process conditions are healthy. Availability may be defined at a

device group or sequence level.

The Group Availability is indicated as follows:

Green = Available,

Yellow = Not Available

Every condition that is part of the Group Availability is displayed in the availability faceplate.

This condition will determine if the Group is Available for sequence control and may consist of

the following:

XV’s available

Mainline pump available

Auxiliary pump/fan available

ZV’s open

Process healthy (Level made, drains closed, etc.)

4.3.2 Group Ready

A device group is defined as being Ready when the device Group is Available and in

Automatic Mode of Operation. If the group is Not Ready, associated sequences cannot be

controlled. Ready may be defined at a device group or sequence level.

If the group becomes Not Ready, all associated online and flushing sequences are aborted.

Offline sequences are also aborted if defined as such.

4.3.3 Sequence Fault

A Sequence fault is active if any of the devices in the group that are controlled from the

sequence are Not Available during execution of the sequence:

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XV’s Not Available

Mainline pump Not Available

Auxiliary pump/fan Not Available

Instrument Fault, where defined as such

ZV’s are not included as they are not controlled from the sequences.

Note: Wirebreak is taken in most instances as an Open status when determining flow-path.

The Sequence Fault can be used to start the offline sequences where required.

4.3.4 Group Flow-path

A Group Flow-path bit is active when valves are in the state as described in the figure below.

Actuated valves and hand valves are evaluated for a Flow-path. Control valves are not

evaluated for a flow-path. Flow-path may be defined at a route or group level.

&

Group flowpath

&

Group flowpath

>=1

Open OR Wirebreak

>=1

Open OR Wirebreak

Valve open

Valve Wirebreak

>=1

Open OR Wirebreak

Valve open

Valve Wirebreak

>=1

Open OR Wirebreak

>=1

Open OR Wirebreak

Valve open

Valve Wirebreak

>=1

Open OR Wirebreak

Valve open

Valve Wirebreak

Valve typical

Valve typical

Figure 4.3-1: Group Flow-path logic

4.3.5 Group Flushing

[For Device Groups that require to be flushed e.g. receivers, launchers, HP strainers, mainline

pump sets]

Flushing is initiated by operator request, interface detection or by route change (site

dependent). Flushing will be terminated based on operator request.

A “Not flushed” status is determined by a device group not being placed on flush within a

configurable time (configurable within the PLC, for each device group) after flushing is

initiated.

Flushed status for device groups is not tracked.

For additional details, refer to the individual group flush details.

4.4 Control Modes (Overview)

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4.4.1 Modes of Control

The control mode defines the location that has control. Mode of Control affects the operator’s

ability to control a device (example by issuing commands) from the PCS.

The PCS will evaluate the control mode for each device and determine if the control or

change functions are allowed. These control and change functions are:

Control requests

Substitute selection and substitute value/state change

Any other operator requests or changes

Alarm handling (Routing, acknowledgment, suppression)

All requests emanating from sources other than from the location in control is blocked on the

PCS.

For automatic control across groups, all associated groups need to be in the same MoC. This

is typically used for station sequences.

Modes of Control are latched internally and are linked to all the devices in a Device Group.

On a cold restart or power up of the PCS, all HP groups default to MCC mode of control and

all LP groups default to Station mode of control, unless otherwise superseded for a group in

station specific EDS’s.

Two modes of control are defined as follows:

4.4.1.1 Station

This is defined as the mode in which control requests to the Control System can only be

issued from the SCADA situated at the station itself.

4.4.1.2 MCC

This is defined as the mode in which control requests to the Control System can only be

issued from the SCADA situated at the Master Control Centre in Durban.

4.4.2 Mode of Operation

Modes of Operation are latched internally and are linked to all the devices in a Device Group.

On a cold restart or power up of the PCS, all groups default to automatic mode of operation,

unless otherwise superseded for a group in station specific EDS’s.

4.4.2.1 Local

In this mode, control of a Device occurs either from the device itself (in the case of valve

actuators) or from Starter Panels in the Switchgear Room (in the case of Motors). Note that

although control action from the PCS is ignored in this mode, hard-wired interlock

functionality remains enabled (e.g. Pump Switchgear Trips, etc.). The PCS still monitors and

indicates the status of the devices in local.

Hardwired trips (either independent of the PCS or emanating from the PCS and hardwired to

operate in Local) are active in this mode.

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4.4.2.2 Manual

In this mode, control of a Device occurs from the PCS System. Note that when in manual

mode of operation, direct control of the device is possible with responsibility for control of the

plant resting with the operator.

Hard wired PLC trips and PLC Interlocking are active in this mode.

Responsibility for selecting Control Modes of Operation (MAN/AUTO) for Device Groups shall

remain the responsibility of the Operator who is in control of the Group i.e. a Group will

remain in MANUAL Mode until the Operator changes to AUTOMATIC Mode and vice versa.

4.4.2.3 Automatic

In this mode, device groups are controlled by the PCS via control sequences initiated via the

PCS.

In automatic, devices are controlled via the automatic commands. The automatic commands

are switched from:

Sequences

Duty controller

Hard wired PLC trips and PLC Interlocking are active in this mode.

Responsibility for selecting Control Modes of Operation (MAN/AUTO) for Device Groups shall

remain the responsibility of the Operator who is in control of the Group is, i.e. a Group will

remain in AUTOMATIC Mode until the Operator changes to MANUAL Mode and vice versa.

4.5 Route Definitions

(For purpose of illustration, a route is considered containing three valves, namely XV1, XV2

and ZV3).

Primary Route Primary route is defined as the first delivery/intake route selected for

a product.

Transition Route Transition route is defined as the second delivery/intake route selected for a product. Transition occurs when the delivery/intake

route is switched from the primary to the transition route.

Route Closed Any one (1) valve on the route is confirmed Closed.

Route Closed = XV1 Closed OR XV2 Closed OR ZV3 Closed.

Route Not Closed All valves on the route are confirmed Not Closed.

Route Not Closed = Not (Route Closed) = XV1 Not Closed AND XV2

Not Closed AND ZV3 Not Closed

This status is used by PLMS to determine a flow-path.

Route Open All valves on the route are confirmed Open. LP ZVs and HP isolation valves include wirebreak in the Open condition.

Route Open = Header Closed AND XV1 Open AND XV2 Open AND

ZV3 Open/Wirebreak.

Route Offline All valves on the route except ZVs are confirmed Closed. Other

conditions may be required for the Offline state depending on the specific route. For example, if the route contains pumps, then Pump

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Not Running.

Route Offline = XV1 Closed AND XV2 Closed.

Route Online All valves on the route are confirmed Open. LP ZVs and HP isolation

valves include wirebreak in the Open condition. Other conditions may

be required for the Online state depending on the specific route. For example, if the route contains pumps then Pumps in a Running state

etc.

Route Online = XV1 Open AND XV2 Open AND ZV3 Open/Wirebreak.

Valid Flow-path All valves on the route are confirmed Open/Wirebreak.

Valid Flow-path = XV1 Open/Wirebreak AND XV2 Open/Wirebreak AND ZV3 Open/Wirebreak.

No Valid Flow-path

No Valid Flow-path = Not (Valid Flow-path)

4.6 Interlocks

4.6.1.1 Hard wired interlocks

Hard-wired Interlocks are defined as interlocks, which are physically wired and act

independently of the control system. Due to safety reasons, these may not be overridden.

Hard-wired Interlock functionality remains active in all modes of operation i.e. automatic,

manual and local.

For example:

Emergency stop push button hardwired into motor bucket

Safety Instrumented Function trip

TVR trip emanating from PLC and hardwired into motor bucket.

4.6.1.2 PLC Interlocks and Trips

PLC Interlocks/trips are programmed in the PLC and due to safety reasons, should not be

overridden e.g. tank inlet valve is interlocked closed on activation of a high level switch.

PLC interlock and trip functionality remains active in both manual and automatic mode of

operation i.e. not in local, with the exception of motor protection trips which remain active in

all three modes of operation.

TRIP action is associated with device protection and returns a device to a predefined safe

state until the condition that caused the trip has been removed (e.g. All Motor Protection

Trips). A trip condition is indicated on the control system graphic by means of a flashing red

device symbol and is only active within an associated device group i.e. never across device

groups.

INTERLOCK action is associated with process safety functions and returns the process to a

predetermined safe state and holds the process in that state until the condition that caused

the interlock has been removed (e.g. associated control valve is closed on tank high level).

An interlock condition is indicated on the control system graphic by means of a purple border

around the device being interlocked and may be active both within and across device groups.

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4.7 Switching definitions

Switching applies to manifolds that have more than one route configured and apply to both

LP and HP manifolds.

Switching may be performed manually or automatically using online sequences for HP routing

and start intake/delivery sequences for LP routing.

4.7.1.1 Open Switch

When switching product from route A to route B, the valve/s to route B is/are opened while

the valve/s to route A is/are still fully open. Flow is not stopped during open switching.

4.7.1.2 Closed Switch

When switching product from route A to route B, the valve/s to route B is/are opened only

when the valve/s to route A is/are fully closed. Flow is stopped during a transfer operation.

4.7.1.3 Fly Switch

When switching product from route A to route B, the valve/s to route B is/are opened whilst

valve/s to route A is/are being closed. Flow is not stopped during fly-switching. Fly-switching

is not permitted on custody metered routes as fly-switching is not supported by the Custody

Metering Systems installed on Transnet Pipeline depots. Fly-switching can also cause a

blocked flow path if associated valve/s is/are not fully open and can cause upstream pressure

build-up.

4.8 General

Consignee Valve The customer destination valve, receiving product from the network.

(Delivery Station).

Consignor Valve The customer source valve, receiving product into the network. (Intake Station).

Controller A device or program that operates automatically to regulate a controlled variable.

PID Controller A controller that produces proportional-plus-integral (reset)-plus-derivative (rate) control action.

Intermix Intermix is any mixture of diesel, petrol, and jet fuel or off-spec

product. As pipelines contain more than one product batch there is an interface between products where mixing occurs.

4.9 Sequence Control

4.9.1 Sequence Control Matrix

Control and monitoring of Routing Sequences for the following device groups within the PCS

is standardized using a Sequence Control Matrix:

HP Routing

LP Routing

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Prover

Intermix Blend Control

Inter-tank Transfers and Transfers from Sump

The Matrix lists all route sources in the left column and all route destinations in the top row.

Routing Sequence statuses are displayed using a standard sequence icon. Sequence statuses

and availability are indicated on the Matrix by means of colour.

Figure 4.9-1: Typical Matrix Status Indications

The operator can select the route he wants to place online or offline from the matrix by

selecting the applicable route sequence icon by means of source and destination. This will

open up a dialog box with an online and offline sequence selection.

Figure 4.9-2: Typical Sequence Matrix for Intermix Blend & Transfer

4.9.2 Sequences

Sequences are used for the automatic control of Device Groups. In automatic Mode of

Operation, the PLC stops and starts sequences according to operator group commands,

process conditions, process errors or other sequences.

SFC charts are used to ensure step-by-step execution of sequences. SFC Charts comprise of

Steps (which contain control requests that are required to be executed) and transitions

(which contain conditions that are required to be fulfilled prior to moving to the next Step).

Device control requests are issued to device typicals from within SFC Steps, with device

feedback status forming part of conditions defined in the SFC Transition. Control Errors

generated from control requests will cause associated Device Groups to become not available

and will cause the sequence to stop, if defined as such.

The Transition checks for the correct feedback of the devices switched in the active Step. The

transition of an offline sequence that continues running on a fault also checks if the device is

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not available. This enables the sequence to continue even when a control command has not

been successfully executed.

4.9.2.1 SFC Legend

START

XV R1A Opened

END

Open R1AOpen

XV R1A

1 0s

Maximum execution time

(default if not used)

Minimum execution time

(Only shown where applicable)

Step number

-s

Start Step

End Step

Step actionText description to be

displayed to operator

Transition condition

Empty Transition condition = “True”

All faults during the process

result in the sequence aborting,

complete with all associated

alarming and event logging.

Figure 4.9-3: SFC Legend

4.9.2.1.1 Start Step

This step is normally used to reset all the commands that are used in the sequence. This is

not really required as every sequence command is reset in the step.

4.9.2.1.2 Start Transition

This transition is usually empty.

4.9.2.1.3 Step Action

Indicates the action that is taken in the step. If more than one device is used, they all need

to be listed.

4.9.2.1.4 Step Number

The step number is used for documentation reference purpose. It may differ in the software.

The step number is unique per sequence.

4.9.2.1.5 Step Comment

The comment field should give a basic indication of the action that is taken. The detailed

device command associated with the steps will be reflected in the step itself in SFC

visualization, and will give the operator an indication of all the actions and transition

associated with the step.

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4.9.2.1.6 Step Monitoring Time

The step time shown is the maximum step time after which the sequence will abort. Typically

this value is used as a catch-all.

If the monitoring time is not used, -s is to be written.

4.9.2.1.7 Step Waiting Time

This time indicated the minimum time a step will wait until it continues.

This time should only be used when it is necessary to wait a time period i.e. for flushing.

If the waiting time is not used, 0s is to be written.

4.9.2.1.8 Transition Condition

List all devices that need to be checked for the correct feedback. If all conditions are met,

then the next step in the sequence is executed.

4.9.2.1.9 End Step

This step is normally used to reset all the commands that are used in the sequence.

4.9.2.2 Alternative Branch

START

XV3 Opened

Open XV3OpenXV3

3 -s

END

XV2 Opened

Open XV2OpenXV2

2 -s

XV1 Opened

Open XV1OpenXV1

1 -s

Condition 1 Condition 2





Figure 4.9-4: Alternative Branch

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4.9.2.3 Simultaneous Branch

START

XV3 Opened

Open XV3OpenXV3

3 -s

END

XV2 Opened

Open XV2OpenXV2

2 -s

XV1 Opened

Open XV1OpenXV1

1 -s





Figure 4.9-5: Simultaneous Branch

4.9.2.4 Abort on Error

START

XV R1A Open ANDXV R1E Open

END

Open R1A, R1EOpen XV R1AOpen XV R1E

1 -s





Figure 4.9-6: Abort on error

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4.9.2.5 Continue on Error

START

XV R1A Open Or Not Available

END

Open R1AOpen XV R1A

1 -s


result in the sequence

continuing, complete with all

associated alarming and event

logging.

Figure 4.9-7: Continue on Error

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5 GENERAL CONTROL PHILOSOPHY - DEVICES

The core requirements applicable to software control modules (devices) utilized within

Process Control Systems are detailed in the Process Control System Software Control Module

Standard [3] and Alarm Configuration Database [6].

These requirements specify the end-user requirements regarding control and HMI

requirements.

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6 GENERAL CONTROL PHILOSOPHY – DEVICE GROUPS

6.1 Introduction

The following Device Groups are usually associated with HP Manifold facilities:

Receiver

Launcher and Interface Handling

MV Booster Pump Set (DOL) – Series Configuration

MV Booster Pump Flow Control

MV Mainline Pump Set (DOL) – Series Configuration

MV Mainline Pump Set (VSD) – Parallel Configuration

Lube Oil System (Mainline Pumps) – 24” MPP Stations

Lube Oil System (Mainline Pumps) – RPP/COP Stations

HP Routing

Dual Strainers

Flow Control – HP Application

Duty & Speed Control (VSD) – Parallel Configuration

SIS – Line Over-Pressure Protection

Sumps & Intermix Transfer (including Road Loading)

Sump Injection (Venturi)

Purge Air Fans

Pressurisation Fans

Inhibitor & DRA (Drag Reducing Agent) Injection

General (including Utilities, Instrument Air, Fire Systems)

Electrical Distribution (including MV Gensets, Diesel Supply and Diesel Offloading

facilities)

System Diagnostics

Station Sequences

The following Device Groups are usually associated with LP Manifold facilities:

LP Routing - General

LP Routing - Product Groups

Flow Control – LP Application

Prover

Tank Farms

SIS – Tank Overfill Protection

Intermix Blend Control

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6.2 Receiver Device Group

This section is associated with the control and monitoring of the Receiver Device Group.

Receivers are used to remove incoming spheres and pigs from the pipeline and are installed

on most TPL Stations where pigging operations are required.

6.2.1 Group Description

The Receiver Group may be controlled either in automatic, manual or local mode. Receiver

pressurisation and sphere removal however, remains a local operation. This functionality

requires the installation of motorised actuators on the Bypass, Inlet and Outlet Valves, as

well as the installation of both low and high level switches on the receiver to ensure

successful draining and filling prior to being placed on-line.

The Receiver is classed as a pressure vessel and thus a local pressure gauge is installed on

the Receiver to provide local indication of the pressure within the Receiver Barrel.

A Local Sphere Detector is located within the Receiver barrel to provide an indication of

spheres received. Sphere Detector switches are mounted remotely to provide an indication of

the impending arrival of Spheres. Two types of sphere detectors may be installed; namely

non-intrusive and intrusive. Where intrusive types are used, two are installed for reliability

purposes. Pulses received from the sphere detectors are interfaced into high-speed interrupt

modules. A software based counter is associated with each sphere detector switch.

Receiver valve actuators are selected to ensure that the time it takes to place the Receiver on

line is faster than the time it takes for the sphere to reach the receiver after the sphere has

been remotely detected.

It should be noted that four different types of spheres are used as follows: -

Intelligent Pigs

Batching Pigs

Cleaning Pigs

Spheres

Receiver/Launcher Transfer Tanks may be installed and used to hold receiver product during

draining operations. This product is then re-introduced back into the receiver before being

placed back online. Use of transfer tanks is intended to reduce the amount of intermix

created during maintenance operations. These facilities comprise of a transfer tank, routing

valves, and transfer pump. This operation is intended to be a manual operation, locally

controlled by the operator. The valves are thus hand-operated, and the pump locally

controlled. No level transmitter is installed on these transfer tanks.

Control and monitoring functionality is achieved via the following devices:

Instruments

Remote Sphere Detector/s ZI x01/x02 Receiver Sphere Detector ZI x03

Receiver Low Level LSL x01

Receiver High Level LSH x02 Remote Sonic Velocity KT x01*

Receiver Transfer Pump Flow FS x01 Receiver Transfer Pump Current IT x01

* Devices form part of another group

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Valves

Receiver Inlet Valve XV RxA Receiver Inlet Isolation Valve ZV RxB

Receiver Outlet Valve XV RxE

Receiver Outlet Isolation Valve ZV RxF Receiver Inlet Bleed Valve ZV RxT

Receiver Outlet Bleed Valve ZV RxU Receiver Bypass Valve XV RxK

Receiver Drain Valve ZV FxA

Receiver Transfer Outlet Valve ZV FxE Receiver Transfer Inlet Valve ZV FxB

Receiver Transfer 4-Way Valve ZV FxR

Pumps

Receiver Transfer Pump X0x

6.2.1.1 Functional Layout of the Receiver

To have clarity when describing the function of the Receiver, the layout and position of the

valves and instrumentation must be defined.

The diagram below shows the functional layout of the Receiver indicating where the valves

and instrumentation are located.

XV R1E

XV

R1

K

ZV

R1

W

ZI

101

ZI

103

LSL

101

LSH

102

Remote Chamber

To

Strainers

From

Upstream

StationZV R1B

ZV

R1

TZ

V R

1U

KT

101

To Sump

Figure 6.2-1: Functional Layout of the Receiver R01


The Receiver may be controlled from the PCS either locally at the Station or remotely from

the MCC.

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6.2.3 Modes of Operation

All devices related to the Receiver shall have the following three Modes of Operation:

Local

Manual

Automatic

6.2.4 Group Functionality

6.2.4.1 Mode

A single software control module has been developed to cater for both receiver and launcher

device group functionality. Receiver or launcher functionality is selected by means of the

Mode selector and is either hard-coded for uni-directional receivers/launchers or

automatically changed based on flow direction for bi-directional receivers/launchers.

6.2.4.2 Receiver States

6.2.4.2.1 Receiver Online

The Receiver is in an Online state if:

XV RxA is Opened AND

ZV RxB is Opened AND

XV RxE is Opened AND

ZV RxF is Opened AND

XV RxK is Closed

6.2.4.2.2 Receiver Offline

The Receiver is in an Offline state if:

XV RxA is Closed AND

XV RxE is Closed AND

XV RxK is Opened

6.2.4.3 Receiver No Valid Flow-path Status

A Valid Flow-path for the Receiver exists if the following conditions are met:

XV RxK

OR

XV RxA AND

ZV RxB AND

XV RxE AND

ZV RxF

Note that the "Open OR Wirebreak" state is required from each device.

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6.2.4.4 Remote Sphere Counter Control

The Remote Sphere Detector Switch/es (ZI x01/02) are used to provide input for software

implemented Remote Sphere Counter/s in Receiver Mode. The Remote Sphere Counter/s

shall be incremented on successful detection of incoming pigs or spheres.

The Remote Sphere Counter/s are reset (set to zero) in two possible ways:

By the operator from either of the Remote Sphere Counter faceplates

Change in Mode (Launcher/Receiver)

When the Local Sphere Counter is reset by the operator from the faceplate, the Remote

Sphere Counter/s are set to the difference between the Local and Remote Sphere Counters,

in order to accurately indicate outstanding pigs or spheres not yet received.

6.2.4.5 Local Sphere Counter Control

The Local Sphere Detector switch (ZI x03) is used to provide input for a software

implemented Local Sphere Counter in Receiver Mode. The Local Sphere Counter shall be

incremented on successful detection of incoming pigs or spheres in order to indicate the

number of pigs or spheres received.

The Local Sphere Counter is reset (set to zero) in two possible ways:

By the operator from the Local Sphere Counter faceplate


6.2.4.6 Double Block and Bleed Valves

Double block and bleed valves may be installed at the inlet of the Receiver as well as on the

kicker line, in addition to the existing Receiver Inlet and Outlet valves. These double block

and bleed valves are installed as safety isolation valves to be utilized during maintenance and

or pig or sphere retrieval. Valves of size > 400NB will be actuated and interfaced into the

Control system as ZV valves.

The first block valve on both the inlet and outlet will be actuated and controlled during the

normal Receiver operation.

The second block valve and bleed valve on both the inlet and outlet of the Receiver will be

hand operated, with the block valve being left open and the bleed valve closed during normal

operation. These valves will then be hand-operated during maintenance and or pig or sphere

insertion. Both these valves will have feedback interfaced to the control system and will form

part of the availability of the Receiver.

6.2.4.7 Receiver Flushing

A Receiver Flush Online Request is activated, on receipt of:

a Flush Online Request from the SCADA, if not Online OR

a Manifold Flush Request from the SCADA Overview Screen, if not Online (Station

dependent) OR

a Route change (Station dependent)

On receipt of a Receiver Flush Online Request, the Receiver Online Sequence is initiated if

Ready and not already online.

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Flushing will be terminated by initiating the Receiver Offline Sequence, based on operator

request.



initiated.

6.2.4.8 Receiver Flags

These flags are raised by the process control software as configured on the Receiver block.

The flags are used to generate Group Status Indications, Group Availability Indications and

for Group Event and Group Alarm logging. The triggering of each flag is described here in

detail.

6.2.4.8.1 Sphere Outstanding

A Sphere Outstanding flag is raised when either of the Remote Sphere Counters indicates a

value greater than the Local Sphere Counter. This flag is only raised in Receiver Mode.

The Sphere Outstanding flag will be cleared when both Remote Sphere Counters indicate a

value that is equal to or less than the Local Sphere Counter (i.e. all outstanding spheres are

received or the counters are reset by the operator).

6.2.4.8.2 Remote Sphere Detector Fault

If the Remote Sphere Counters differ one from another (in the case where two remote

detectors are installed); OR if the Local Sphere Counter indicates a value greater than any of

the Remote Sphere Counters (i.e. the local sphere detector detects a sphere and the remote

detector/s do not), a remote detector fault alarm is generated. This flag is only raised in

Receiver Mode.

The Remote Sphere Detector Fault flag is cleared when all the sphere detector counters are

reset (set to zero).

6.2.4.8.3 Remote Sphere Detected

If either remote sphere detector is activated, the operator will receive an alarm “Remote

Sphere detected” in receiver mode. This Alarm condition is automatically cleared after a

configurable time (default 10 seconds).

6.2.4.8.4 Incoming Sphere Not Received

If either Remote Sphere Detector switch is triggered and a timer (configurable in the PLC)

has elapsed from time of detection, before the Local Sphere Detector switch is triggered, an

Incoming Sphere Not Received flag is raised. This flag is only raised in Receiver Mode.

The Incoming Sphere Not Received flag is automatically cleared after configurable time

(default 10 seconds).

6.2.4.8.5 Sphere Detected - Receiver Not Online

When a pig or sphere has been detected by a Remote Sphere Detector switch i.e. the Sphere

Outstanding flag is raised, and the Receiver is either;

not Online (as determined by valve status) and not Ready OR,

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device failure while running the Online sequence OR,

receiver not online timer (configured as the time it takes the Receiver to reach an

Online state) has expired;

a Sphere Detected – Receiver Not Online flag is raised. Note that if the receiver is not Online

and not Ready, the flag is set immediately. This flag is only set in Receiver Mode.

The Receiver Not Online flag is cleared if the Receiver is placed online or when both Remote

Sphere Counters indicate a value that is equal to or less than the Local Sphere Counter (i.e.

all outstanding spheres are received or the counters are reset by the operator).

6.2.4.8.6 Receiver Not Primed

The Receiver Not Primed flag is the inverse of Level Full, refer to Section 6.2.4.8.13.

6.2.4.8.7 Receiver Trap Full

If the Local Sphere Counter reaches capacity – 1, configured in the PLC, a Trap Full flag is

raised. The default capacity is set at 7. This flag is only raised in Receiver Mode.

The Trap Full flag is cleared when the Local Sphere Counter is reset to zero.

6.2.4.8.8 Receiver Trap Fault

If a Trap Full flag is raised and another remote pig or sphere is detected a Trap Fault flag is

raised.

The Trap Fault flag is cleared when the Local Sphere Counter is reset to zero.

6.2.4.8.9 Receiver Fault

The Receiver fault flag is set when a Sphere Detected - Receiver Not Online or a Trap Fault

Alarm condition is detected. This status is communicated to Line Wide Control as part of

Station Statuses.

6.2.4.8.10 Receiver Flow-path

The Receiver Flow-path flag is raised whenever the Receiver has a valid flow-path as defined

in Section 6.2.4.3.

6.2.4.8.11 Receiver Not Flushed

The Not Flushed flag is raised under the following conditions:

Receiver Flush Online request initiated

AND

device failure while running the Online sequence OR Receiver Not Online timer

(configured as the time it takes the Receiver to reach an Online state) has expired.

The Not Flushed flag is cleared if the Receiver is placed online as determined by valve status.

6.2.4.8.12 Possible Hotspot

Should a Receiver not be flushed (i.e. the "Receiver Not Flushed" flag is raised) AND an

Interface is not present in the Online route (Interface in Station Flag set High), and the

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Receiver moves from an Offline state (as determined by valve status), a Possible Hotspot flag

is raised.

This alarm is cleared when the Receiver goes Online.

6.2.4.8.13 Level Full

The Level Full indication is provided when both the Receiver High Level switch (LSH x02) and

the Receiver Low Level switch (LSL x01) indicate a High level. Substitute (operator action)

and override values (device fault) are used when determining this state.

6.2.4.8.14 Level Not Empty

The Level Not Empty indication is provided when the Receiver High Level switch (LSH x02)

indicates a Low level and the Receiver Low Level switch (LSL x01) indicates a High level.

Substitute (operator action) and override values (device fault) are used when determining

this state.

6.2.4.8.15 Level Empty

The Level Empty indication is provided when both the Receiver High Level switch (LSH x02)

and the Receiver Low Level switch (LSL x01) indicate a Low level. Substitute (operator

action) and override values (device fault) are used when determining this state.

6.2.4.8.16 Level Switches Fault

The Level Switches Fault indication is provided when the Receiver High Level switch (LSH

x02) indicates a high level and the Receiver Low Level switch (LSL x01) indicates a low level.

When either the high or low level switch is faulty (hardware fault, signal out of range), the

faulty switch automatically defaults to the override value of 7.77mA (low level). The faulty

level switch will thus be red in colour except for the case where the low level switch is in fault

and the high level switch indicates a high condition. In this implausible case, both level

switches will be blue in colour to indicate an implausible state.

6.2.4.9 Receiver Online Sequence

The Receiver Online Sequence is activated, if Ready, on receipt of:

an Online Request from the SCADA, OR

a signal from the Remote Sphere detector, if not Online, OR

a Receiver Flush Online Request

If Ready, the Receiver Inlet and Outlet valves are opened and on successful completion the

Bypass valve is closed.

The following conditions while the sequence is running will result in the sequence aborting,

complete with all associated alarming and event logging:

Any actuated valve Not Available (XV RxA, XV RxE, XV RxK)

Any Drain or Fill valve Not Closed (ZV RxU, ZV RxT, ZV FxA)

Any Inlet/Outlet ZV valve Not Opened (ZV RxB, RxF)

Level Switches Fault (LSH x02, LSL x01 in Fault or Implausible)

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Placing the Group in Manual mode

See flow diagram for details:

7.2.1.1: Receiver R01 Online Sequence

6.2.4.10 Receiver Offline Sequence

The Receiver Offline Sequence is activated, if Ready, on receipt of:

an Offline Request from the SCADA

If Ready, the Receiver Bypass valve is opened and on successful completion, the Receiver

Inlet and Outlet valves are closed.



Any actuated valve Not Available (XV RxA, XV RxE, XV RxK)

Any Drain or Fill valve Not Closed (ZV RxU, ZV RxT, ZV FxA)

Any Inlet/Outlet ZV valve Not Opened (ZV RxB, RxF)

Level Switches Fault (LSH x02, LSL x01 in Fault or Implausible)



7.2.1.2: Receiver R01 Offline Sequence

6.2.5 Group Availability

6.2.5.1 Receiver Availability

The following conditions will render the Receiver Device Group “Not Available”.

Condition Text Logic

Receiver Not Primed Receiver Not Primed Refer to Section 6.2.4.8.6

Receiver Trap Full and Offline

Receiver Trap Full & Offline Refer to Section 6.2.4.8.7 and Section 6.2.4.2.2

Sphere Outstanding and

Online

Sphere Outstanding & Online Refer to Section 6.2.4.8.1 and

Section 6.2.4.2.1

XV RxA Not Available XVRxA Not Avail Refer to [3]

XV RxE Not Available XVRxE Not Avail Refer to [3]

XV RxK Not Available XVRxK Not Avail Refer to [3]

ZV RxB Not Open ZVRxB Not Opened Refer to [3]

ZV RxF Not Open ZVRxF Not Opened Refer to [3]

ZV RxT Not Closed ZVRxT Not Closed Refer to [3]

ZV RxU Not Closed ZVRxU Not Closed Refer to [3]

ZV FxA Not Closed ZVFxA Not Closed Refer to [3]

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Level Switches Fault Level Switches Fault Refer to Section 6.2.4.8.16

Table 6.2-1: Receiver Availability

6.2.6 Group Status

6.2.6.1 Receiver Group Status

The following status indications are to keep the Operator informed of the status of the

Receiver.

6.2.6.1.1 Group Alarm Status Indication

The following Group Alarm Statuses are configured using display LEDs which are grey in the

inactive condition and red in the active condition, with an associated alarm. Refer to the

ACDB (1) for details, including the text to be used for the alarm messages.


Sphere Detected - Receiver Not Online

Sphere Det-Receiver Not Online

Refer to Section 6.2.4.8.5

Possible Hotspot Possible Hotspot Refer to Section 6.2.4.8.12

Incoming Sphere Not

Received

Incoming Sphere Not Received Refer to Section 6.2.4.8.4

Receiver Trap Full Receiver Trap Full Refer to Section 6.2.4.8.7

Receiver Trap Fault Receiver Trap Fault Refer to Section 6.2.4.8.8

Remote Sphere Detector

Fault

Remote Sphere Detector Fault Refer to Section 6.2.4.8.2


Remote Sphere Detected Remote Sphere Detected Refer to Section 6.2.4.8.3

Table 6.2-2: Receiver Group Alarm Status

6.2.6.1.2 Group Error Status Indication

The following Group Error Statuses are configured using display LEDs which are grey in the

inactive condition and red in the active condition, with an associated event. Refer to the

ACDB (2) for details, including the text to be used for the event messages.


No Valid Flow-path No Valid Flow-path Refer to Section 6.2.4.3

Receiver Not Flushed Receiver Not Flushed Refer to Section 6.2.4.8.11

Table 6.2-3: Receiver Group Error Status

6.2.6.1.3 Group Information Status Indication

The following Group Information Statuses are configured using display LEDs which are grey

in the inactive condition and green in the active condition, with an associated event. Refer to

the ACDB (2) for details, including the text to be used for the event messages.


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Level Full Level Full Refer to Section 6.2.4.8.13

Level Not Empty Level Not Empty Refer to Section 6.2.4.8.14

Level Empty Level Empty Refer to Section 6.2.4.8.15

Table 6.2-4: Receiver Group Information Status

6.2.7 Group Interlocks

6.2.7.1 Hardwired Interlocks

None defined.

6.2.7.2 PLC Interlocks

6.2.7.2.1 X0x: FS x01 No Flow

If a low flow (FS x01) is detected for a configurable time (default 5s) after the pump is

started, the Receiver Transfer Pump (X0x) will be interlocked off. This interlock and

associated alarm is blocked if the Pump is not running.

6.2.7.2.2 X0x: IT x01 Current Low

If an alarm low current (IT x01) is detected for a configurable time (default 5 seconds) and

the pump is running, the Rx Transfer pump (X0x) will be interlocked off. This interlock and

associated alarm is blocked if the Pump is not running.

6.2.7.2.3 X0x: LT x31 Sump Level High

If the Manifold Sump Tank Level High Alarm (LT x31) is reached the Receiver Transfer pump

(X0x) will be interlocked off.

6.2.8 Failure Modes

None defined.

6.2.9 Graphic Representation

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6.3 Launcher

This section is associated with the control and monitoring of the Launcher Device Group.

Launchers are used to introduce spheres, batching pigs and scraper pigs into the pipeline and

are installed on most Stations.


The Launcher group can be controlled in automatic or in manual, whilst Launcher

Pressurisation and Sphere Loading remain local operations. This Functionality requires the

installation of Motorised Actuators on the Bypass, Inlet, Discharge and Launcher Valves, as

well as the installation of both Low and High Level Switches on the Launcher to ensure

successful Pressurisation prior to being switched online.

The Launcher is a pressure vessel and thus a local pressure gauge is installed on the

Launcher to provide local indication of the pressure within the Launcher Barrel. A loaded

sphere counter is implemented in the SCADA to indicate the amount of spheres available for

launching.

Where required, double block and bleed valves will be installed at the outlet of the Launcher

as well as on the kicker line. These double block and bleed valves have been installed as

safety isolation valves to be utilized during maintenance and or Pig / sphere loading.

A Sphere Detector and Launcher Densitometer are installed directly after the Launcher in

order to monitor interface handling and sphere launching (watchdog).

It shall be noted that three different types of spheres are used as follows: -

Batching Pigs (loaded from the launcher barrel)

Cleaning Pigs (loaded from the launcher barrel)

Spheres (loaded into the launcher magazine)

Receiver/Launcher Transfer Tanks may be installed and used to hold launcher product during

draining operations. This product is then re-introduced back into the launcher before being

placed back on line. Use of transfer tanks is intended to reduce the amount of intermix

created during maintenance operations. These facilities comprise of a transfer tank, routing

valves, and transfer pump. This operation is intended to be a manual operation, locally

controlled by the operator. The valves are thus hand-operated, and the pump locally

controlled. No level transmitter is installed on the transfer tank.


Instruments

Launcher Sphere Detector ZI x11

Launcher Low Level LSL x11

Launcher High Level LSH x12 Launcher Transfer Pump X06 Flow FS x11

Station Outlet Sample Flow FS x21 Launcher Transfer Pump X06 Current IT x11

Valves

Launcher Inlet Valve XV LxA

Launcher Inlet Valve ZV LxB

Launcher Outlet valve XV LxE

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Launcher Outlet Valve ZV LxF

Launcher Bypass valve XV LxK Launcher Inlet Bleed valve ZV LxT

Launcher Outlet Bleed valve ZV LxU

Launcher Transfer Valve ZV FxA Launcher Transfer Tank Inlet Valve ZV FxB

Launcher Transfer Tank Outlet Valve ZV FxE Launcher Transfer Pump 4-way Valve ZV FxR

Drives

Launcher Transfer Pump X0x

6.3.1.1 Functional Layout of Launcher

To have clarity when describing the function of the Launcher, the layout and position of the

most important valves and instrumentation must be defined.

The diagram below shows the functional layout of the Launcher indicating where the valves

and instrumentation are located.

XVL1A

XVL1K

XVL1E

ZI 111

0

TNI ZVL1F

ZVL1B

LSL 111

LSH 112

XVL1Y

DT 112

7

Loaded Sphere CounterXVL1X

ZV

L1U

ZV

L1T

F06

X06FS111

ZV

F6R

ZV

F6B

ZV

F6E

ZV

F6A

Figure 6.3-1: Functional Layout of the Launcher


The Launcher may be controlled from the PCS either locally at the Station or remotely from

the MCC.


All devices related to the Launcher shall have the following three Modes of Operation:

Local

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Manual

Automatic


6.3.4.1 Mode

A single software control module has been developed to cater for both receiver and launcher

device group functionality. Receiver or launcher functionality is selected by means of the

Mode selector and is either hard-coded for uni-directional receivers/launchers or

automatically changed based on flow direction for bi-directional receivers/launchers.

6.3.4.2 Launcher States

6.3.4.2.1 Launcher Online/Flushing

The Launcher is in an Online/Flushing state if:

XV LxA Opened AND

ZV LxB Opened AND

XV LxE Opened AND

ZV LxF Opened AND

XV LxK Closed

6.3.4.2.2 Launcher Offline

The Launcher is in an Offline state if:

XV LxA Closed AND

XV LxE Closed AND

XV LxK Opened

6.3.4.3 Launcher No Valid Flow-path Status

A Valid Flow-path for the Launcher exists if the following conditions are met:

XV LxK

OR

XV LxA AND

ZV LxB AND

XV LxE AND

ZV LxF


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6.3.4.4 Sphere Counter Control

6.3.4.4.1 Launcher sphere counter

The Sphere detector ZI x11 is used to provide input for a software implemented Sphere

counter in Launcher mode. If the Launcher Sphere detector is triggered, the Launcher Sphere

counter is incremented to indicate the number of pigs/spheres launched.

The Launcher Sphere detector counter can be reset (set to zero) in the following ways:

Operator command


6.3.4.4.2 Launcher Sphere Loaded counter

A software implemented Sphere Loaded counter is used to keep track of spheres loaded in

the Launcher barrel.

Before a sphere can be launched, they need to be loaded. The operator will drain the

launcher until the level has dropped below the magazine i.e. not high level. He will then load

the spheres into the magazine and pressurize the launcher again until the high level is made.

On successful completion of sphere loading, the operator shall enter the number of spheres

loaded into the input field. The Sphere Loaded Counter input field is enabled at all times.

Upon a successful launch, the Sphere Loaded counter is decremented to indicate remaining

spheres in the Launcher magazine.

6.3.4.5 Double Block and Bleed Valves

Double block and bleed valves are installed at the inlet of the Launcher as well as on the

kicker line, in addition to the existing Launcher Inlet and Outlet valves. These double block

and bleed valves have been installed as safety isolation valves to be utilized during

maintenance and or pig or sphere removal.

The first block valve on both the inlet and outlet are actuated and controlled during the

normal Launcher operation.

The second block valve and bleed valve on both the inlet and outlet of the Launcher are hand

operated, with the block valve being left open and the bleed valve closed during normal

operation. These valves will then be hand-operated during maintenance and or pig or sphere

insertion. Both these valves will have feedback interfaced to the control system and will form

part of the availability of the Launcher.

6.3.4.6 Launcher Flushing

A Launcher Flush Online Request is activated, on receipt of:

an Flush Online Request from the SCADA, if not Online OR


dependent) OR


On receipt of a Launcher Flush Online Request, the Launcher Online Sequence is initiated if

Ready and not already online.

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Flushing will be terminated by initiating the Launcher Offline Sequence, based on operator

request.



initiated.

6.3.4.7 Launcher Flags

These flags are raised by the process control software as configured on the Launcher block.



detail.

6.3.4.7.1 Launcher Flow-path

The Launcher Flow-path flag is raised whenever the Launcher has a valid flow-path as

defined in Section 6.3.4.3.

6.3.4.7.2 Launcher Not Flushed


Launcher Flush Online request initiated

AND

device failure while running the Online sequence OR Launcher Not Online timer

(configured as the time it takes the Launcher to reach an Online state) has expired.

The Not Flushed flag is is cleared if the Launcher is placed online as determined by valve

status.


Should a Launcher not be flushed (i.e. the "Launcher Not Flushed" flag is raised) AND an

Interface is not present in the Online route (interface in station flag set high), and the

Launcher moves from an Offline state (as determined by valve status), a Possible Hotspot

flag is raised.

This alarm is cleared when the Launcher goes Online.

6.3.4.7.4 Magazine Empty

The Magazine Empty flag is raised if no spheres are remaining in the launcher magazine

(Loaded Sphere Count =0) to warn the operator.

6.3.4.7.5 Pig Launched

A message “Pig Launched” is displayed on the barrel of the launcher if the Launcher sphere

detector switch is activated and the Launcher valve is not open.

This message is cleared if:

A sphere is launched successfully i.e. the Launcher valve is open and a sphere is

detected within a configurable time.

ZIx11 counter is reset (operator password protected) and indicate “0”

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Mode is changed to receiver

6.3.4.7.6 Sphere Launched

A Sphere Launched flag is pulsed when the Launcher Sphere Detector switch is activated and

the Launcher valve is open.

6.3.4.7.7 Sphere Failed to Launch

The Sphere Failed to Launch indication is provided when a sphere has been launched but not

detected after a time configured in the PLC. This Alarm condition is automatically cleared

after a configurable time (default 10 seconds).

6.3.4.7.8 Launcher Not Primed

The Launcher Not Primed is the inverse of Level Full, refer to Section 6.3.4.7.10

6.3.4.7.9 Sample Point Monitoring

When sampling from the density hut, a flow switch, FS x21, is used to trigger an event for

recording purposes. The signal is held active for 2 seconds.

6.3.4.7.10 Level Full

The Level Full indication is provided when both the Launcher High Level switch (LSH x12)

and the Launcher Low Level switch (LSL x11) indicate a High level. Substitute (operator


6.3.4.7.11 Level Not Empty

The Level Not Empty indication is provided when the Launcher High Level switch (LSH x12)

indicates a Low level and the Launcher Low Level switch (LSL x11) indicates a High level.

Substitute (operator action) and override values (device fault) are used when determining

this state.

6.3.4.7.12 Level Empty

The Level Empty indication is provided when both the Launcher High Level switch (LSH x12)

and the Launcher Low Level switch (LSL x11) indicate a Low level. Substitute (operator


6.3.4.7.13 Level Switches Fault

The Level Switches Fault indication is provided when the Launcher High Level switch (LSH

x12) indicates a high level and the Launcher Low Level switch (LSL x11) indicates a low level.

When either the high or low level switch is faulty (hardware fault, signal out of range), the

faulty switch automatically defaults to the override value (low level). The faulty level switch

will thus be red in colour except for the case where the low level switch is in fault and the

high level switch indicates a high condition. In this implausible case, both level switches are

blue in colour to indicate an implausible state.

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6.3.4.7.14 Sphere Loaded (Launcher Pins only)

The Sphere Loaded Flag will be set 5 seconds (configurable) after receipt of the open

indication of the Load Valve. The loaded indication will be reset upon detection of a

successful Launch Flag.

6.3.4.8 Launcher Sequences

6.3.4.8.1 Launcher Online Sequence

The Launcher Online Sequence is activated, if Ready, on receipt of:

an Online Request from the SCADA

Launcher Flush Online request

If Ready, the Launcher Inlet and Outlet valves are opened and on successful completion the




Any actuated launcher valve Not Available (XV LxA, XV LxE, XV LxK)

OR

Any launcher hand valve Not Opened (ZV LxB, ZV LxF) OR

Any Drain or Fill valve Not Closed (ZV LxU, ZV LxT, ZV FxA) OR

Level Switches Fault (LSH x12, LSL x11 in Fault or Implausible) OR



7.2.2.1: Launcher L01 Online Sequence

6.3.4.8.2 Launcher Offline Sequence

The Launcher Offline Sequence is activated, if Ready, on receipt of:


If Ready, the Launcher Bypass valve is opened and on successful completion, the Launcher

Inlet and Outlet valves are closed.

The following faults while the sequence is running will result in the sequence aborting,


Any actuated launcher valve Not Available (XV LxA, XV LxE, XV LxK)

OR

Any launcher hand valve Not Opened (ZV LxB, ZV LxF) OR

Any Drain or Fill valve Not Closed (ZV LxU, ZV LxT, ZV FxA) OR

Level Switches Fault (LSH x12, LSL x11 in Fault or Implausible) OR



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7.2.2.2: Launcher L01 Offline Sequence


6.3.5.1 Launcher Availability

The following conditions render the Launcher Device Group “Not Available”.

Table 6.3-1: Launcher Availability

6.3.6 Group Status

6.3.6.1 Group Alarm Status Indications



Alarm Configuration Database (3) for details including text to be used for the message.



Pig Launched Pig Launched Refer to Section 6.3.4.7.5

Level Switch Fault Level Switch Fault Refer to Section 6.3.4.7.13

Sphere Failed to Launch

Sphere Failed to Launch


Table 6.3-2: Launcher Group Alarm Status

6.3.6.2 Group Error Status Indications






Launcher Not Primed Launcher Not Primed Refer to Section 6.3.4.7.8

XV LxA Not Available XVLxA Not Avail Refer to [3]

XV LxE Not Available XVLxE Not Avail Refer to [3]

XV LxK Not Available XVLxK Not Avail Refer to [3]

ZV LxB Not Opened ZVLxB Not Opened Refer to [3]

ZV LxF Not Opened ZVLxF Not Opened Refer to [3]

ZV LxT Not Closed ZVLxT Not Closed Refer to [3]

ZV LxU Not Closed ZVLxU Not Closed Refer to [3]

ZV FxA Not Closed ZVFxA Not Closed Refer to [3]


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Launcher Not Flushed

Launcher Not Flushed


Loaded Sphere Counter Inhibited

Loaded Sphere Counter Inhibited


No Valid Flow-path

No Valid Flow-path Refer to Section 6.3.4.7.1

Table 6.3-3: Launcher Group Error Status

6.3.6.3 Group Information Status Indications



the Alarm Configuration Database (3) for details including text to be used for the message.


Level Full Level Full Refer to Section 6.3.4.7.10

Level Not Empty Level Not Empty Refer to Section 6.3.4.7.11

Level Empty Level Empty Refer to Section 6.3.4.7.12

Sphere Loaded Sphere Loaded Refer to Section 6.3.4.7.14

Magazine Empty Magazine Empty Refer to Section 6.3.4.7.4

Table 6.3-4: Launcher Group Information Status

6.3.7 Additional Device Alarms

None defined.


The following group interlocks are defined for the Launcher Device Group:


None defined.


6.3.8.2.1 X0x: Launcher Transfer Pump No Flow

Launcher Transfer Pump X0x is interlocked off if there is no flow after the pump has been

running for a configurable time as determined by flow switch FS x11. This interlock and

associated alarm is blocked if the pump is not running.

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6.3.8.2.2 X0x: Launcher Transfer Pump Under-Current

Launcher Transfer Pump X0x is interlocked off if there is a under current after the pump has

been running for a configurable time as determined by IT x11. This interlock and associated

alarm is blocked if the pump is not running.

6.3.9 Failure modes

None defined.


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6.4 Launcher Interface Handling


Interface Handling (Sphere Launching) shall be controllable manually, whilst Launcher

Pressurisation and Sphere Loading remain local operations.

Two types of launcher exist within Transnet pipelines; namely those with single launcher

valves (XVLxX), and those with two launcher pins (XVLxX and LxY).

A Sphere Detector and Launcher Densitometer are installed directly after the Launcher in

order to monitor interface handling and sphere launching (watchdog).

No automatic sphere table functionality is provided for launching of spheres. Launching may

only be done via operator request. Launching of spheres will be time dependent

(configurable) when launching from the density hut, and not volume displacement

dependent. A launch command from the SCADA is not time delayed.

It should be noted that three different types of spheres are used as follows: -

Batching Pigs (loaded from the launcher barrel)

Cleaning Pigs (loaded from the launcher barrel)

Spheres (loaded into the launcher magazine)

All control associated with this device group is implemented in the HP Routing PLC.

Instruments

Launcher Density DT x12

Valves

Launcher Launch Valve XV LxX

Launcher Load Valve (Launcher Pins only) XV LxY


Launcher Interface Handling may be controlled from the PCS either locally at the Station or

remotely from the MCC.


All devices related to Launcher Interface Handling shall have the following two Modes of

Operation:

Local

Manual


6.4.4.1 Volume Calculation

Launching of spheres will be time dependent (configurable) when launching from the field

launcher panel and not volume displacement dependent. A launch command issued from the

SCADA is not time delayed.

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6.4.4.2 Launch Valve Control

The Launch valve is opened in Manual on a:

Manual Open request from the SCADA

The Launch valve is interlocked open in Manual on a:

Density Hut Launch valve Open request

The Launch valve is closed in Manual on a:

Manual Close request from the SCADA

The Launch valve is interlocked closed in Manual on a:

the Successful Sphere Launch flag is pulsed, OR

the Failed Sphere Launch flag is pulsed, OR

Density Hut Launch valve Close request

6.4.4.3 Load Valve Control (Launcher Pins only)

A sphere is loaded if the load valve is open for 5 sec (configured in the PLC). This indication

is reset if the launch is successful. The loaded indication does not depend on the number on

the loaded sphere counter.

The load valve is opened in manual on a:

Load valve manual open request

The load valve is interlocked open in manual on a:

Density hut load valve open request

The load valve is closed in manual on a:

Load valve manual close request

The load valve is interlocked closed in manual on a:

Sphere loaded indication, OR

Density hut load valve close request

6.4.4.4 Density Hut Control

It is possible to control the Launcher valve from the density hut in Manual mode of operation.

The Launcher valve is opened and if the Launcher valve is Open and the Sphere Detector

switch is activated or on a timeout, a close request is automatically issued. It is however

possible to issue a close command from the density hut before it is closed automatically.

It is possible to open the Launcher valve regardless of the value in the loaded sphere

counter.

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6.4.4.5 Interface Handling Flags

6.4.4.5.1 Successful Sphere Launch

The Successful Sphere Launch flag is pulsed for 2 seconds (configurable) when the Launch

valve has been opened and the Sphere Detector switch is triggered before the launch timer

has expired.

The launch timer is started when the Launch valve is fully opened.

6.4.4.5.2 Failed Sphere Launch

The Failed Sphere Launch flag is pulsed for 10 seconds (configurable) when the Launch valve

has been opened and a launch timer is expired before the Sphere Detector switch is

triggered.

The launch timer is started when the Launch valve is fully opened.

6.4.4.6 Density Hut Launcher Panel DHx1

Density Hut Launcher Panel DHx1 makes provision for the following functionality:

6.4.4.6.1 Selector Switch

Where a Launch Panel is required to control multiple launchers, a selector switch may be

provided enabling the operator the ability to select the launcher required for launching.

Commands issued and status indicated is determined by the launcher that has been selected

on the panel.

6.4.4.6.2 Command Push-Buttons

The launcher panel makes provision for the operator to issue the following commands to the

control system:

Launch Valve Open Request (XS x11)

Launch Valve Closed Request (XS x12)

Reset Sphere Detector Request (XS x13)

Load Valve Open Request (XS x14)

Load Valve Closed Request (XS x15)

6.4.4.6.3 Indication Lamps

The launcher panel makes provision for the following status indications from the control

system to the operator.

Launch Available Indication (XI x11) - Lamp (Green)

Launch Valve Open Indication (XI x12) - Lamp (Green)

Launch Valve Closed Indication (XI x13) - Lamp (Red)

Reset Sphere Detector Indication (XI x14) - Lamp (Amber)

Load Valve Open Indication (XI x15) - Lamp (Green)

Load Valve Closed Indication (XI x16) - Lamp (Red)

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Sphere Loaded Indication (XI x17) - Lamp (Amber)


6.4.5.1 Density Hut Launch Availability

The following conditions render a Density Hut Launch “Not Available” and Load and Launch

valve open and close commands will be inhibited.

Condition Logic

Launcher Not Online Refer to Section 6.3.4.2.1

XV LxY Not Available Refer to [3]

XV LxX Not Available Refer to [3]

Launcher Not Primed Refer to Section 6.3.4.7.8

Table 6.4-1: Density Hut Launch Availability

6.4.6 Group Status

6.4.6.1 Launcher 3 Interface Handling Group Status


None defined.


None defined.


None defined.



None defined.


6.4.7.2.1 XV LxX: Launcher Valve (Launcher Pins only)

The launcher valve (XV LxX) is interlocked closed if the load valve (XV LxY) is not closed.

6.4.7.2.2 XV LxY: Load Valve (Launcher Pins only)

The load valve (XV LxY) is interlocked closed if the launcher valve (XV LxX) is not closed.

6.4.8 Failure modes

None defined.

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6.5 MV Booster Pump Sets – DOL

This section is associated with the control and monitoring of MV Booster Pump Set – DOL

Device Groups.

MV Booster Pump Sets – DOL associated with this device group are installed Island View and

Jameson Park Terminals.


This section covers Medium Voltage, direct-online driven pump sets used in booster pump

applications on IVW and JMP Terminals. These pump-sets are not equipped with individual

Lube Oil Systems. They are equipped with Machine Monitoring Systems (GE System 1, based

on Bentley Nevada 3500 sensing equipment). These MMS signals are interfaced to the PLC

via hardwired and Modbus RS-422 interfaces.

Note: For Hazardous Area Classification reasons, these booster pumps may be fitted with

twin seal arrangements.

This control and monitoring functionality is achieved via the following devices:

6.5.1.1 Signals Interfaced from the Field to the PLC via Hardwired Interface

Instruments (Typically)

Booster Pump Bxx Suction Pressure PT xx1

Booster Pump Bxx Discharge Pressure PT xx2 Booster Pump Bxx Flow FT xx1A

Booster Pump Bxx Flow (for future use) FT xx1B Booster Pump Bxx Casing Temperature TT xx4

Booster Pump Bxx NDE Seal Leak Detection(i)

LSH xx1

Booster Pump Bxx DE Seal Leak Detection(i)

LSH xx2

Booster Pump Bxx Motor Winding Temperature A(i)

TT xx7A

Booster Pump Bxx Motor Winding Temperature B(i)

TT xx7B

Booster Pump Bxx Motor Winding Temperature C(i)

TT xx7C

Valves

Booster Pump Bxx Suction Valve ZV BxxA Booster Pump Bxx Discharge Valve ZV BxxF

Booster Pump Bxx Discharge Valve XV BxxE

Heater

Booster Pump Bxx Motor Heater On Request BxxH IRC

Drives

Booster Pump Bxx(i)

Bxx

Control Valves

Bxx Spillback Flow Control Valve CV BxxJ*

6.5.1.2 Signals Interfaced from the Electrical Switchgear to the PLC via Hardwired

Interface

Typical electrical interface for Booster Pump Set Breakers installed on stations associated

with the 24” MPP Pipeline is as follows:

MV01 Bxx Running (i)

MV01Bxx PON

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MV01 Bxx Stopped (i)

MV01Bxx POF

MV01 Bxx In Local (i)

MV01Bxx SLO

MV01 Bxx Electrical Latched Trip (i)

MV01Bxx ETR

MV01 Bxx Electrical Non-Latched Trip (i)

MV01Bxx ETP

MV01 Bxx Remote Emergency Stop (i)

MV01Bxx RES

MV01 Bxx Multi-Start Inhibit (i)

MV01Bxx SPH

MV01 Bxx Start Request (i)

MV01Bxx IRC

MV01 Bxx Stop Request (i)

MV01Bxx IRT

MV01 Bxx Process Trip Request (i)

MV01Bxx PTR

MV01 Bxx Mechanical Trip Request (i)

MV01Bxx TVR1

Mv01 Bxx Current (i)

IT xx1

6.5.1.3 PLC - MMS Interface

6.5.1.3.1 Signals Interfaced between the PLC – MMS (Modbus Interface)

The following signals are interfaced between the PLC and MMS System via Modbus interface:

Booster Pump Bxx Pump Thrust Bearing Temp TT xx1A/B Booster Pump Bxx Pump NDE Journal Bearing Temp TT xx2A/B

Booster Pump Bxx Pump DE Journal Bearing Temp TT xx3A/B Booster Pump Bxx NDE Bearing Vibration ST xx1

Booster Pump Bxx DE Bearing Vibration ST xx2

Booster Pump Bxx Keyphase KT xx2

Booster Pump Bxx Motor DE Radial Bearing Temp TT xx5A/B Booster Pump Bxx Motor NDE Radial Bearing Temp TT xx6A/B

Booster Pump Bxx Motor DE Bearing Vibration ST xx3 Booster Pump Bxx Motor NDE Bearing Vibration ST xx4

6.5.1.3.2 PLC / MMS Hardwired signals (MMS)

The following signals are interfaced between the PLC and MMS System via hardwired

interface:

Booster Pump Bxx MMS Fail (i)

Bxx BNARM

Booster Pump Bxx Pump High Vibration Alarm(i)

P0x SSH0x1

Booster Pump Bxx Motor High Vibration Alarm(i)

P0x SSH0x2

Booster Pump Bxx Pump Radial Bearing High Temperature Alarm(i)

P0x TSH0x1

Booster Pump Bxx Motor Radial Bearing High Temperature Alarm(i)

P0x TSH0x2

Booster Pump Bxx Pump High Vibration Trip(i)

P0x SSHH0x1

Booster Pump Bxx Motor High Vibration Trip(i)

P0x SSHH0x2

Booster Pump Bxx Pump Radial Bearing High Temperature Trip (i)

P0x TSHH0x1

Booster Pump Bxx Motor Radial Bearing High Temperature Trip(i)

P0x TSHH0x2

Booster Pump Bxx MMS Trip Multiply(i)

Bxx BNTM

Booster Pump Bxx MMS Trip Reset(i) Bxx BNRST

Booster Pump Bxx MMS Alarm Inhibit (Not Used) (i)

Bxx BNINH

6.5.1.3.3 PLC to System 1 Modbus signals (MMS System)

The following signals are interfaced via Modbus to the System 1 Server for diagnostic

purposes

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Booster Pump Bxx Suction Pressure PT xx1

Booster Pump Bxx Discharge Pressure PT xx2 Booster Pump Bxx Flow FT xx1A

Booster Pump Bxx Seal Leak LSH xx1/2

Booster Pump Bxx Motor Winding Temperature A-C TT xx7A/B/C


The Booster Pump Set may be controlled from the PCS either locally at the Station or



All devices related to the Booster Pump Set shall have the following three Modes of

Operation:

Local

Manual

Automatic

The Control Valve CV BxxJ has its own Mode of Operation, independent of the Group. Default

mode of operation is Auto.


6.5.4.1 Maximum Demand Inhibit

Booster/Mainline Pumps are combined for maximum demand inhibit. This implies that only

one pump can be started at a time. In automatic, the pumps of each manifold are started in

the same order as the start commands were issued.

If a pump running feedback is detected, this pump sets a maximum demand inhibit for all the

other pumps. The maximum demand is active for the required delay time as preconfigured

per pump. Pump current is not used for the maximum demand inhibit.

6.5.4.2 Booster Pump States

6.5.4.2.1 Booster Pump No Valid Flow-path Status

If a Booster Pump No Valid Flow-path condition is detected, a group ‘No Valid Flow-path’ bit

is set.

A Valid Flow-path for the Booster Pump exists if the following conditions are met:

ZV BxxA (Open OR Wirebreak) AND

ZV BxxF (Open OR Wirebreak) AND

XV BxxE (Open OR Wirebreak)

6.5.4.2.2 Booster Pump Set Online Status

The Pump Set is in an Online state if:

ZV BxxA is Opened AND

ZV BxxF is Opened AND

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XV BxxE is Opened AND

Bxx is Running

6.5.4.2.3 Booster Pump Set Offline

The Pump Set is in an Offline state if:

XV BxxE is Closed AND

Bxx is Stopped

6.5.4.3 Motor Heater Control

Motor heater control is affected as follows:

Pump running feedback – motor heater off

Pump stopped feedback – motor heater on

6.5.4.4 Flushing

Booster Pump Flushing is not required as booster pumps are dedicated to single products.

6.5.4.5 Booster Pump Set Online Sequence

The Booster Pump Set Online sequence is activated on receipt of:


a Booster pump circulation online sequence request (station dependent)

If the group is not ready the sequence cannot be initiated.

Note: The first step of the online sequence checks if there is a flow-path through the rest of

the manifold before the sequence continues. If there is no flow-path through the rest of the

manifold the sequence is aborted.

The Online sequence performs the following functions:

Perform a trip reset on the relevant Bentley Nevada rack

Check if Bentley Nevada rack MMS healthy signal is present

Close the discharge valve.

Once the discharge valve is closed, and there is no Maximum demand inhibit from

another pump, start the booster pump (remote start signal (IRC) from PLC is pulsed).

Note the activation of the MMS trip multiplier is implemented within the device

typical.

Once the booster pump running feedback is received, reset the trip multiplier

function of Bentley Nevada system after 10s (configurable). Note the reset of the trip

multiplier is implemented within the device typical.

Once the booster pump running feedback is received for more than 5s

(configurable), open the discharge valve.


Figure 7.2-5: Booster Pump Set B01 Online sequence

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ZVBxxA OR ZVBxxF Fault OR

XVBxxE Not Available OR

Bxx Not Available OR

No valid flow-path trip (Internal to sequence) OR

MMS not Healthy (Internal to sequence)

Placing the Group in Manual mode while the sequence is running will result in the sequence

aborting.

Note: The Booster Pump Offline Sequence is activated on receipt of an Online Sequence

Abort Status.

Note: The activate and reset of the “Trip Multiply” is included in the device typical to allow

these functions to be available in Manual and Local modes of operation.

6.5.4.6 Booster Pump Set Offline Sequence

The Booster Pump Set Offline sequence is activated on receipt of:

an offline request from the SCADA

a Booster pump circulation offline sequence request (station dependent)

due to the pump being tripped via PTR or TVR output

a device fault (Bxx OR XV BxxE) condition exists

a No Valid Flow-path trip condition exists

a flow low trip condition exists after a configurable time (default 5 sec) has elapsed

a tank level low trip condition exists when route online

an online sequence aborted

Offline sequence performs the following functions:

Stop the booster pump (remote stop signal (IRT) from PLC is removed)

On receipt of pump stopped feedback, close pump discharge valve XV BxxE. The

Spillback control valve CV BxxJ is interlocked closed when the Booster Pump is

stopped.


7.2.3.2Figure 7.2-6: Booster Pump Set B01 Offline sequence

Any faults encountered during the running of the offline sequence results in the sequence

continuing to completion. Placing the Group in Manual mode while the sequence is running

will result in the sequence aborting.


The following conditions render the Booster Pump Set Device Group “Not Available”.


Bxx Not Available Bxx Not Avail Refer to [3]

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XV BxxE Not Available Or Interlocked

XV BxxE Not Avail or Intlk Refer to [3]

ZV BxxA Not Opened/WB

ZV BxxA Not Opened/Wb Refer to [3]

ZV BxxF Not Opened/WB

ZV BxxF Not Opened/Wb Refer to [3]

MMS Rack Failed MMS Rack Fail The MMS Rack Failed availability status indicates that a fault exists within the MMS rack associated with the pump.

Insufficient Power Available

Insufficient Power Available Refer to Section 6.5.8.2.3

Number of Starts Exceeded

Number Of Starts Exceeded Refer to Section 6.5.8.2.6

Table 6.5-1: Booster Pump Set Bxx Availability

A no flow path condition is not monitored for availability. The online sequence checks if there

is a flow-path in the first step before the sequence is executed. It is however possible to run

an offline sequence with a no flow path condition.

6.5.6 Group Status






No Valid Flow-path Interlock

No Valid Flow-path Trip


MMS Modbus failure

Bxx MMS Comms Fail The MMS Modbus Failure indication is provided when the Modbus communications link has failed.

Table 6.5-2: Booster Pump Set Bxx Group Alarm Status






No Valid Flow-path Status

No Valid Flow-path Refer to Section 6.5.4.2.1

Insufficient Power Insufficient Power Refer to Section 6.5.8.2.3

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Available Available


Number Of Starts Exceeded


Table 6.5-3: Booster Pump Set Bxx Group Error Status


None defined.


None defined.



A hardwired MMS trip signal TVR2 is used to interlock the pump off independently of the

control system. When the TVR2 trip condition resets or returns to a healthy condition, the

TVR2 output is latched in the MMS and needs to be manually reset.


To achieve control of the pump while in local the hardwired PTR and TVR1 trip signals are

used to interlock the pump off if required. When the PTR trip condition resets or returns to a

healthy condition the PTR output is reinstated. When the TVR1 trip condition resets or

returns to a healthy condition, the TVR1 output is latched in the electrical protection relay

and needs to be manually reset.

6.5.8.2.1 Bxx: Flow Low Trip (FT xx1A) (PTR)

If low flow (FT xx1A < xxxx L/min,) is detected for a configurable time (default 30 seconds)

on startup, the Booster Pump Set is tripped. This protection inoperative delay is used during

start-up to prevent spurious trips from occurring. This interlock’s associated alarm is blocked

if the pump is not running.

Trip after startup is instantaneous.

6.5.8.2.2 Bxx: Suction Pressure Low Trip (PT xx1) (PTR)

If a low suction pressure trip (PT xx1) is detected after a configurable time (default 10

seconds on startup), the Booster Pump Set is tripped. This protection inoperative delay is

used during start-up to prevent spurious trips from occurring. This interlock’s associated

alarm is blocked if the pump is not running.


6.5.8.2.3 Bxx: Insufficient Power Available Start Interlock

If insufficient power is available to run the Pump Set (either utility or MV Genset), this

interlock will prevent the pump set from starting in Auto, Manual and Local. Insufficient

Power Available is a signal generated within the Electrical Device Group.

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Refer to Section 6.27.4.2 for details.

6.5.8.2.4 Bxx: No Valid Flow-path Trip Interlock

If any of the valves, which block the flow through the booster pump and spillback, are not

open and not in Wirebreak, a “No Valid Flow-path” interlock is activated.

LP Route No Valid Flow-path

AND

(ZV BxxA Not Open AND Not Wirebreak AND

ZV BxxF Not Open AND Not Wirebreak)

6.5.8.2.5 Bxx: Axx Tank Low Level Trip

If a Route is Online (as determined by device status), and Pump Running, and a low level trip

is detected on the associated Accumulator Tank, the Booster Pump Set (Bxx) is tripped

(unless there is another route online to the same pump from a tank without a low level).

This alarm/trip is suppressed if there is no route online and the pump is not running.

6.5.8.2.6 Bxx: Number Of Starts Exceeded

In order to prevent the motor from overheating due to high inrush current, the number of

starts is limited within the EPR Relay. When the thermal energy count is exceeded, the EPR

Relay issues a Multi-Start Inhibit signal to the PLC. On receipt of Bxx_SPH, the Booster Pump

is prevented from starting via an interlock and an event message is generated.

The Booster Pump will not be interlocked off if it is already running, i.e. the signal inhibits the

start request only.

6.5.9 Failure Modes

None defined.


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6.6 Booster Pump Bxx Flow Control

This section is not a device group on its own, but these devices and associated control forms

part of the MV Booster Pump Set Bxx device group.

MV Booster Pump Sets – DOL associated with this device group are installed Island View and

Jameson Park Terminals.


The flow control valve is either under closed- (automatic) or open-loop (manual) control to

control the spillback flow.

There is no pressure (ICP or SDP) override configured on this control valve.

Flow control is based on the booster pump uncompensated flow.


Valves

Bxx Spillback Flow Control Valve CV BxJ

Instrumentation

Booster Pump Bxx Flow FT xxx_G*



The Booster Pump Flow Control may be controlled from the PCS either locally at the Station

or remotely from the MCC.


The Control Valve has its own Mode of operation, independent of the Group:

Local

Manual

Automatic

Default mode of operation is Auto.


6.6.5 Spillback control

Spillback control is implemented to provide minimum flow protection to the associated

booster pump. Spillback flow control is achieved via a PID controller and control valve, which

is by default enabled and in Auto. When the Booster pump is stopped the spillback Control

valve is interlocked closed. The interlock is removed as soon as the Booster pump reaches a

state of not stopped.

Control is based on uncompensated flow FT xxx_G.

Minimum flow protection is achieved by minimum flow override. In addition to the minimum

flow pump protection, the spillback line is also used for inter-tank transfers.

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6.6.5.1 Inter-tank Transfer control

Inter-tank transfers shall take place via the booster pumps and associated spillback lines.

Inter-tank transfer is a manual function, with correct line-up and flowrate selection remaining

the responsibility of the operator.

6.6.5.2 Non-Modulating Actuators

Not applicable to this device group.

6.6.5.3 Modulating Actuators

Figure 6.6-1: Booster pump Bxx spillback - Flow Control Schematic

Control valves are part of the respective Booster pump Group and do not have their own

graphic. Hence the PV’s and control loop are not visible to the operator.

The typical consists of two PID loops each with a hard coded override:

Flow PID

SDP PID (not used)

The operator can choose to control on:

Flow

Manual (manual mode only)

6.6.5.4 Flow compensation

FT xxx_G is uncompensated.


Not Required.

xxx

PT

xxxCV

xxxCV

FT

xxx

xxxPT

PT

xxxFIC

xxxPT

xxxPIC

xxxOVR

xxxOVR xxx

PICxxx

OVR

ICPSDP

FLOW

xxxMAN

SP SPOR

SP

SP

CONTROL VALVE

SPOR

SPOR

0%

100%

SPOR

ICP

Va

lve

Ove

rrid

e

Po

stio

n

0%

100%

Flow/SDP

Va

lve

Ove

rrid

e

Po

stio

n

SPOR

OVERRIDE FUNCTIONS

LinearisationLinearisation

FT xxx_S

(Not used)

>

(Not used)

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6.6.7 Group Status

6.6.7.1 Group Alarm Status Indication

None defined.

6.6.7.2 Group Error Status Indication

None defined.

6.6.7.3 Group Information Status Indication

None defined.


Flow Deviation High alarm is not used for this application.


6.6.9.1 Hard-wired Interlocks

None defined.


6.6.9.2.1 CV BxxJ: Booster Pump Spillback Control Valve Interlock

The Booster Pump Spillback Control valve (CV BxxJ) is interlocked closed when the Booster

Pump Bxx is stopped.

6.6.10 Failure Modes

In the case of transmitter failures, the following should apply:

Should a flow transmitter fail, the substitute value is shown to the operator (hold

last).

On instrument failure, the instrument goes into substitute value (hold last) complete with

alarming. Operator action is required to prevent control loop wind-up.


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6.7 MV Mainline Pump Sets – DOL (Series Configuration)

This section is associated with the control and monitoring of MV Mainline Pump Set – DOL

Device Groups.

MV Mainline Pump Sets are installed on most stations associated with the Crude, Refined

Product and Inland Pipeline networks.


This section covers Medium Voltage DOL Pump-sets used in mainline, accumulator and

Mainline pump applications, where the Pump-set is not equipped with its own individual Lube

Oil System, where Machine Monitoring Systems are not installed and where the Pump-sets

are placed in a series configuration.

A Medium Voltage Pump Set Device Group comprises of the pump, motor, inlet (PxA), outlet

(PxE) and bypass (PxK) valves. Multistage pump sets are used to maintain desired pressure

profiles, by switching online and offline as required. Valves and instrumentation may vary

according to application.



Instruments (Typically)

Mainline Pump Pxx Suction Pressure PT 0x1

Mainline Pump Pxx Discharge Pressure PT 0x2

Mainline Pump Pxx Seal Leakage (i)

PS 0x1

Mainline Pump Pxx Flow FS 0x1

Mainline Pump Pxx Pump NDE Bearing Temperature (i)

TT 0x1

Mainline Pump Pxx Pump Casing Temperature TT 0x2

Mainline Pump Pxx Pump DE Bearing Temperature (i)

TT 0x3

Mainline Pump Pxx Motor DE Bearing Temperature (i)

TT 0x4

Mainline Pump Pxx Motor Winding Temperature (i)

TT 0x5

Mainline Pump Pxx Motor NDE Bearing Temperature (i)

TT 0x6

Mainline Pump Pxx Pump Vibration (i)

VT 0x1

Mainline Pump Pxx Motor Vibration (i)

VT 0x2

Mainline Pump Pxx Motor Current (i)

IT 0x1

Valves

Mainline Pump Pxx Suction Valve ZV PxA Mainline Pump Pxx Bypass Valve XV PxK (1)

Mainline Pump Pxx Discharge Valve XV PxE

Drives

Mainline Pump P0x (i)

P0x

6.7.1.2 Signals Interfaced from the Electrical Switchgear to the PLC via Hardwired

Interface

Typical electrical interface for Mainline Pump Set Breakers installed on stations associated

with the RPP and COP Pipelines is as follows:

MV01 P0x Running (i)

MV01P0x PON

MV01 P0x Stopped (i)

MV01P0x POF

MV01 P0x In Local (i)

MV01P0x SLO

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MV01 P0x Master Trip Relay (i)

MV01P0x MTR

MV01 P0x Thermal Overload Trip (i)

MV01P0x TOP

MV01 P0x Earth Fault Trip (i)

MV01P0x ELP

MV01 P0x Fuse Blown Trip (i)

MV01P0x FBL

MV01 P0x Electronic Protection Relay Fail (i)

MV01P0x ERP

MV01 P0x Loss of Control Voltage (i)

MV01P0x VT

MV01 P0x Remote Emergency Stop (i)

MV01P0x RES

MV01 P0x Multi-Start Inhibit (i)

MV01P0x SPH

MV01 P0x Breaker Racked Out (i)

MV01P0x BRS

MV01 P0x Start Request (i)

MV01P0x IRC

MV01 P0x Stop Request (i)

MV01P0x IRT

MV01 P0x Process Trip Request (i)

MV01P0x PTR

MV01 P0x Mechanical Trip Request (i)

MV01P0x TVR

Mv01 P0x Current (i)

IT 0x1

(i) Devices form part of Pump Device Typical

Notes:

1. In some installations, XV PxK may be a check valve.

2. The control and monitoring functionality of the Mainline Pump Device Typical is described

in the Software Control Module Standard [3].

3. Refer to Electrical Device Group Section 6.26.1 for details on motor electrical interface.


The Mainline Pump Set may be controlled from the PCS either locally at the Station or



All devices related to the Mainline Pump Set shall have the following three Modes of

Operation:

Local

Manual

Automatic



Booster/Mainline Pumps are combined for maximum demand inhibit. This implies that only

one pump can be started at a time. In automatic, the pumps of each manifold are started in

the same order as the start commands were issued.

If a pump running feedback is detected, this pump sets a maximum demand inhibit for all the

other pumps. The maximum demand is active for the required delay time as preconfigured

per pump. Pump current is not used for the maximum demand inhibit.

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6.7.4.2 Mainline Pump States

6.7.4.2.1 Mainline Pump Online

The Mainline Pump is in an Online state if:

Pump Inlet Valve ZV PxA is Open AND

Pump Outlet Valve XV PxE is Open AND

Pump Bypass Valve XV PxK is Open AND

Mainline Pump P0x is running

6.7.4.2.2 Mainline Pump Offline

The Mainline Pump is in an Offline state if:

Pump Outlet Valve XV PxE is Closed AND

Pump Bypass Valve XV PxK is Open AND

Mainline Pump P0x is stopped

6.7.4.2.3 Mainline Pump Flushing

The Mainline Pump is in an Online/Flushing state if:



Pump Bypass Valve XV PxK is Closed

6.7.4.3 Valid Flow-path

The Mainline Pump has a valid flow-path if:

Pump Bypass Valve XV PxK is Open/Wire-break

OR

Pump Inlet Valve ZV PxA is Open/Wire-break AND Pump Outlet

Valve XV PxE is Open/Wire-break.

Note: This status is not the same as the No Valid Flow-Path Interlock detailed in the

interlock section.

6.7.4.4 Mainline Pump Flags

These flags are raised by the process control software as configured on the Mainline Pump

block. The flags are used to generate Group Status indications, Group Availability indications

and for Group Event and Group Alarm logging. The triggering of each flag is described here

in detail.

6.7.4.4.1 Mainline Pump Flow-path

The Mainline Pump Flow-path flag is raised whenever the Mainline Pump has a Valid Flow-

path as defined in Section 6.7.4.2.3.

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Should a Mainline Pump not be flushed (i.e. the "Mainline Pump Not Flushed" flag is raised)

AND an Interface is not present in the Online route (Interface in Station Flag set High), and

the Mainline Pump moves from an Offline state (as determined by valve status), a Possible

Hotspot flag is raised.

This alarm is cleared when the Mainline Pump goes Online.

6.7.4.4.3 Mainline Pump Not Flushed


A Mainline Pump Set Flush request initiated

AND

device failure while running the Flush sequence OR Mainline Pump Set Flush not

online timer (configured as the time it takes the Mainline Pump Set to reach a Flush

Online state) has expired.

The Not Flushed flag is cleared if the Mainline Pump Set is placed online as determined by

valve status.

6.7.4.5 Mainline Pump Set Online Sequence

The Mainline Pump Set On-line Sequence is activated on receipt of –


a LWC Online Sequence request from the MCC

a Station Online Sequence request

A check is undertaken to ascertain if the Pump Set Device Group is "Ready". If the group is

not ready, the sequence will not be initiated. The first step of the online sequence also checks

if there is a flow path before the sequence continues. If there is no flow path the sequence is

aborted.

The Bypass Valve is initially opened (if not already open) and the Discharge Valve closed (if

not already closed). The sequence will now wait until all the other Pump Sets “Start Inhibits”

are reset before the pump is started.

When the Discharge valve is closed and there is no maximum demand inhibit from another

pump, a Start-up Request (via the IRC Output) is then issued to the Switchgear. When the

pump is running, the discharge valve is opened. The sequence does not look at the motor

current after the pump is started and opens the discharge valve if the pump running feedback

is detected and a configurable timer (default 5 secs) has elapsed. The Bypass Valve is left

open.


7.2.4.1: Mainline Pump P01 Online Sequence



ZVPxA Fault OR

XVPxK Not Available OR

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XVPxE Not Available OR

Pxx Not Available OR

No valid flow-path trip (Internal to sequence)


aborting.

Note: The Mainline Pump Offline Sequence is activated on receipt of an Online Sequence

Abort Status.

6.7.4.6 Mainline Pump Set Offline Sequence

The Mainline Pump Set Offline sequence is activated on receipt of:

an offline request from the SCADA

a Station Offline request

a LWC Offline Sequence request from the MCC

a Pump Set Online sequence aborted


a device fault (Pxx OR XV PxK OR XV PxE) condition exists

a No Valid Flow-path Trip condition exists

Lube Oil not healthy as per Section 6.7.8.2.6

Insufficient power is available (usually determined by all Incomer OCB’s being open).

a Line Over-pressure interlock (P0x-SIF1 is activated)

Station Discharge Pressure High interlock as per Section 6.7.8.2.4

The Pump Set Offline Sequence is always Available.


not “Ready”, the sequence cannot be initiated by operator request (Note the sequence can

be initiated by device fault/interlock conditions if in automatic).

The Remote Stop Signal (IRT) from the PLC is first removed. On receipt of the Pump

Stopped Feedback (POF), the Bypass valve is opened and once open, the Discharge valve is

closed, and the Offline Sequence completed. Should the bypass valve fail to open, the

sequence will abort to prevent a no flow path condition.


7.2.4.2: Mainline Pump P01 Offline Sequence

Any faults encountered during the running of the offline sequence results in the sequence

continuing to completion. Placing the Group in Manual mode while the sequence is running

will result in the sequence aborting.

6.7.4.7 Pump Set Flushing Sequence

A Mainline Pump Set Flush Request is activated, on receipt of:

an Flush Request from the SCADA, if not Online OR


dependent) OR

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On receipt of a Mainline Pump Set Flush Request, the Mainline Pump Set Flush Sequence is

initiated if Ready and not already online. The Discharge Valve is initially opened and on

successful completion, the Bypass Valve closed.

Note that the bypass valve actuator limits are set to ensure that the bypass valve is only

partially closed. Setting of bypass valve limits ensures that, during flushing, the pump is not

wind milled beyond a predetermined limit.

Mainline Pump sets not flushed will need to be manually isolated, drained and re-primed by

operators on site.

Flushing will be terminated based on operator request.


7.2.4.3: Mainline Pump P01 Flush Sequence



ZVPxA Fault OR

XVPxK Not Available OR

XVPxE Not Available


aborting.


The following conditions render the Mainline Pumpset Device Group “Not Available”.


P0x Not Available P0x Not Avail Refer to [3]

ZV PxA Not Opened or Wirebreak

ZVPxA Not Opened/Wb Refer to [3]

XV PxE Not Available XVPxE Not Avail Refer to [3]

XV PxK Not Available or

Interlocked

XVPxK Not Avail or Intlk Refer to [3]

No Lube Oil Flow (or Pressure)

No Lube Oil Flow (or Pressure) As per Section 6.11.4.2

No Purge Air Flow No Purge Air Flow As per Section 6.21.4.2

Insufficient Power

Available

Insufficient Power Available As per Section 6.7.8.2.5

SDP High Trip Station Discharge Pressure High Refer to Section 6.7.8.2.4

Line Over-pressure Protection Activated

Line Overpressure Protection Refer to 6.7.8.2.8. Includes:

- Line Over-Pressure Protection

Interlock

- SIF Failure Time Exceeds MTTR

- PTxxx Fault and in MTTR Trip

- Pressure Deviation High and in MTTR

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Trip

Table 6.7-1: Mainline Pump Set Pxx Availability

A no flow path condition is not monitored for availability. The online sequence checks if there

is a flow-path in the first step before the sequence is executed. It is however possible to run

an offline sequence with a no flow path condition.

6.7.6 Group Status






No Valid Flow-path Interlock

No Valid Flow-path Trip Refer to Section 6.7.8.2.7


Table 6.7-2: Mainline Pump Set Pxx Group Alarm Status






Pump Not Flushed Pump Not Flushed As per Section 6.7.4.4.3

No Valid Flow-path No Valid Flow-path As per Section 6.7.4.2.3


Insufficient Power Available As per Section 6.7.8.2.5


Number Of Starts Exceeded Refer to Section 6.7.8.2.9

Table 6.7-3: Mainline Pump Set Pxx Group Error Status


None defined


None defined


The following interlocks have been defined for the MV Mainline Pump Sets – DOL Group:

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6.7.8.1.1 PTR Trip

The PTR Trip signal is hardwired into the electrical switchgear starter circuit via a PLC

controlled interposing relay and will result in a non-latched trip within the starter circuit.

When the condition resets or returns to a healthy condition the P0x PTR output is reinstated.

6.7.8.1.2 TVR Trip

The TVR signal is hardwired into the electrical switchgear starter circuit via a PLC controlled

interposing relay and will result in a latched trip within the starter circuit (Master Trip Relay).

When the condition resets or returns to a healthy condition the P0x TVR output is reinstated.

6.7.8.1.3 Line Over-pressure Trip

An independent SIL rated safety system is installed to perform the following functionality:

On detection of a high trip Station Outlet pressure all the pumps are tripped

simultaneously via a SIL1 rated relay, and will result in a non-latched trip within the

starter circuit.


Interlocks run the pump set offline sequence if in auto and will interlock the pump off if in

manual or local.

6.7.8.2.1 P0x: Pump Suction Pressure Low (PT 0x1) (Trip)

On low-low suction pressure to Mainline Pump P0x as detected by PT 0x1 after a configurable

time (default 10 seconds) on startup, trip Mainline Pump P0x. This protection inoperative

delay is used during start-up to prevent spurious trips from occurring. This interlock and



6.7.8.2.2 P0x: Pump Discharge Pressure High (PT 0x2) (Trip)

On high-high discharge pressure from Mainline Pump P0x as detected by PT 0x2 after a

configurable time (default 10 seconds) on startup, trip Mainline Pump P0x. This protection

inoperative delay is used during start-up to prevent spurious trips from occurring. This

interlock and associated alarm is blocked if the pump is not running.


6.7.8.2.3 P0x: Pump Casing Temperature (TT 0x4) (Trip)

When the pump casing temperature (TT 0x4) exceeds a pre-defined high limit the pump is

tripped.

6.7.8.2.4 P0x: Station Discharge Pressure High (PT x2x) (Interlock)

Protection against line overpressure is performed by constantly monitoring the station

discharge pressure. Should the discharge pressure exceed the safe limit [configurable in the

PLC], pump sets are prohibited from starting by interlocking non-running pumps off and a

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check is undertaken to see which is the last running pump on the Station. This pump is

interlocked off irrespective of the mode i.e. automatic, manual or local, and if Ready will run

off line.

The station discharge pressure is then re-evaluated after an elapsed time (configurable in the

PLC - default 5 seconds). Should the pressure still be above the safe limit, the next last-

running pump will be interlocked off (and run off line if Ready) and the same process

repeated until all Pump sets are interlocked off (and run off line if Ready) or station discharge

pressure has fallen within limits.

6.7.8.2.5 P0x: Insufficient Power Available (Interlock)

If insufficient power is available to run the pump set (defined as all electrical incomer OCBs

being open), the pump P0x is interlocked off.

6.7.8.2.6 P0x: No Lube Oil Flow (or Pressure) (Interlock)

If the lube oil system indicates a no flow (or pressure) condition after a configurable time

(default 15 secs) has elapsed and the Mainline Pump is running, the Mainline Pump is

interlocked off.

If the Lube Oil System indicates a no flow (or pressure) condition after a configurable time

(default 15 secs) has elapsed and the Mainline Pump is not running, the Mainline Pump is

interlocked off. This is a start interlock.

6.7.8.2.7 P0x: No Valid Flow-path Trip (Interlock)

If any of the valves which block the flow through the relevant manifold are Not Open, a “No

Valid Flow-path Trip” interlock is activated.

This No Valid Flow Path Interlock is a combination of the Valid Flow Path Interlocks as

defined in the following Device Groups:

Receiver

Launcher

HP Routing

LP Routing

Other Pump Set D.O.L (series configuration)

6.7.8.2.8 P0x: Line Over-Pressure Protection (LOP) (SIF) (Interlock)

On detection of a line over-pressure active (PYx2xA_SIF) or QSifEnable signal the Mainline

Pump is interlocked off. Signal QSifEnable is calculated in SisLop function block. See SIS

Section 6.16.7.2.1

6.7.8.2.9 P0x: Number Of Starts Exceeded (Interlock)

In order to prevent the motor from overheating due to high inrush current, the number of

starts is limited within the EPR Relay. When the thermal energy count is exceeded, the EPR

Relay issues a Multi-Start Inhibit signal to the PLC. On receipt of Pxx_SPH, the Mainline Pump

is prevented from starting via an interlock and an event message is generated. The Mainline

Pump will not be interlocked off if it is already running, i.e. the signal inhibits the start

request only.

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6.7.8.2.10 Maximum Demand Inhibit (interlock)

If the pump is in local or manual mode and it is not running, a maximum demand inhibit from

another pump will interlock this pump off to prevent it from starting.

6.7.8.2.11 P0x: No Purge Air Flow (Interlock)

If the purge air system indicates a no flow condition after a configurable time (default 15

secs) has elapsed and the Mainline Pump is running, the Mainline Pump is interlocked off.

If the purge air system indicates a no flow condition after a configurable time (default 15

secs) has elapsed and the Mainline Pump is not running, the Mainline Pump is interlocked off.

This is a start interlock.

6.7.9 Failure Modes

None defined.


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6.8 MV Mainline Pump Sets – VSD (Parallel Configuration)

This section is associated with the control and monitoring of MV Mainline Pump Set – VSD

Device Groups.

MV Mainline VSD Pump Sets are installed on stations associated with the new 24” Multi-

product Pipeline.


This section covers Medium Voltage Pump Sets used in mainline applications, where ABB

ACS1000 air/water-cooled VSD’s with Machine Monitoring Systems are installed and where

the Pump-Sets are placed in a parallel configuration.

VSD Pump Sets are used to maintain pressure/flow along the pipeline as required.

Note: A Pump Set is operated in conjunction with Inlet and Discharge Valves. Only the

discharge valve is automated.

Pumps will start on an open flow-path (never against closed input/output valves).

The drive is inhibited from operating in local (at the VSD panel) without the PLC, SIS and

MMS providing protective interlocking, i.e. NO operation without the PLC online (the

protection hard-wired links from the PLC (P01 PTR and P01 TVR1)), the MMS (P01 TVR2) and

SIF Trip relay (P01 SIF1) signals being healthy. Note that local control at the VSD itself is

possible, provided the hard-wired PTR and TVR signals are in a healthy state.

VSDs that are water-cooled have a chiller interface, those that are air-cooled do not.

The pump set is connected to a Machine Monitoring System (GE System 1 based on Bentley

Nevada 3500 sensing equipment). Signals are interfaced to the PLC via hardwired and

Modbus RS422 interface.

The control and monitoring functionality is achieved via the following devices:


Valves and Pumps

Mainline Pump P0x Inlet Valve ZV PxA

Mainline Pump P0x Discharge Valve XV PxE

Mainline Pump P0x (i)

P0x

Instruments

Station Discharge Pressure * PT x2x

Mainline Flow * FT x2x

Instruments (Hardwired)

Mainline Pump P0x Suction Pressure PT 0x1

Mainline Pump P0x Discharge Pressure PT 0x2 Mainline Pump P0x Flow FT 0x1

Mainline Pump P0x Sonic Velocity KT 0x1

Mainline Pump P0x Casing Temperature TT 0x4

Mainline Pump P0x NDE Seal Leak Detection (i)

LS 0x1

Mainline Pump P0x DE Seal Leak Detection (i)

LS 0x2

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6.8.1.2 Signals Interfaced between the PLC – VSD (Modbus Interface)

Typical electrical interface for Mainline MV Pump Set VSD installed on stations associated with

the 24” MPP Pipeline is as follows:

MV01 P0x Current (i)

IT0x1

MV01 P0x Speed (i)

ST0x1

MV01 P0x Motor Winding Current (i)

TT0x8A/B/C

MV01 P0x Speed Reference (i)

SC0x1

MV01 P0x VSD VCB Ready to be Closed (i)

MV01P0x RDYON

MV01 P0x VSD Ready to Run (i)

MV01P0x RDYRUN

MV01 P0x VSD Running (i)

MV01P0x RDYREF

MV01 P0x VSD Running at Speed (i)

MV01P0x ASP (AT_SETPOINT)

MV01 P0x VSD Mechanical Trip Request (i)

MV01P0x MTR (TRIPPED)


MV01P0x RES (EmergStop)


MV01P0x VT (AUX POWER)

MV01 P0x Motor Winding Temp Wirebreak (i)

MV01P0x TT0x5WB (MotWdgMLoss)

MV01 P0x Under Voltage (i)

MV01P0x UV (Undervoltage)

MV01 P0x VSD In Local (i)

MV01P0x SLO (REMOTE)

MV01 P0x VSD Chiller Alarm (i)

MV01P0x CHALM (ExtWtrCool)

MV01 P0x VSD Chiller Fault (i)

MV01P0x CHFLT (ExtWtrCool)

MV01 F5x VCB Close Request (i)

MV01F5x C


MV01P0x IRC

MV01 P0x VSD Remote Reset Request (i)

MV01P0x RR

6.8.1.3 Signals Interfaced between the PLC – VSD (Hardwired Interface)


MV01P0x PTR


MV01P0x TVR1

6.8.1.4 PLC - MMS Interface

6.8.1.4.1 Signals Interfaced between the PLC – MMS (Modbus Interface)

The following signals are interfaced between the PLC and MMS System via Modbus interface:

Mainline Pump P0x Pump NDE Thrust Bearing Temp TT 0x1A/B

Mainline Pump P0x Pump NDE Thrust Bearing Temp TT 0x2A/B

Mainline Pump P0x Pump NDE Radial Bearing Temp TT 0x3A/B Mainline Pump P0x Pump NDE Radial Bearing Temp TT 0x5A/B

Mainline Pump P0x Pump NDE Radial Bearing Vib X-Axis VT 0x1x Mainline Pump P0x Pump NDE Radial Bearing Vib Y-Axis VT 0x1y

Mainline Pump P0x Pump DE Radial Bearing Vib X-Axis VT 0x2x

Mainline Pump P0x Pump DE Radial Bearing Vib Y-Axis VT 0x2y Mainline Pump P0x NDE Thrust Bearing Axial Displacement ZT 0x1

Mainline Pump P0x NDE Thrust Bearing Axial Displacement ZT 0x2 Mainline Pump P0x NDE Bearing Vibration ST 0x1

Mainline Pump P0x DE Bearing Vibration ST 0x2 Mainline Pump P0x Keyphase KT 0x2

Mainline Pump P0x Motor DE Radial Bearing Temp TT 0x6A/B Mainline Pump P0x Motor NDE Radial Bearing Temp TT 0x7A/B

Mainline Pump P0x Motor DE Radial Bearing Vib X-Axis VT 0x3x

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Mainline Pump P0x Motor DE Radial Bearing Vib Y-Axis VT 0x3y

Mainline Pump P0x Motor NDE Radial Bearing Vib X-Axis VT 0x4x Mainline Pump P0x Motor NDE Radial Bearing Vib Y-Axis VT 0x4y

Mainline Pump P0x Motor DE Bearing Vibration ST 0x3

Mainline Pump P0x Motor NDE Bearing Vibration ST 0x4

6.8.1.4.2 Signals Interfaced between the PLC – MMS (Hardwired Interface)

The following signals are interfaced between the PLC and MMS System via hardwired

interface:

Mainline Pump P0x MMS Fail P0x BNARM

Mainline Pump P0x Pump Radial Bearing High Vibration Alarm (i)

P0x VSH0x1

Mainline Pump P0x Motor Radial Bearing High Vibration Alarm (i)

P0x VSH0x2

Mainline Pump P0x NDE Thrust Bearing Axial Displacement Alarm (i)

P0x ZSH0x1

Mainline Pump P0x Pump High Vibration Alarm (i)

P0x SSH0x1

Mainline Pump P0x Motor High Vibration Alarm (i)

P0x SSH0x2

Mainline Pump P0x Pump Radial Bearing High Temperature Alarm (i)

P0x TSH0x1

Mainline Pump P0x Motor Radial Bearing High Temperature Alarm (i)

P0x TSH0x2

Mainline Pump P0x Pump Radial Bearing High Vibration Trip (i)

P0x VSHH0x1

Mainline Pump P0x Motor Radial Bearing High Vibration Trip (i)

P0x VSHH0x2

Mainline Pump P0x NDE Thrust Bearing Axial Displacement Trip (i)

P0x ZSHH0x1

Mainline Pump P0x Pump High Vibration Trip (i)

P0x SSHH0x1

Mainline Pump P0x Motor High Vibration Trip (i)

P0x SSHH0x2

Mainline Pump P0x Pump Radial Bearing High Temperature Trip (i)

P0x TSHH0x1

Mainline Pump P0x Motor Radial Bearing High Temperature Trip (i)

P0x TSHH0x2

Mainline Pump P0x MMS Trip Multiply (i)

P0x BNTM

Mainline Pump P0x MMS Trip Reset (i) P0x BNRST

Mainline Pump P0x MMS Alarm Inhibit (Not Used) (i)

P0x BNINH

6.8.1.4.3 PLC to System 1 Modbus signals (MMS)

The following signals are interfaced via Modbus to the System 1 Server for diagnostic

purposes:

Station Discharge Pressure* PT x2x Mainline Pump P0x Suction Pressure PT 0x1

Mainline Pump P0x Discharge Pressure PT 0x2 Mainline Pump P0x Flow FT 0x1

Mainline Pump P0x Casing Temperature (i)

TT 0x4

Mainline Pump P0x Lube Oil Flow * FS 16x Mainline Pump P0x Lube Oil Header Pressure* PT 16x

Mainline Pump P0x Lube Oil Tank Level* LT 16x

Mainline Pump P0x Lube Oil Strainer Diff Pressure* PDT 16x Mainline Pump P0x Lube Oil Tank Temperature* TT 16xA

Mainline Pump P0x Lube Oil Cooler Outlet Temp* TT 16xB

Mainline Pump P0x Seal Pressure (i)

PT 16x

Mainline Pump P0x Seal Pressure (i)

PT 16x

Mainline Pump P0x Motor Winding Temperature A-C (i) TE 0x8A-C



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Notes:

1. The control and monitoring functionality of the Mainline Pump VSD Device Typical is

described in the Software Control Module Standard [3].


3. MMS Protection instrumentation form part of the Mainline Pump Device Typical.






Operation:

Local

Manual

Automatic


6.8.4.1 Flow Compensation

FT 0x1_S is compensated for pressure, temperature and density.


Not required.


6.8.4.4 Pump Set Lined up State

The Pump Set is in a Lined up state if:

Breaker closed AND

XV PxE is Closed

6.8.4.4.1 Mainline Pump Online/Flushing State

The Mainline Pump is in an Online/Flushing state if:



Pump P0x is Running

6.8.4.4.2 Mainline Pump Offline State


Pump Outlet Valve XV PxE is Closed AND

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Pump Px1 is Stopped

6.8.4.5 Pump Set No Valid Flow-path Status

If a Pump Set No Valid Flow-path alarm condition is detected, a group 'No Valid Flow-path'

bit is active.

A Valid Flow-path for the Mainline VSD Pump exists, if the following conditions are met:

Discharge Valve XV PxE is (Open OR Wirebreak) AND

Suction Valve ZV PxA is (Open OR Wirebreak)





in detail.



path as defined in Section 6.8.4.5.


Should a Mainline Pump not be flushed (i.e. the "Mainline Pump Not Flushed" flag is raised)

AND an Interface is not present in the Online route (Interface in Station Flag set High), and

the Mainline Pump moves from an Offline state (as determined by valve status), a Possible

Hotspot flag is raised.

This alarm is cleared when the Mainline Pump goes Online.



A Mainline Pump Set Flush request initiated

AND

device failure while running the Flush sequence OR,

Mainline Pump Set Flush not online timer (configured as the time it takes the

Mainline Pump Set to reach a Flush Online state) has expired.

The Not Flushed flag is is cleared if the Mainline Pump Set is placed online as determined by

valve status.

6.8.4.7 Pump Set Line-up Sequence

The sequence prepares the pump set for startup as part of the Station Online sequence.

The Pump Set Line-up sequence is activated on receipt of:

a line-up request from the SCADA

a station line-up request

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The Pump Set Line-up sequence does two things:

close the pump set breaker

close the pump set discharge valve (XV PxE)



XV PxE Not Available OR

P0x Not Available OR



7.2.5.1: Mainline Pump Set P01 Line-Up Sequence

6.8.4.8 Pump Set Online Sequence

The Pump Set Online Sequence is activated on receipt of:


a LWC Online Sequence request from the MCC


A check is undertaken to ascertain if the Pump Set Device Group is “Ready.” If the group is

not ready the sequence cannot be initiated. The first step of the online sequence also checks

if there is a flow-path through the rest of the manifold before the sequence continues. If

there is no flow-path through the rest of the manifold the sequence is aborted.

The Pump Set is started as follows:

Check for a No valid flow path trip condition (through the rest of the manifold). If not

the sequence is aborted.

Perform a “Trip Reset” on the relevant Bentley Nevada 3500 Rack (MMS)

Check if relevant Bentley Nevada 3500 Rack "MMS Healthy" signal present. If not,


Open the Mainline Pump P0x Discharge valve.

Close the pump breaker at the same time as the discharge valve is opened.

Start the Mainline Pump.

Note that the “Trip Multiply” function on Bentley Nevada system and a 2 second

timer (configurable) is initiated in the Bentley Nevada system prior to issuing a start

command. This function is done outside the sequence to cater for manual and local

mode and is implemented within the device typical.

Once the pump running feedback is received, reset the trip multiplier function of

Bentley Nevada system after 10s (configurable). Note the reset of the trip multiplier

is implemented within the device typical.


7.2.5.2: Mainline Pump Set P01 Online Sequence

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ZV PxA Fault OR


P0x Not Available or Interlocked OR

No Flow-path Trip (internal in sequence) OR

MMS not healthy (internal in sequence) OR


Note: The Mainline Pump Set Offline Sequence is activated on receipt of an Online Sequence

Aborted.

6.8.4.9 Pump Set Offline Sequence

The Pump Set Offline Sequence is activated on receipt of:

an Offline request from the SCADA.

A Station Offline request

a command from Duty Speed Controller



a device fault condition exists (P0x OR XV PxE)

a No Valid Flow-path Trip interlock condition exists.

Lube Oil not healthy

A Pump Set Online sequence Aborted

Insufficient power is available. If the VSD under voltage indicates a power failure for

a configurable time (up to 15 seconds) the drive stops (Note: station brownout of

< 5 seconds does not stop drive).

a Line Over-pressure interlock (P0x_SIF is activated).

Station Discharge pressure high interlock as per Section 6.8.7.2.5.





The Pump Set is run offline as follows:

place the lube oil system online unless it is already running

stop the Mainline Pump (the remote stop signal (IRT) from the PLC is removed)

on receipt of the Pump Stopped feedback (POF) close the Mainline Pump P0x

discharge valve (XV PxE)


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7.2.5.3: Mainline Pump Set P01 Offline Sequence

Any faults encountered during the running of the offline sequence (stopping P01) result in

the sequence continuing to completion, complete with all associated alarming and event

logging procedures.


aborting.


Refer to HP Routing - Interface detection section 6.12.4.8 for general flushing requirements.

Note that a pump set flush will always handle all parallel pump sets as a unit for flushing.

The pump set flushing sequence is only allowed to run if the lube system for the associated

pump is healthy.

The Pump Set Flushing Sequence is activated:

an Flushing request from the SCADA


dependent) OR


an Flushing request from the Mainline Pump Flush Sequence controller

The Mainline Pump Sequence Controller will determine if the pump needs to be flushed. The

pump speed is determined by the duty controller that will assume a “Flush Active” condition

during flushing – see “Duty and Speed Controller” in section 6.15.4.1.6 for more details.

All Pump Sets will only be flushed if the flow rate, as measured by the sum of mainline pump

flowmeters (FT0x1), through the station is more than 12000 L/min (configurable). This

minimum flowrate of is achieved by running three pumps at minimum speed of 1611 rpm

(4000 L/min per pump).

Mainline Pump sets not flushed due to low flow rates will need to be manually isolated,

drained and re-primed by operators on site.




ZV PxA Fault OR



No Flow-path Trip (checked in sequence) OR

MMS not healthy(checked in sequence) OR


Pump Set Offline Sequence running


7.2.5.4: Mainline Pump Set P01 Flush Sequence

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The following conditions render the Line-up sequence “Not Available” and automatic

sequences are inhibited:


P0x Not Available P0x Not Avail Refer to [3]


Table 6.8-1: Mainline VSD Pump Set P0x Line-up Availability

The following conditions render the Online, Offline and Flush sequence “Not Available” and

automatic sequences are inhibited:


P0x Not Available or Interlocked

P01 Not Avail or Intlk Refer to [3]


ZV PxA Not Opened or WB


MMS Rack Fail MMS Rack Fail The MMS Rack Failed availability status indicates that the MMS Rack communication link has failed.

Lube Oil Not Ready Lube Oil Not Ready Refer to Section 6.8.7.2.7




SDP High Trip Station Discharge Pressure High


Line Over-pressure Protection Activated

Line Overpressure Protection


Table 6.8-2: Mainline VSD Pump Set P0x Online, Offline and Flush Availability

6.8.6 Group Status

The following status indications are to keep the Operator informed of the status of the Device

Group



inactive condition and red in the active condition, with an associated event.


Possible Hotspot Possible Hotspot As per Section 6.8.4.6.2

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MMS Modbus Failure MMS Modbus Failure The MMS Modbus Failure indication is provided when the Modbus communications encounters a fault state.


No Valid Flow-path Trip As per Section 6.8.7.2.8

Table 6.8-3: Mainline VSD Pump Set P0x Group Alarm Status




Alarm Configuration Database (3) for details, including the text to be used for the event

messages.


Pump Not Flushed Pump Not Flushed As per Section 6.8.4.6.3

No Valid Flow-path

No Valid Flow-path As per Section 6.8.4.5



As per Section 6.8.7.2.6

Table 6.8-4: Mainline VSD Pump Set P0x Group Error Status


None defined.


The following interlocks have been defined for the Pump Sets – VSD Group:


6.8.7.1.1 PTR Trip

The PTR trip signal is hardwired to the VSD panel as a “Process Stop” input and will result in

a non-latched trip within the VSD. When the condition resets or returns to a healthy condition

the P01 PTR output is reinstated.

6.8.7.1.2 TVR Trip

TVR1 (and TVR2, SIF1) signals are hardwired to the VSD panel as an “External Motor

Protection” input and will result in a latched trip within the drive, and the VCB is opened.

When the condition resets or returns to a healthy condition the P0x TVR output is reinstated.

6.8.7.1.3 Line Over-pressure Trip

An independent SIL rated safety system is installed to perform the following functionality:

On detection of a high trip Station Outlet pressure all the pumps are tripped

simultaneously via the TVR input to the VSD.

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Operation of this trip is interfaced to the PLC for alarming purposes and also for

remote reset function once the condition has normalised.



manual or local.

6.8.7.2.1 P0x: Pump Suction Pressure Low (PT 0x1)






6.8.7.2.2 P0x: Pump Discharge Pressure High (PT 0x2)


configurable time (default 10 seconds) on startup, trip Mainline Pump Px1. This protection




6.8.7.2.3 P0x: Pump Flow Low (FT 0x1) (PTR)

On detection of low flow (FT0x1 < 500 L/min, 30s (configurable) after pump speed > min

speed) the pump is tripped. This protection inoperative delay is used during startup to

prevent spurious trips from occurring. This interlock and associated alarm is blocked if the

pump is not running.


6.8.7.2.4 P0x: Pump Casing Temperature (TT 0x4) (PTR)


tripped.


When station discharge pressure (PT x2x) exceeds a pre-defined high limit all pumps are

interlocked off.


If insufficient power is available to run the pump set (either utility or MV Genset), this

interlock prevent the Mainline Pump Set from starting in Auto, Manual and Local. Note that

for this interlock to occur, utility power needs to be lost for a period > 5 seconds

(configurable). Restoration of utility power within 5 seconds is termed a brownout condition,

and the pumps carry on running. Insufficient Power is a signal generated within the MV

Switchgear and interfaced to the PLC.

Refer to section 6.27.4.2 for details.

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6.8.7.2.7 P0x: Lube Oil Not Healthy (P0x-LBFLT) (Interlock)

If the lube oil system indicates not healthy and the Mainline Pump is running, the Mainline

Pump is interlocked off.

If the Lube Oil System indicates Not Ready and the Mainline Pump is not running, the

Mainline Pump is interlocked off. This is a start interlock.






Receiver

Launcher

HP Routing

LP Routing

Other Pump Set D.O.L (series configuration)

6.8.7.2.9 P0x: Line Over-Pressure Protection (LOP) (SIF) (Interlock)

On detection of a line over-pressure active (PYx2xA_SIF) or QSifEnable signal the Mainline

Pump is interlocked off. Signal QSifEnable is calculated in SisLop function block. See SIS

Section 6.16.7.2.1 for details.

6.8.8 Failure Modes

Failure of communication between PLCs and MMS: Alarm only

Instrument failures: Alarm and use substitute values


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6.9 MV Mainline Pump Sets – VSD (Crude Booster Stations)

This section is associated with the control and monitoring of MV Mainline Pump Set – VSD

Device Groups.

MV Mainline VSD Pump Sets are installed on stations associated with the Crude Booster

Stations.


This section covers Medium Voltage Pump Sets used in mainline applications, where ABB

ACS1000 air-cooled VSD’s without Machine Monitoring Systems are installed and where the

Pump-Sets are placed in a series configuration.

VSD Pump Sets are used to maintain pressure/flow along the pipeline as required.

Note: A Pump Set is operated in conjunction with Inlet and Discharge Valves.

Pumps will start on an open flow-path (never against closed input/output valves).

The drive is inhibited from operating in local (at the VSD panel) without the PLC providing

protective interlocking, i.e. NO operation without the PLC online (the protection hard-wired

links from the PLC (P01 PTR and P01 TVR) being healthy). Note that local control at the VSD

itself is possible, provided the hard-wired PTR and TVR signals are in a healthy state.

VSDs are air-cooled i.e. chillers are not installed.



Valves and Pumps

Mainline Pump P0x Inlet Valve ZV PxA Mainline Pump P0x Discharge Valve ZV PxE

Mainline Pump P0x P0x

Instruments (Hardwired)

Pump seal leak detection (i) PS0x1

Pump suction pressure PT0x1 Pump discharge pressure PT0x1

Pump non-drive end (NDE) bearing temperature (i) TT0x1

Pump casing temperature (i) TT0x2

Pump drive end (DE) bearing temperature (i) TT0x3

Motor drive end (DE) bearing temperature (i) TT0x4

Motor Winding temperature (i) TT0x5a

Motor Winding temperature (i) TT0x5b

Motor Winding temperature (i) TT0x5c

Motor non-drive end (NDE) bearing temperature (i) TT0x6

Pump vibration (i) VT0x1

Motor vibration (i) VT0x2

6.9.1.2 Signals Interfaced between the PLC – VSD (Modbus Interface)

Typical electrical interface for Mainline MV Pump Set VSD installed on Crude Booster stations

associated with the Crude Pipeline is as follows:

MV01 P0x Current (i)

IT0x1

MV01 P0x Speed (i)

ST0x1

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MV01 P0x Motor Winding Current (i)

TT0x8A/B/C

MV01 P0x Speed Reference (i)

SC0x1

MV01 P0x VSD VCB Ready to be Closed (i)

MV01P0x RDYON

MV01 P0x VSD Ready to Run (i)

MV01P0x RDYRUN

MV01 P0x VSD Running (i)

MV01P0x RDYREF

MV01 P0x VSD Running at Speed (i)

MV01P0x ASP (AT_SETPOINT)

MV01 P0x VSD Mechanical Trip Request (i)

MV01P0x MTR (TRIPPED)


MV01P0x RES (EmergStop)


MV01P0x VT (AUX POWER)

MV01 P0x Motor Winding Temp Wirebreak (i)

MV01P0x TT0x5WB (MotWdgMLoss)

MV01 P0x Under Voltage (i)

MV01P0x UV (Undervoltage)

MV01 P0x VSD In Local (i)

MV01P0x SLO (REMOTE)

MV01 F5x VCB Close Request (i)

MV01F5x C


MV01P0x IRC

MV01 P0x VSD Remote Reset Request (i)

MV01P0x RR

6.9.1.3 Signals Interfaced between the PLC – VSD (Hardwired Interface)


MV01P0x PTR


MV01P0x TVR


Notes:

1. The control and monitoring functionality of the Mainline Pump VSD Device Typical is

described in the Software Control Module Standard [3].







Operation:

Local

Manual

Automatic



FT 0x1_S is compensated for pressure, temperature and density.


Not required.

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6.9.4.3.1 Pump Set Lined up State

The Pump Set is in a Lined up state if:

Breaker closed AND

XV PxE is Closed

6.9.4.3.2 Mainline Pump Online State

The Mainline Pump is in an Online state if:


Pump Outlet Valve ZV PxE is Open AND

Pump P0x is Running

6.9.4.3.3 Mainline Pump Offline State


Pump Px1 is Stopped

6.9.4.4 Pump Set No Valid Flow-path Status

If a Pump Set No Valid Flow-path alarm condition is detected, a group 'No Valid Flow-path'

bit is active.

A Valid Flow-path for the Mainline VSD Pump exists, if the following conditions are met:

Discharge Valve ZV PxE is (Open OR Wirebreak) AND

Suction Valve ZV PxA is (Open OR Wirebreak)





in detail.



path as defined in Section 6.9.4.4.


Not required – dedicated product.



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6.9.4.6 Pump Set Line-up Sequence

The sequence prepares the pump set for startup as part of the Station Online sequence.

The Pump Set Line-up sequence is activated on receipt of:

a line-up request from the SCADA

a station line-up request

The Pump Set Line-up sequence does two things:

close the pump set breaker

close the pump set discharge valve (XV PxE)




P0x Not Available OR



7.2.6.1: Mainline Pump Set P01 Line-Up Sequence

6.9.4.7 Pump Set Online Sequence

The Pump Set Online Sequence is activated on receipt of:



A check is undertaken to ascertain if the Pump Set Device Group is “Ready.” If the group is

not ready the sequence cannot be initiated. The first step of the online sequence also checks

if there is a flow-path through the rest of the manifold before the sequence continues. If

there is no flow-path through the rest of the manifold the sequence is aborted.

The Pump Set is started as follows:

Check for a No valid flow path trip condition (through the rest of the manifold). If not


Close the pump breaker.

Start the Mainline Pump.


7.2.6.2: Mainline Pump Set P01 Online Sequence



ZV PxA Fault OR

ZV PxE Fault OR


No Flow-path Trip (internal in sequence) OR

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Note: The Mainline Pump Set Offline Sequence is activated on receipt of an Online Sequence

Aborted.

6.9.4.8 Pump Set Offline Sequence

The Pump Set Offline Sequence is activated on receipt of:

an Offline request from the SCADA.

A Station Offline request

a command from Duty Speed Controller



a device fault condition exists (P0x OR XV PxE)

a No Valid Flow-path Trip interlock condition exists.

Insufficient power is available. If the Power Quality Meter (PQM) indicates a power

failure for a configurable time (up to 15 seconds) the drive stops (Note: station

brownout of < 5 seconds does not stop drive) OR all electrical Incomer OCBs indicate

an open status.

Fire detected – Plant active

Station Discharge pressure high interlock as per Section 6.9.7.2.4.





The Pump Set is run offline as follows:

stop the Mainline Pump (the remote stop signal (IRT) from the PLC is removed)


7.2.6.3: Mainline Pump Set P01 Offline Sequence

Any faults encountered during the running of the offline sequence (stopping P01) result in

the sequence continuing to completion, complete with all associated alarming and event

logging procedures.


aborting.




The following conditions render the Online and Offline sequence “Not Available” and

automatic sequences are inhibited:

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P0x Not Available or Interlocked

P01 Not Avail or Intlk Refer to [3]

ZV PxA Not Opened or WB


ZV PxE Not Opened or WB

ZVPxE Not Opened/Wb Refer to [3]




SDP High Trip Station Discharge Pressure High


Table 6.9-1: Mainline VSD Pump Set P0x Online, Offline and Flush Availability

6.9.6 Group Status

The following status indications are to keep the Operator informed of the status of the Device

Group



inactive condition and red in the active condition, with an associated event.



No Valid Flow-path Trip As per Section 6.9.7.2.6

Table 6.9-2: Mainline VSD Pump Set P0x Group Alarm Status




Alarm Configuration Database (3) for details, including the text to be used for the event

messages.


No Valid Flow-path

No Valid Flow-path As per Section 6.9.4.4



As per Section 6.9.7.2.5

Table 6.9-3: Mainline VSD Pump Set P0x Group Error Status


None defined


The following interlocks have been defined for the Pump Sets – VSD Group:

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6.9.7.1.1 PTR Trip

The PTR trip signal is hardwired to the VSD panel as a “Process Stop” input and will result in

a non-latched trip within the VSD. When the condition resets or returns to a healthy condition

the P0x PTR output is reinstated.

6.9.7.1.2 TVR Trip

The TVR signal is are hardwired to the VSD panel as an “External Motor Protection” input and

will result in a latched trip within the drive, and the VCB is opened. When the condition resets

or returns to a healthy condition the P0x TVR output is reinstated.



manual or local.

6.9.7.2.1 P0x: Pump Suction Pressure Low (PT 0x1)






6.9.7.2.2 P0x: Pump Discharge Pressure High (PT 0x2)


configurable time (default 10 seconds) on startup, trip Mainline Pump Px1. This protection




6.9.7.2.3 P0x: Pump Casing Temperature (TT 0x4) (PTR)


tripped.


When station discharge pressure (PT x2x) exceeds a pre-defined high limit the pump is

interlocked off.


If insufficient power is available to run the pump set, this interlock prevent the Mainline

Pump Set from starting in Auto, Manual and Local. Note that for this interlock to occur, utility

power needs to be lost for a period > 15 seconds (configurable) OR all electrical Incomer

OCBs indicate an open status. Restoration of utility power within 5 seconds is termed a

brownout condition, and the pumps carry on running. Insufficient Power is a signal generated

within the MV Switchgear (Power Quality Meter) and interfaced to the PLC.

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Receiver

Launcher

HP Routing

6.9.7.2.7 P0x: Routing Valve Failure (Interlock)

If a remote pig is detected, pig in station or multiple pigs detected and a routing valve is not

available then the Pump Set will run offline if in auto or forced off if in manual or local.

Refer to HP routing (Station specific EDS) for impact on station bypass.

6.9.7.2.8 P0x: Fire Detected - Plant (Interlock)

On detection of Plant Fire Alarm UA198, P0x is forced off.

6.9.8 Failure Modes

Instrument failures: Alarm and use substitute values


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6.10 Lube Oil System – 24” MPP Stations

This section is associated with the control and monitoring of MV Mainline Pump Set – Lube

Oil Device Group.

Lube Oil Systems of this type have been installed on stations associated with the new 24”

Multi-product Pipeline.


The lube oil device group will consist of all individual lube oil systems associated with the MV

Mainline Pump Sets installed on 24” MPP Stations.

Each Mainline Pump set is equipped with a separate lube oil system. The lube oil system is

used for the lubrication of pump set bearings where forced lubrication is required. Lube oil is

circulated through the pump set bearings and back to a lube oil tank.

Pump sets may only be run with lube oil circulation active.

There are two lube oil pumps per pump set. A mechanical pump which operates when the

Mainline Pump is in operation, and an electrical auxiliary lube oil pump. A single flow switch

and pressure transmitter are used to indicate lube oil header flow and pressure.

The mechanically driven pump is active as soon as the Mainline Pump is running and will

remain active until the pump set is stopped. Once the Mainline Pump set is running at

minimum speed the electrically driven pump may be switched off but will remain on standby

(if in automatic) should the mechanically-driven pump not supply sufficient flow or pressure.

All lube oil systems associated with a Mainline Pump manifold are placed online and offline

together in order to cater for the possible windmilling of Mainline Pumps.

The auxiliary lube oil pump can be switched on at any time to keep the lube oil circulating.

Lube oil cooling is achieved by means of a heat exchanger, which includes two cooling fans

controlled by means of a duty/standby controller.

Lube oil heating is achieved by means of heaters that are switched by means of dual

thermostats (hardwired). These heaters are also interlocked on and off from the PLC.


Instruments

Mainline Pump P0x Lube Oil Flow FS 16x

Mainline Pump P0x Lube Oil Header Pressure PT 16x

Mainline Pump P0x Lube Oil Tank Level LT 16x Mainline Pump P0x Lube Oil Strainer Diff Pressure PDT 16x

Mainline Pump P0x Lube Oil Tank Temperature TT 16xA Mainline Pump P0x Lube Oil Cooler Outlet Temperature TT 16xB

Equipment

P0x Lube Oil Pump Xxx

P0x Lube Oil Cooling Fans 1, 2 Q0x P0x Lube Oil Heater H0x


The Mainline Pump Lube Oil System may be controlled from the PCS either locally at the

Station or remotely from the MCC.

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Operation:

Local

Manual

Automatic


6.10.4.1 Lube Oil System

A lube oil system is left operational (auxiliary pump running) while the Mainline Pump is not

in operation in order to permit flushing of the pump-set. In addition, the power to the lube oil

heater is left ON, which ensures that the lube oil is kept at the right temperature to ensure a

“quick” start-up of the Mainline Pump.

6.10.4.1.1 Pressure Control (PT 16x)

A pressure transmitter is provided on the lube oil discharge header line for control and

monitoring of the lube oil system.

A “self-regulating” (mechanical) spillback pressure control valve is installed to protect the

lube oil system (set at 200 kPa).

If pressure in the lube oil header is below a pre-configured set-point, 150 kPa (low pressure),

the lube ready signal is removed (via P0x-LBRDY) and the Mainline Pump is prevented from

starting.

If the lube oil group is in automatic, the auxiliary pump is switched on automatically if the

pressure in the lube oil header drops below 120 kPa (low pressure) if the Mainline Pump is

not stopped.

If the pressure in the lube oil header drops below a pre-configured set-point, 80 kPa (low trip

pressure) while the Mainline Pump is running, the Mainline Pump is interlocked off. In order

to protect against lube oil leakage, the auxiliary lube oil pump is interlocked off if a lube oil

header low pressure trip condition exists (< 80 kPa) for longer than a configurable time (120

secs) with the lube oil pump running.

After initial start of the Mainline Pump operation the auxiliary pump is switched off after a

predetermined time (default 60 seconds) if the Mainline Pump is running and the lube oil

header pressure is above 120 kPa (the mechanical lube oil pump continues to supply enough

lube oil header pressure and flow).

6.10.4.1.2 Filtering System

A duplex filtering system is installed, one in operation and one for standby.

Switching between the operational and standby filters is done manually at the filters

themselves without interrupting the operation of the lube oil system. Indication of filter

blockage is achieved via a differential pressure alarm in the PLC (PDT 16x > 100kPa).

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6.10.4.1.3 Oil Cooling

Oil cooling is achieved by dedicated air coolers with redundant fans, one in operation and one

in standby. These fans are controlled by a duty/standby controller within the PLC (see PCS

Software Control Module Standard [3].

Each fan is designed to handle 100% of the cooling power needed by the system.

If the Mainline Pump is not running and the lube oil header temperature (TT 16xB) rises

above 60°C, the Mainline Pump is prevented from starting.

If the Mainline P0x is Running and the Lube Oil Header Temperature (TT 16xB) > 60°C, the

standby fan is started.

If the lube oil header temperature (TT 16xB) rises above 40°C and the lube oil group is in

automatic, the lube oil fan duty controller is started.

If the lube oil header temperature (TT 16xB) drops below 25°C, the lube oil fan duty

controller is stopped. It is also stopped when the Mainline Pump is stopped after a

configurable time (default 60 seconds).

The standby fan is stopped at TT 16xB < 55°C.

Note: At least one fan needs to be ready for duty for the Duty Controller to run

6.10.4.1.4 Temperature Control

A local thermostat-controlled heater is provided to heat up the lube oil in the lube oil tank.

An internal thermostat is installed to switch the heater on for temperatures below 25°C,

regardless of whether the associated Mainline Pump-set is running or not.

For safety reasons a second thermostat is installed to switch the heater off above 85°C

(manual reset required).

A third safety interlock is provided by the PLC as follows:

In the event of a lube oil tank temperature (TT 16xA) high (80°C) being detected, the supply

to this heater is interlocked off. A low temperature below 20°C results in the heater being

interlocked on.

A low lube oil temperature below 20°C in the lube oil tank (TT 16xA) prevents the Mainline

Pump from starting – if not already running (via P0x-LBRDY).

6.10.4.1.5 Level Control

A level transmitter (LT 16x) is installed on the lube oil tank for monitoring and control.

If a low level (40%) is detected inside the lube oil tank, the lube oil heater is interlocked off

and the Mainline Pump is prevented from starting in Auto and Manual.

A low alarm will be raised when the level drops below 50%. This will prevent the lube oil

from starting in Automatic and the mainline pump will be prevented from starting, in

Automatic and Manual.

A low-low lube oil tank level (25%) stops the lube oil pump X2x, unless the Mainline Pump is

running.

6.10.4.1.6 Flow Control

A flow switch (FS 16x) installed in the lube oil header is used as follows:

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If low flow is detected by the PLC while the Mainline Pump is running, the auxiliary lube oil

pump is started automatically. If low flow is still detected after 2 minutes of auxiliary lube oil

pump start, the Mainline Pump is tripped interlocked off.

If low flow is detected by the control system and the Mainline Pump is not running, this

interlock prevents the Mainline Pump from starting (via P0x-LBRDY).

A low lube oil tank level will prevent the lube oil pump from starting in Auto, when the

mainline pumps are not running.

6.10.4.1.7 Lube Oil Auxiliary Pump Control

An auxiliary lube oil pump is started in cases of no flow or low pressure (PT 16x < 120 kPa)

in the lube oil header when the Mainline Pump is not stopped and the lube oil device group is

in automatic.

After restart of the auxiliary lube oil pump by either No Flow or Low Pressure, the auxiliary

lube oil pump will remain on for a configurable time (default 90sec) if the Mainline Pump is

not stopped and the flow and pressure is healthy. This timer can be set to indefinite if the

auxiliary pump is required to run until an operator stop command.

The auxiliary lube oil pump is stopped on request by the operator in manual, irrespective of

whether the Mainline Pump is running or not. If the lube oil system is placed online by the

operator, it is restarted if not already running after the Mainline Pump has been switched off

(provided the lube oil device group is in automatic).

After initial start of the Mainline Pump the auxiliary pump is switched off after a

predetermined time (default 60 seconds) if the Mainline Pump is running and the lube oil

header pressure is above 120 kPa (the mechanical lube oil pump continues to supply enough

lube oil header pressure).

6.10.4.2 Lube Oil System Statuses

Two statuses are defined for the Lube Oil System that may be used in order to simplify the

interface into this packaged unit.

6.10.4.2.1 Lube Oil System Ready (P0x-LBRDY)

Lube oil system not ready status prevents the Mainline Pump from starting in automatic and

in manual.

Lube Oil Ready Status is defined as follows:


LT16x Lube Tank Level Low


If the Lube Oil tank level LT16x falls below the low level limit set-point (LT 16x < 50%).

TT16xA Temperature Not Between 20°C And 80°C

TT16xA Not Between 20°C and 80°C

The Lube Oil Tank Temperature TT 16xA is not between 20°C and 80°C then the P0x Lube Oil Group status indicates a not ready status.

TT16xB Temperature Not Between 20°C And 60°C

TT16xB Not Between 20°C and 60°C

The Lube Oil Cooler Outlet Temperature TT 16xB is not between 20°C and 60°C then the P0x Lube Oil Group status

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indicates a not ready status.

PDT16x Strainer Differential Pressure High

PDT16x Strainer Diff Press High

The Strainer Differential Pressure PDT 16x across Lube Oil duplex filters is greater than the High limit set-point (PDT 16x >100kPa(g)) then the P0x Lube Oil Group status indicates a not ready status.

PT16x Header Pressure < 150kPa

PT16x Header Press <150kPa

The Header Pressure PT16x is less than High limit set-point (PT 16x <150kPa(g)) then the P0x Lube Oil Group status indicates a not ready status.

FS16x Header Flow Not Healthy

FS16x Header Flow Not Healthy

The Header Flow FS16x is not healthy then the P0x Lube Oil Group status indicates a not ready status.

Table 6.10-1: P0x Lube Oil Ready Status

6.10.4.2.2 Lube Oil System Not-Healthy status (P0x-LBFLT)

Lube oil not-healthy status detected whilst the Mainline Pump is running trips the pump in

manual and automatic, and is defined as follows:

Lube oil header pressure below a predefined limit (PT 16x < 80kPa)

Lube oil inlet header flow (FS 16x not healthy, detected for 2 minutes)

6.10.4.3 Lube Oil Online Sequence

All lube oil systems (P0x) are started simultaneously, and are treated as one within the online

sequence.

The lube oil system online sequence is activated on:

A Start Online Sequence request from the SCADA or

A Station Lineup request or

A VSD Pump Set Offline Sequence request or

At the end of the Mainline Pump Flushing sequence

If any devices controlled by the sequence becomes Not Available (Xxx) during the running of

the online sequence, the sequence continues, complete with all associated Alarming and

Event Logging procedures. Placing the Group in Manual mode while the sequence is running

results in the sequence aborting.


7.2.7.1: Lube Oil Online Sequence

6.10.4.4 Lube Oil Online Indication

The Lube Oil is in an Online state if:

Xxx Running

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6.10.4.5 Lube Oil Offline Sequence

The lube oil system offline sequence is activated on:

A Start Offline sequence request from the SCADA or

A Station Isolation sequence request from the SCADA

Any faults encountered during the running of the offline sequence will result in the sequence

continuing to completion, complete with all associated Alarming and Event Logging

procedures. Placing the Group in Manual mode while the sequence is running results in the

sequence aborting.


7.2.7.2: Lube Oil Offline Sequence

6.10.4.6 Lube Oil Offline Indication

The Lube Oil is in an Offline state if:

Xxx Stopped


6.10.5.1 Lube Oil Availability

At least one of the Lube Oil systems should be available (as below) for the Lube Oil Sequence

to be available.

The following conditions will render the P01 Lube Oil Group "Not Available".


Xxx Pump Not Available

Xxx Pump Not Avail

Refer to [3]



The Lube Tank level is below the Low alarm set-point (50%).

TT16xA < 20C Tank Temp Low

TT16xA < 20°C Lube Tank Temp Low

The Tank Temperature is below the Low alarm set-point (< 20°C).

Q0x Fan Duty Not Available

Q0x Fan Duty Not Avail

No Fans are Ready for Duty (Duty Controller)

Instrument Fault Instrument Fault Any Instrumentation Fault (FS16x, PT16x, LT16x, PDT16x, TT16xA and TT16xB)

Table 6.10-2: P0x Lube Oil Availability

6.10.6 Group Status


None defined

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None defined


None defined


The following interlocking strategies have been defined for the Lube Oil System Group:


6.10.7.1.1 Lube Oil Electric Heater

If the lube oil reaches an alarm high temperature (85°C) the lube oil thermostat trips the

lube oil heater off and will need to be manually reset.


6.10.7.2.1 H0x: Lube Oil Tank Temperature High

If a high lube oil temperature (TT 16xA > 80°C) is indicated the lube oil heater is interlocked

off.

6.10.7.2.2 H0x: Lube Oil Tank Temperature Low

If a low lube oil temperature (TT 16xA < 20°C) is indicated the lube oil heater is interlocked

on.

6.10.7.2.3 H0x: Lube Oil Tank Level Low

If the level (LT 16x) in the lube oil tank reaches a low level (LT 16x < 40%), the lube oil

heater is interlocked off.

6.10.7.2.4 Xxx: Lube Oil Tank Level Low

If the Mainline Pump is running and a low level is reached (LT16x < 25%) inside the lube oil

tank the auxiliary pump is not prevented from starting. This is to protect the Mainline Pump.

The limits will be configured at acceptable values to allow enough buffer that prevent

unnecessary stoppages of the Mainline Pump.

If the Mainline Pump is not running and the lube oil tank level low is reached (LT16x < 25%),

the auxiliary lube oil pump is interlocked off and the Mainline Pump is prevented from

starting in automatic.

6.10.7.2.5 Xxx: Lube Oil Header Pressure Low

The auxiliary lube oil pump is interlocked off in the event that the lube oil header pressure

low trip condition exists (<80 kPa) for longer than a configurable time (120 sec) while the

lube oil pump is running and provided the Mainline Pump is not running.

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None defined.


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6.11 Lube Oil System – RPP & COP Stations

This section is associated with the control of the Lube Oil Device Group and its associated

devices.

Lube Oil Systems of this type have been installed on stations associated with the RPP and

COP Pipelines.


The lube oil device group comprises of a single lube oil system used to provide lubrication for

all associated MV Mainline Pump Sets installed on COP and RPP Stations.

A single lube oils system is used for the lubrication of pump set bearings where forced

lubrication is required. Lube oil is circulated through the pump set bearings and back to a

lube oil tank.

Pump sets may only be run with lube oil circulation active.


Instruments

Lube Oil Flow FS 16x (RPP Pipeline installations)

Lube Oil Header Pressure PT 16x (COP Pipeline installations) Lube Oil Tank Level LS 16x (COP Pipeline installations)

Equipment

Lube Oil Pumps 1, 2 X0x, X0y

Lube Oil Cooling Fan Q0x


Control is from the SCADA system locally at the station, or remotely from the MCC or SCC.


All devices related to the Lube Oil Group shall have the following three modes of operation:

Local

Manual

Automatic


6.11.4.1 Duty Controller

No sequences have been defined for the lube oil system but the two lube oil pumps are

controlled according to the duty/standby controller typical (Refer to [3] for details).

Automatic selection of duty and standby status of pumps is based on Run Hour differentials

[Configurable in the PLC – Default 100 hours]. Note that each pump will run for a period of

twice the set point, i.e. 200 hours.

If the group is ready, the duty controller is activated from a:

Start sequence Request from the SCADA

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An indication “control active” is indicated on the SCADA. The duty controller is now activated

and will start and stop the lube oil pumps accordingly.

The duty controller is stopped from a:

Stop sequence Request from the SCADA

Manual mode

Group not available

6.11.4.2 Lube Oil Flow/Pressure

Mainline pumps can only run if the lube oil flow switch is active. If the duty controller is

running and the flow switch is not active, after a delay of 5 seconds the standby pump is also

started and the duty controller is switched off (duty control not active). The operator needs

to investigate the problem and restart the duty controller or stop the standby pump in

manual mode.

If no flow is detected after 15 seconds, the mainline pumps are interlocked off.


The following conditions render the DuC “Not Available”.


Xxx Not Available Xxx Not Avail or Intlk Refer to [3]

Table 6.11-1: Lube Oil DuC Availability

6.11.6 Group Status


None defined.


None defined.


None defined.


None defined.



None defined.

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6.11.8.2.1 Xxx: Lube Oil Pump No Flow (RPP Stations only)

If a low flow (FS 16x) is detected while the Lube Oil Pump (Xxx) is running, after a

predefined time (15 seconds) after the pump has been started, the Lube Oil Pump is

interlocked off. This interlock and associated alarm is blocked if the pump is not running.

6.11.8.2.2 Xxx: Lube Oil Header Pressure Low (COP Stations only)

If a low header pressure (PS 16x) is detected while the Lube Oil Pump (Xxx) is running, after

a predefined time (15 seconds) after the pump has been started, the Lube Oil Pump is

interlocked off. This interlock and associated alarm is blocked if the pump is not running.


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6.12 HP Routing

This section is associated with the control and monitoring of HP Routing Manifold Device

Groups.


Control and Monitoring functionality shall be achieved via the following devices:

Valves

Station Inlet Isolation Valve (XV IxA)

Station Outlet Isolation Valve (XV IxE)

Strainer Inlet Valves (XV SxA)

Strainer Outlet Valves (XV SxE)

Strainer Bypass Valves (XV SxK)

Main Flow Control Valve (CV PxJ)

Instrumentation

Station Inlet temperature (TTx21)

Station Outlet temperature (TTx22)

Station Inlet pressure (PTx21)

Station Outlet pressure (PTx22)

Strainer differential pressure (PDT x21)

Mainline Flow (FTx21)

Mainline Product Sonic Velocity (KT x21)

Remote Density (DTx21)

Remote Optic Interface Detector (OTx21)

Remote Chamber Intruder Alarm (AS x21)

Remote Chamber Panel Intruder Alarm (AS x22)

Station Inlet Chamber Intruder Alarm (AS x23)

Station Outlet Chamber Intruder Alarm (AS x24)

Remote Chamber High Level switch (LSH x21)

Station Inlet Chamber High Level switch (LSH x22)

Station Outlet Chamber High Level switch (LSH x23)

Where xx denotes the HP Routing Device Group ID

6.12.1.1 HP Strainers

Dual HP Strainers form a separate device group enabling local operation of strainers outside

of the HP Routing device group.

Single Strainers form part of the HP Routing device group.


HP Routing may be controlled from the PCS either locally at the Station or remotely from the

MCC.

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Operation:

Local

Manual

Automatic


6.12.4.1 Remote Block Valve Chamber

The Remote Chamber may be used to house the following equipment:

Sphere Detector/s to detect incoming spheres or pigs.

Densitometer (DT-xx1) is used to measure product density and detect product

interface. Primary function of interface detection is assist in switching operations and

placement of device groups on flushing.

Optic Interface Detector (OT-xx1) and Sonic Velocity measurement (KT-xx1) is used

to detect product interface. Primary function of interface detection is assist in

switching operations and placement of device groups on flushing.

Intruder switches and a product level switch make up the remainder of the

instrumentation within the Remote chamber.

6.12.4.2 Station Outlet Isolation Valve Chambers

The Station Isolation Valve Pits are used to isolate the station for maintenance and shutdown

purposes. Pressure and temperature instrumentation installed in these pits are used in

conjunction with flow meters by the Pipeline Monitoring System for Leak Detection.

6.12.4.3 Product Identification: SCADA Line Colouring

Product Identification and the associated SCADA Line coloring for multi-product HP Routing

manifolds will be determined by valve status and interface detection i.e. volume tracking

through the station will not be provided.

Line coloring will not differentiate between different grades of the same product where the

product is determined by interface detection. Dedicated product lines will differentiate

between different grades of product where possible.

6.12.4.4 Density Hut HP Routing Panel

The Density Hut HP Routing Panel is installed where HP switching facilities are required at a

particular station and where they are required to be based on hydrometer readings as taken

within the Density Hut. The HP Routing Panel provides the following functionality:

6.12.4.4.1 Command Push-Buttons

The interface makes provision for the operator to issue the following commands to the

control system, on an individual sequence basis:

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1. Route xx Online (XS121) - integral P/Button / Lamp (Green)

2. Route xx Offline (XS122) - integral P/Button / Lamp (Red)

All command buttons comprise of an integral push-button/lamp facility, the lamp being lit

when the command button is enabled (as per the MDS Interface):

6.12.4.4.2 Indication Lamps

The interface makes provision for the following status indications from the control system to

the operator, on an individual sequence basis:

1. Route xx Online sequence available (XI121) - Lamp (Green). Lit when all

associated actuated valves are either available or in their correct state and all associated ZV’s are in their correct state.

2. Route xx Offline sequence available (XI122) - Lamp (Red). Lit when all associated actuated valves are either available or in their correct state and all

associated ZV’s are in their correct state.

3. Route xx running/online (XI803) - Lamp (Green). Flashes when the route is in the process of being opened. Changes to steady state on when the route has

been successfully put online. 4. Route xx running/offline (XI804) - Lamp (Red). Flashes when the route is in

the process of being closed. Changes to steady state on when the route has been successfully put offline.

5. Sequence Fault (XI805) - Lamp (Red). Lit when the selected sequence is in

Fault condition.

6.12.4.5 No Valid Flow-path Status

A HP Routing No Valid Flow-path status is determined by any of the valves on the route

being in a Not Open OR Wirebreak state. This status is used for mainline pump interlocking

purposes.

6.12.4.6 Pipeline Monitoring System Interface

Interface to the PCS is limited to the following functionality:

6.12.4.6.1 Station No Valid Flow-path

Station No Valid Flow-paths are used by the PLMS System for determining routes that are on

line. Station No Valid Flow-paths differ from Device Group No Valid Flow-paths in that 'valve

not-closed OR wire break' states are used (as opposed to 'valve open OR wire break' status).

The PLMS requires, as input, an indication of which routes are online. For a route to be

active, all the valves marked with ‘X’ are ((Not Closed) OR (Wirebreak)). When this condition

is true, the route is considered Not Closed. Each route has an associated inlet and outlet

flowmeter so that PLMS can verify the amount of product flowing into each direction.

Each route corresponds to a single bit of a 32-bit integer value and when a route is Not

Closed, the corresponding bit is high (e.g. 0000 0000 1000 0000 0100 0000 0000 0000). If

multiple routes are online, each corresponding bit will be high and the PLMS will perform bit-

stripping to determine which are not closed.

The no valid flow-path (required for LDS) for a particular source can be derived from no

routes open from that source.

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6.12.4.6.2 Leak Detection RTA

The following statuses and alarms shall be interfaced from the PLMS System and

displayed/alarmed on the PCS:

Leak Detection warning and alarm

6.12.4.6.3 Batch Tracking RTA



Batch ETA (Estimated Time of Arrival)

6.12.4.6.4 Dynamic Pig Tracking RTA



Pig/Sphere ETA (Estimated Time of Arrival)

6.12.4.6.5 Pressure Dynamic Tracking RTA



MAOP Violation warning and alarms

Pressure POI (Points of Interest)


The uncompensated flowrate, FT 12x, is used by PLMS.

The compensated flowrate, FT 12x_S is used for control purposes. Flow compensation is

done using the pressure, temperature and density values as follows:

Flow Transmitter Pressure Temperature Density

FT 12x PT 12x TT 12x HP/LP Route dependent

Table 6.12-1: HP Routing Flow compensation

Where no densitometer is installed, a fixed density value per product is selected depending

on the online route. Where 2 routes are online (i.e. during switching), density for flow

compensation will be based on the first route open until the switch is completed. Refer to

section 7.1 for details.

6.12.4.8 Interface Detection

Density, Sonic Velocity and Refractive Index (OID) is currently used to detect interfaces on

the multi-products line, based on rate of change.

The “Interface Detected bit” will be configured to return a value of true based on rate of

change in the values of KT, DT or OT. The signal will be based on the following:

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There will be two Low Pass Filters to smooth noise out of the signal while allowing

detection of interface:

Reference LPF Value

Current LPF Value

The Reference LPF Value will have a time typical constant of 1 minute (configurable

per instrument) while the Current LPF Value will have a typical time constant of 5

seconds.

If the absolute value of the instantaneous difference between these two Low Pass

Filters is greater than a preconfigured threshold value (configurable per instrument),

the Interface Detected bit will be set.

The end of the interface is at the time when the difference between the Reference LP

Value and Current LPF Value drops and remains below the set threshold value for a

preconfigured time.

Should additional interfaces be detected, instantaneous alarms will be issued for each

occurrence. No volume tracking shall be provided and switching of interfaces to respective

interface tanks remains the responsibility of the operator.

6.12.4.8.1 Operator Flush

Any device group will not be flushed unless the operator places them online manually/locally.

Flushing is initiated by any of the following conditions (flush request bit is set):

an Flush Online Request from the SCADA, if not Online OR


dependent) OR





initiated.

Flushed status for device groups will no longer be tracked.

6.12.4.8.2 Interface Passed

After the interface detected bit has cleared and an additional pre-calculated time has elapsed

(configurable in PLC) has passed through the manifold, a bit “Interface Passed” is indicated.

This bit indicates that the interface has passed.

6.12.4.8.3 Interface in Station

The “Interface in Station” indicates that the product in the station is Intermix. This indication

is used for line colouring.

It is set when a “Interface Detected” alarm is triggered and reset when the “Interface

Passed” is active.

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6.12.4.9 Station Discharge Pressure Deviation High

If the deviation between PT12x and PY12xA_AI is greater than a pre-defined percentage

(default 1%) an indication will be triggered. This deviation is calculated on the basis of a 5

min moving average. When the two signals fall within a configurable percentage (default

0.5%) of each other, this status is automatically reset.

6.12.4.10 Station Efficiency Calculations

Station efficiency information as calculated within the PLMS and displayed on the SCADA is

no longer required to be displayed on the SCADA.

6.12.4.11 HP Routing Sequences

6.12.4.11.1 HP Routing Matrix

A HP Routing Matrix is used by the operator for selection of multiple HP Routing sequences.

For Routing Matrix details refer to Section 4.9.

6.12.4.11.2 HP Routing Online Sequence

HP Routing online sequence is activated on receipt of:


an Online Request from the HP Routing Panel DH12 within the Density hut

A check is undertaken to ascertain if the HP Routing Group is "Ready". If so, the associated

HP Routing valves are opened or closed as required. If the group is not “Ready”, the

sequence cannot be initiated.

When the HP Routing Online sequence is initiated, the strainer software will also be enabled.

See typical flow diagram for details:

7.2.8.1: HP Routing Isolation Online Sequence (Typical)

All faults during the online process shall result in the Sequence aborting, complete with all

associated alarming and event logging procedures. Placing the Group in Manual mode while

the sequence is running will result in the sequence aborting.

6.12.4.12 HP Routing Offline

HP Routing off-line sequence is activated on receipt of:


an Offline Request from the HP Routing Panel DH12 within the Density hut

A check is undertaken to ascertain if the HP Routing Group is "Ready". All Mainline Pumps are

stopped. Associated HP Routing valves are closed and opened as required.. If the group is

not “Ready”, the sequence cannot be initiated.

When the station is taken offline, the strainer flow path will remain. This implies that the

operator needs to change to manual and close the flow path should he want to close all

valves.


7.2.8.2: HP Routing Isolation Offline Sequence (Typical)

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continuing to completion. Device faults during offline shall be used to continue the Sequence,

complete with all associated Alarming and Event Logging procedures.


6.12.5.1 Sequence Availability

Availability is indicated on the ‘Routing Matrix Sequence’ button displaying either yellow (not

available) or green (available).

6.12.6 Group Status






Station Discharge Pressure Deviation

SDP Deviation High Refer to Section 6.12.4.9

Strainer Sxx Blocked Strainer Sxx Blocked Refer to Section 6.12.4.9

Table 6.12-2: HP Routing Group Alarm Status

6.12.6.1.1 Station Discharge Pressure Deviation High

If the deviation between PT12x and PY12xA_AI is greater than a pre-defined percentage

(default 1%) will be alarmed as ‘Station Discharge Pressure Deviation'. This deviation is

calculated on the basis of a 5 min moving average. When the two signals fall within a

configurable percentage (default 0.5%) of each other, this status is automatically reset.

6.12.6.1.2 Strainer Blocked (Single Strainers)

If the duty strainer indicates a high differential pressure, an alarm shall be issued. This alarm

is reset once both the strainer valves are closed.






HP No Valid Flow-path HP No Valid Flow-path Refer to Section 6.12.4.5

Station No Valid Flow-path

Station No Valid Flow-path Refer to Section 6.12.4.6.1

Remote Interface Detected

Remote Interface Detected Refer to Section 6.12.4.8

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Table 6.12-3: HP Routing Group Error Status






Interface in Station Interface in Station Refer to Section 6.12.4.8.3

Interface Passed Interface Passed Refer to Section 6.12.4.8.2

Table 6.12-4: HP Routing Group Information Status


None defined.



None defined.


None defined.


None defined.


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6.13 Dual Strainers

This section is associated with the control and monitoring of Dual Strainer Device Groups.

Dual Strainers are installed within HP and LP Manifolds on most stations.



Instruments

Strainer S01 Diff Pressure PDT xx1 Strainer S02 Diff Pressure PDT xx2

Valves

Strainer S01 Inlet Valve XV S1A

Strainer S01 Outlet Valve ZV S1E

Strainer S02 Inlet Valve XV S2A Strainer S02 Outlet Valve ZV S2E


Dual Strainers may be controlled from the PCS either locally at the Station or remotely from

the MCC.

This device group has a separate Mode of Control to that of HP/LP Routing, although they

appear on the HP/LP Routing graphics. The Strainer MoC is independently handed over, i.e.

does not necessarily follow the HP/LP groups MoC.



Operation:

Local

Manual

Automatic


Dual strainers have separate control and indication per strainer leg.

Dual Strainer control is enabled from the associated HP/LP Routing online sequence.

6.13.4.1 Strainer States

6.13.4.1.1 Strainer Online/Flushing

The Strainer S01 is in an Online/Flushing state if:

XV S1A is Open AND

ZV S1E is Open / Wirebreak

The Strainer S02 is in an Online/Flushing state if:

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XV S2A is Open AND

ZV S2E is Open / Wirebreak

6.13.4.1.2 Strainer Offline

The Strainer S01 is in an Offline state if:

XV S1A is Closed OR

ZV S1E is Closed

The Strainer S02 is in an Offline state if:

XV S2A is Closed OR

ZV S2E is Closed

6.13.4.2 Strainer Flags

These flags are raised by the process control software as configured on the Strainer block.



detail.

6.13.4.2.1 No Valid Flow-path

A Valid Flow-path for the Strainer exists if the following conditions are met:

XV S1A AND

ZV S1E

OR

XV S2A AND

ZV S2E


6.13.4.2.2 Possible Strainer Hotspot

Should a Strainer leg fail to be flushed (i.e. the Flushed flag is not raised or the Failed to

Flush flag is raised) and the Strainer leg moves from an Offline state (as determined by valve

status), a Possible Hotspot flag is raised.

6.13.4.2.3 Strainer Not Flushed

The Strainer Not Flushed indication is provided when a flush is requested and a strainer leg

has not been placed online, either automatically or manually; the interface has passed

through the station and a configurable timer has elapsed.

6.13.4.2.4 Strainer S0x Blocked

Set strainer S0x blocked

PDT xx1 high for 5 seconds

Reset strainer S0x blocked

PDT xx1 Not High AND

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XV S1A is Closed AND

ZV S1E is Closed

The Strainer Blocked flag is indicated on the SCADA per strainer leg. This flag results in the

Strainer software being disabled and will generate a message "Strainer Software Disabled" on

the SCADA.

Alarm and trip set points on PDT xxx shall be configured so as to give the operator enough

time to take corrective action on receipt of the alarm.

6.13.4.2.5 Strainer Fault

A Strainer Fault flag is raised in the event that the online Strainer Blocked flag is active and

the standby strainer is not available or online as detailed below:

S01 Blocked AND (S02 Not Online AND S02 Not Available) OR

S02 Blocked AND (S01 Not Online AND S01 Not Available) OR

S01 Blocked AND S02 Blocked

6.13.4.2.6 Strainer Failure Modes

The following conditions detail the Strainer Failure modes:

PDT Failure - Switch and Disable Strainer Software

Wirebreak on Online XV - Switch and Disable Strainer Software

Wirebreak on Offline XV - Disable Strainer Software

Wirebreak on either ZV - No Change, Strainer Software remains

Enabled

6.13.4.2.7 Enable Strainer

The “Enable strainer” flag is set (Strainer is enabled):

From HP/LP Route Online sequence OR

From the Enable Strainer Button

The “Enable strainer” flag is reset (Strainer is disabled):

From HP/LP Route Offline Sequence, if the Route is Online OR

Strainer Group in manual OR

Strainer Fault

The Enable strainer flag will activate the dual strainer control software.

6.13.4.2.8 Strainer Control

The intention of the dual strainers is to provide a flow path through one strainer leg at all

times.

Bumpless transfer will be achieved when changing the group between automatic and manual

modes.

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When the Strainer is enabled it will ensure a strainer leg is Open. Strainer S01 has the higher

priority. When the online strainer is blocked, the software will open the other strainer and

close the blocked strainer. No control action will be taken when the Strainer is disabled.

Strainer S01 Online flag (command):

Strainer S02 Not Online AND

Strainer S02 Not Available

OR

Strainer S02 Blocked AND

Strainer Enabled flag AND


Strainer S01 Available

Strainer S01 Offline flag (command):


Strainer S02 Online AND



Strainer S02 Online flag (command):


Strainer S01 Not Available

OR





Strainer S02 Offline flag (command):


Strainer S01 Online AND



If both Strainers are Online and the Strainer Software is enabled, both legs are left Online.

Refer to the Dual Strainer Control Logic detailed in Figure 6.13-1 below.

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Software

Disabled

S06 Online

S05 Online

S05 & S06

Offline

Flush Requested

Software Enabled

If Available

Flush Complete,

Take S06 Offline

S05 Blocked OR

Fault

S06 Offline

Attempt To Take

S06 Offline

Disable Software

S06 Fault

Figure 6.13-1: Dual Strainer (LP Intake) Control Logic

6.13.4.3 Dual Strainer Flushing

A Dual Strainer Flush is initiated from:

A Manual Flush request from the SCADA if Not Online OR

A Receipt of a Manifold Flush Request from the SCADA Overview Screen if Not Online

OR


On receipt of a flush request, the offline strainer valves are opened.

Strainers not flushed will need to be manually isolated, drained and re-primed by operators

on site.


Flushed status will no longer be tracked.


6.13.5.1 Strainer S01 Availability

The following conditions render the Strainer S01 “Not Available”:

XV S1A Not Opened AND Not Available OR

ZV S1E Not Opened AND Not Wirebreak OR

PDT 801 Blocked OR PDT Fault

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6.13.5.2 Strainer S02 Availability

The following conditions render the Strainer S02 “Not Available”:

XV S2A Not Opened AND Not Available OR

ZV S2E Not Opened AND Not Wirebreak OR

PDT 802 Blocked OR PDT Fault

6.13.5.3 Dual Strainer Availability

The following conditions render the Dual Strainer Device Group “Not Available” for LP routing

sequences:

(Strainer S01 Not Available OR not in Auto) AND

(Strainer S02 Not Available OR not in Auto) AND

No Valid Flow-path through the Strainer Set

Note: HP Sequence Availabilities use "Strainer Not Ready AND No Valid Flow-path".

6.13.6 Group Status

6.13.6.1 Strainer (LP Intake) Group Status

The following status indications are to keep the Operator informed of the status of the

Strainer.




ACDB (4) for details, including the text to be used for the alarm messages.


Possible Strainer S01 Hotspot Possible Strainer S01 Hotspot Refer to Section 6.13.4.2.2

Possible Strainer S02 Hotspot Possible Strainer S02 Hotspot Refer to Section 6.13.4.2.2

Strainer Fault Strainer Fault Refer to Section 6.13.4.2.5

Table 6.13-1: Strainer (LP Intake) Group Alarm Status




ACDB (2) for details, including the text to be used for the event messages.


Strainer No Valid Flow-path

Strainer No Valid Flow-path Refer to Section 6.13.4.2.1

Strainer S01 Blocked Strainer S01 Blocked Refer to Section 6.13.4.2.4

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Strainer S02 Blocked Strainer S02 Blocked Refer to Section 6.13.4.2.4

Strainer S01 Not Flushed Strainer S01 Not Flushed Refer to Section 6.13.4.2.3

Strainer S02 Not Flushed Strainer S02 Not Flushed Refer to Section 6.13.4.2.3

Strainer Software

Disabled

Strainer Software Disabled Refer to Section 6.13.4.2.7

Table 6.13-2: Strainer (LP Intake) Group Error Status


None defined.



None defined.


None defined.

6.13.8 Failure modes

None defined.


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6.14 Flow Control – HP Application


part of the HP Routing device group.


The Flow Control Valve installed after the Pump Manifold is used for closed loop control, to

control Station Suction Pressure ICP (Set point configurable by the operator via SCADA),

Manifold Flow (Set point configurable by the operator via SCADA) or Station Discharge

pressure SDP (Set point configurable by the operator via SCADA).

Preferred control at delivery stations is flow, whilst through and intake stations may be either

ICP or SDP control.


Valves

Mainline Flow Control Valve CV PxJ

Instrumentation

Mainline Flow (compensated) FT 121_S2


HP Flow Control may be controlled from the PCS either locally at the Station or remotely from

the MCC.

This device forms part of the HP Routing device group, and thus does not have its own Mode

of Control.



Local

Manual

Automatic


This control valve has a mode of operation that is independent of the HP routing group.



The control valve position is determined by inching and stepping the valve open/ closed.


The control valve position is determined by a 4-20mA analogue output signal.

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xxx

PT

xxxCV

xxxCV

FT

xxx

xxxPT

PT

xxxFIC

xxxPT

xxxPIC

xxxOVR

xxxOVR xxx

PICxxx

OVR

ICP

Route

dependant

SDP

Not UsedFLOW

xxxMAN

SP SPOR

SP

SP

CONTROL VALVE

SPOR

SPOR

0%

100%

SPOR

ICP

Va

lve

Ove

rrid

e

Po

stio

n

0%

100%

Flow/SDP

Va

lve

Ove

rrid

e

Po

stio

n

SPOR

OVERRIDE FUNCTIONS


FT xxx_S

>

Figure 6.14-1: Flow Control – HP Application

Control valves are part of the respective HP Device Group and do not have their own graphic.

Hence the PV’s and control loop are not visible to the operator.

The Control Valve typical has two PID loops configured, each with a hard coded override.

Based on the application, the configured PID loops may be any two of the following

Flow PID

ICP PID

SDP PID

The operator can choose to control on any of two pre-configured PV’s (pre-configured in the

PLC depending on the application):

Flow (Default for Delivery Stations)

ICP (Default for Through and Intake Stations)


When a control parameter is chosen, the other parameters are in override control. The set-

points for override control revert back to the override set-points (not operator settable). Note

that the operator set-points are not overwritten and are reverted to should the operator

change back to the original control parameter. The PID loops are not active in manual.

Override Curve

A hard ramp override curve exists for each PID loop. This is enabled when the PID is too

slow to catch transients. This is especially true if the PID loop is tuned for slow response to

reduce wear on the valve.


Not required.

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6.14.6 Group Status


None defined.


None defined.


None defined.


None defined.



None defined.


6.14.8.2.1 50-CV PxJ: All Routes Closed

The control valve is interlocked closed (i.e. set-point set to 100% and as a result the valve

will ramp closed) when all associated Routes are Closed.


On instrument failure, the instrument goes into override value, complete with alarming.

Operator action will be required to prevent control loop wind-up.


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6.15 Duty and Speed Control

[Copied from 2684358-S-A00-IN-SP-060/G52001-W4000-U412 Rev 05]

The Duty and Speed Control Device Group is associated with the control of MV Mainline

Pumps – VSD (Parallel Configuration).

MV Mainline Pumps – VSD (Parallel Configuration) have been installed on stations associated

with the new 24” Multi-product Pipeline.


Mainline Pumps – VSD (Parallel configuration) are controlled with a single speed set-point

based on the station ICP, SDP or flow, using PID controllers.

A duty controller attempts to match the required number of running pumps with process

conditions.

Each pump has a dedicated drive control which ensures that the individual pump is operated

within its allowable zone.

The following figure details the principle of control:

M

Receiver

M

MM M

M

PT

ES PTFT

PT

ES PTFT

PT

ES PTFT

MM

M

Launcher

DT M

M PT PT TT

TT PT PT M

FT

PIC < PIC

∑

FIC

SDPICP

Speed Setpoint to Drive

Control

Linearisation

MAN

Operator Manual

Speed Input

DrC

DrC

DrC

Figure 6.15-1: Control Methodology

The Station Control Loop will consist of three distinct controllers:

Duty Controller

Speed Controller

Drive Controller

These controllers are described in more detail in subsequent sections below.

The following figure details the functional interface between these three controllers:

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2. Duty Controller

1. Speed Control

V

S

D

V

S

D

V

S

D

3. Drive

Control

3. Drive

Control

3. Drive

Control

Line Wide

Control (LWC)

Drive

Interface

Drive

Interface

Drive

Interface

ICP/SDP/FC

Setpoints

Pump Quantity

Setpoint, Status,

and Sequence

Initation

Flush Request

Speed Setpoints

Pump Requests/

Status

Manual Overrides

Station Duty & Speed Control

Process Feedback (PT,FT

etc)

Trips, Statuses &

Modes of

Operation

Figure 6.15-2: Simplified Pump Station Control Methodology

The Line Wide Controller (LWC) will monitor and control the entire trunkline by manipulation

of each station’s individual set-points. Control loops will be executed by the station control

on the set-points provided by the LWC, and process feedback will be provided to the LWC.

The following signals are used for feedback into the Station Duty & Speed Controller:

Variable Speed Drive

Mainline Pump P0x Speed Reference SC 0x1 Mainline Pump P0x Speed ST 0x1

Instrumentation

Station Inlet Pressure PT 121

Station Discharge Pressure PT 122 Station Inlet Flow FT 121

Mainline Pump P0x Flow FT 0x1

Where x defines the pump number.


The Station Duty and Speed Control Group shall be controllable both locally from the SCADA

System installed at the Station as well as remotely from the Master Control Centre (MCC).


6.15.3.1 Duty Controller (DuC)

The Duty Controller has the following modes of operation:

LWC

Manual

SWC

Refer to section Duty Controller (DuC) for more information.

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6.15.3.2 Speed Controller (SpC)

The Speed Controller’s PID control loops will always be in Automatic (i.e. active).

It will be possible to switch the Station Controller into one of the following modes of

operation:

LWC

Manual

SWC

The Speed Controller provides functionality to allow disabling of the Flow PID controller,

External Speed Set-point and the Manual Operator Speed Set-point.

Refer to section Speed Controller (SpC) for more information.

6.15.3.3 Drive Controller (DrC)

The Drive Controller will always be in Automatic. It will be active whenever its VSD is not in

Local.

Refer to section Drive Controller (DrC) for more information.



The DuC consists of two functional areas:

Run Hour Management

Pump Selection

The Duty controller in Running state is responsible for all remote requests to start and stop

pumps. As a result no Line Wide Controller (remote) sequence can request an individual

pump start without going through the Duty Controller.

For each pump set group there will be an Online, Offline and Flush sequence. These

sequences are available to the operator for starting, stopping and flushing pumps in

Automatic. The Duty Controller will track the states of the pumps and adjust accordingly.

The Duty Controller will trigger the Online and Offline sequences for starting and stopping

pumps.

The diagram below depicts the envisaged control loop for the Duty Controller.

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Pump Scheduler

(DuC)

Load Matching

(DuC)

LWC Mode of Operation

Operator Mode of Operation

LWC Nr Pumps

Operator Nr Pumps

Px Speed FB

Flush Request

Nr Run Pumps Required

Px Ready

Px Online FB

Px Run/Standby Hours

Px Reset Trip for Duty

Px Start Command Pulse

Px Stop Command Pulse

Nr Run Pumps Required

Px Running FB Mask

Nr Running Pumps FB

To / From VSD Pump x Typical, where 1 <= x <= 8

Flush Request

Ave Speed

Speed > Max Speed SP (Staging)

Speed < Min Speed SP (Staging)

Min Switching Speed SP

Max Switching Speed SP

Startup State Matrix

Remaining Time To Start / Stop Next Pump

LWC Start/Stop Command

Actual Mode of Control

Duty State

Operator Start/Stop Command

Run Hr Mgr

(DuC)Px Standby Time

Mx Run Time

Px Run Time

Px Run/Standby Hours

Px Running FB

Px Init Val

Mx Init Val

Px Reset

Mx Reset

Px Trip FB

Pump Sched Stop

Px Flow FB

Figure 6.15-3: Duty Controller Loop

Duty Control will comprise three components:

A Load Matcher to manage set-points and calculations for the “Number of Running

Pumps Required”.

A Run Hour Manager to track pump and motor run and standby hours and provide

information to the Pump Scheduler for pump start / stop order prioritization.

A Pump Scheduler to determine the order in which pumps should start or stop.

6.15.4.1.1 Duty Controller - Pumps Availability

The operator shall start the Duty Controller manually. It can also be started from Station

Online Sequence.

The operator may at any time stop the Duty Controller. This will trigger the Offline sequence

for all running and ready pumps regardless of their availability for duty control. When the

Duty Controller is already in a stopped state, it will not start or stop pumps anymore.

The Duty Controller can only be started if the number of requested pumps is equal or lower

to the number of "Available" pumps.

Pump availability for Duty Control is a combination of two conditions:

Pump "Ready" status

Control button at Duty Controller Faceplate is switched to "AVAIL" mode

The Operator can always exclude pumps from availability by switching control button to the

"NOT AVAIL" state. They will not be treated as "Available" for Duty Controller (i.e. will not be

started by Duty Controller) even if they are ready.

The Duty Controller faceplate below shows:

Pump P01 - Ready and Available (for duty),

Pump P02 - Ready but Not Available (operator action required),

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Pump P03 - Not Ready (can't be selected as Available).

Figure 6.15-4: Duty Controller Faceplate

A pump can lose "AVAIL" state in two cases:

Pump was tripped - control button will change state to “NOT AVAIL” and become

disabled

Pump was "Not Flushed" (Fsh LED is red) and is not "Ready" status (for example

Pump was interlocked before was flushed or was in Manual mode when "not flushed"

state occurred)

If pump with "AVAIL" status becomes not ready, the control button will be disabled but it

remains in "AVAIL" mode. Once it is ready again, it is enabled automatically and the Pump

will be ready for duty control.

When a pump trips (latched or unlatched) it becomes unavailable for duty control (NOT

AVAIL) until reset from the Duty Controller.

To reset a trip on the Duty Controller faceplate, the operator has to change the mode for a

specific Pump (using control button) from “NOT AVAIL” to “AVAIL” after the button is

enabled.

Note: The Duty Controller will latch a “Not Flushed” condition which will prevent the Duty

Controller from starting the pumpset. This “Not Flushed” condition is cleared by running the

pump at a speed of the minimum set-point. Irrespective of the state of the “Not Flushed”

condition, the operator can manually enable the pump for operation for duty control (by

switching the "Not Flushed" Pump to “AVAIL” state after Pump is "Ready" again).

6.15.4.1.2 Duty Controller - Pumps Startup

The Duty Controller has three states:

Startup

Running

Stopped

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The Startup State will look at three operator-configurable parameter sets: Normal (default),

Tightline, and Slackline. Each parameter set comprises the following parameters:

Number of Pumps Required

Pump Speed (for use by the Speed Controller)

Time Expired Trigger Startup Condition

ICP ROC Trigger Startup Condition

SDP Trigger Startup Condition

Flow Trigger Startup Condition

Figure 6.15-5: Duty Controller Faceplate

When started by the SWC, the Duty Controller uses the Startup Matrix (according to the

selected Mode: Normal, Tightline, Slackline) to determine the number of required pumps and

speed.

Duty Controller remains in Startup state until one of the following triggers occurs:

Timer compared with Time Trigger elapsed

Actual value for ICP ROC is greater than ICP ROC Trigger

Actual value for SDP is less than SDP Trigger

Actual value for Flow is greater than Flow Trigger

After a trigger occurred the Duty Controller is changing state from Startup to Running and is

activating the Load Matching function.

Once a trigger is detected, the Duty Controller changes state from Startup to Running and

activates the Load Matching function.

The Speed Controller sets the initial value of the ICP as the set-point. By default the Speed

Controller operates in ICP mode.

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If the active set-point is greater than the actual SDP value, the Speed Controller

changes to SDP mode. The set-point is changed to the SDP set-point.

If the active set-point is greater than the Flow value AND the FlowPID is enabled, the

Speed Controller changes to Flow mode. The set-point is changed to the Flow set-

point.

If the active set-point is greater than the Operator value AND the Operator speed is

enabled, the Speed Controller changes to Operator mode. The set-point is changed

to the Operator set-point.

If the active set-point is greater than the Duty Controller set-point value AND Duty

Control is enabled, the Speed Controller changes to Duty Control mode. The set-point

is changed to the Duty Control set-point.

6.15.4.1.3 Load Matching

The Load Matching component will inhibit load matching calculations while in Startup state.

Upon any of the trigger conditions being achieved, the Load Matching component will go to

Running state.

The Load Matching component is responsible for managing the “Number of Running Pumps

Required” based on its mode of operation.

LWC: The “Number of Running Pumps Required” is, determined by the LWC; i.e. the LWC

passes down the Number of Running Pumps Required based on the required flow set-point

from the Trunkline.

Manual: The “Number of Running Pumps Required” can be entered via a faceplate. The

operator should be able to enter a value of pumps required. This is the default mode with a

value of 1.

SWC: The “Number of Running Pumps Required” is determined by the local station to

enable standalone station operation. The logic behind this selection is based on pump

loading.

This logic shall implement damping to prevent oscillation of starting and stopping

pumps. Any changes in the number of pumps running in response to the local logic

shall require a period of stabilisation before another decision is made.

If the pump speed is above 90% (configurable) for more than a configurable time,

then the “Number of Running Pumps Required” should be increased by 1.

If the pump speed is below 70% (configurable) for more than a configurable time,

then the “Number of Running Pumps Required” should be reduced by 1.

Note that Mode of Operation changes will be edge-triggered; i.e. last one wins.

The Load Matching component will include a configuration parameter for “Auto Load

Matching”. If enabled, the Load Matching component will use LWC “Number of Running

Pumps Required” for start conditions. After a configurable timer has elapsed, the Load

Matcher will revert to calculations executed in SWC Mode of Operation without a mode

change.

6.15.4.1.4 Run Hour Manager

The main function of the Run Hour Manager is to totalise the run hours. The management

will have the following functionality:

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Totalise individual pump and motor run hours separately.

Totalise total individual pump and motor hours since last maintenance (resettable

from SCADA); This shall be protected by password

There are a total of 2 run hours values for a pump set which shall be visible from the

SCADA and 1 x Standby time.

The hours for both the pump and the motor totalizers shall be integrated based on

the running feedback from each motor, therefore it tracks local operation of the

drive.

The standby time (time for which the pump set does not have running feedback) of

each pump and motor shall also be tracked and automatically reset with running

feedback.

6.15.4.1.5 Pump Scheduler

The Pump Scheduler is responsible for ensuring that the “Number of Running Pumps

Required” is achieved.

The following events will be used to initiate a start and stop request to a pump:

Pump trip (will initiate a pump start on the pump marked next to start as detailed

below)

Pump stop (in manual or local)

”Number of Running Pumps Required” changes

Note that pump start and stops will only occur on these start and stop events. Therefore

pumps will not be cycled without an event.

Note that the operator may at any stage force a change by stopping a drive.

The pump chosen to start next will be based on the following criteria:

Pump Ready and selected as "AVAIL" on Duty Controller faceplate. Only that pump

will be "Ready for Duty".

Pump Standby Time – the pump with the highest standby time will be started.

The pump chosen to stop next will be based on the following criteria:

Pump Ready – only pumps marked as “Ready”, correct MoC and running will be

selectable to stop.

Pump Running Hours – The pump with the highest running hours (since last

maintenance) will be stopped.

Note: The Pump may be “Ready” but will still not be in the Duty Controller’s control until it

has been set for duty (with Duty Control button). Stopping Duty Controller will stops all

pumps regardless of MoC.

6.15.4.1.6 Flushing

To avoid conflict of control and loss of flushing functionality when the Duty Controller is in

Stopped state, the Duty Controller will inhibit its activity while at least one of the flushing

sequences is active.

In any Mode of Operation, the Duty Controller will track the drive online and ready feedback

statuses as well as the “Number of Running Pumps Required” set-point from either the LWC,

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SWC or the operator but will not start or stop any pumps. After flushing has completed, the

Duty Controller will immediately revert to the “Number of Running Pumps Required”.

Upon completion of flushing, the Duty Controller will resume its functionality and return the

station to the current “Number of Running Pumps Required” state using the rules described

in the section above. Note that this may result in different pumps running to what was

running before.

If a pumpset was not flushed, the Duty Controller will latch a Not Flushed condition as

described in the section above.


The Speed Controller Loop consists of three independent PID controllers (ICP, Flow, SDP)

and an Override Controller.

The PID Controllers will always be active and their outputs will be limited between the drive

minimum (configurable in the PLC source code) and maximum (100 %, configurable in the

PLC source code) speeds.

The Override Controller will select the active controller and switch its output to the drives.

This switch is inherently bumpless as the override controller will act as a minimum selector.

Gain Scheduling will allow PID gains to be modified in response to changes in the number of

running pumps.

Linearization will be used to linearize the output from the ICP & SDP controllers.

The Station Speed Controller will be activated as soon as at least one pump set is operating

“At Station Set-point” (see section Drive Controller (DrC) for details). While inactive, the

Speed Contoller’s Station Set-point will be set to drive minimum speed (60 %).

The following figure depicts the envisaged control loop for the Speed Controller:

Flow SP

Flow FB

SDP SP

SDP FB

ICP FB

From Duty Controller

Gain

Scheduler

Nr Pumps at Station SP

Selected

Controller

Tracking Output

Enable Flow Ctrl

ICP SP

Flow

PID

SP

PV

Gains

MV

TRK SP

LIM

ICP

PID

SP

PV

Gains

MV

TRK SP

LIM

SDP

PID

SP

PV

Gains

MV

TRK SP

LIM

Gain

Scheduler

Gain

Scheduler

External Speed SP

Station SP

Enable Station ControlCount > 0

Px At Station SP

Pn Clamp Max Flow

Pn Clamp Min Flow

PID LIM

EN

From Drive Controller

Setpoint

Manager

LWC Setpoints

SWC Setpoints

Mode of Operation

Override Controller

(SpC)Operator Speed SP

Figure 6.15-6: Speed Controller Loop

The Speed Controller will comprise the following constituent components which are detailed

in subsections below:

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Set-point Management: this functionality will manage LWC set-points SWC, or

manual set-points and allow for switching between the two sets of set-points.

Manual Entry of Speed: this functionality allows the operator to enter an Operator

Speed Set-point. This entry will only be enabled in Manual Mode of Operation.

Gain Scheduling: a number of sets of gains will be tuned and managed per PID

controller. The gain set will be chosen based on the number of pumps that are

running At Station Set-point.

Flow PID Controller: this PID controller controls the Station Flow Rate.

Flow controller can be enabled / disabled from the Set-point Manager.

ICP PID Controller: this PID controller controls the Station Incoming Pressure.

SDP PID Controller: this PID controller controls the Station Discharge Pressure.

Pressure linearization function for ICP and SDP PID controller outputs.

Override Controller: this controller bumplessly switches the output of the active PID

controller to the Drive Controller. It also performs Limit calculations to prevent

integral windup.

6.15.4.2.1 Set-point Management

The Set-point Management component is responsible for managing the ICP set-point, SDP

set-point, Flow set-point, Operator Speed set-point, Flow enable / disable and Operator

Speed enable / disable based on its mode of operation:

LWC: The LWC will pass down the Flow, ICP and SDP set-points. The Operator Speed Set-

point will be disabled.

SWC: The operator will first nominate a preferred controller (i.e. Flow, ICP, SDP, Operator

Speed Set-point) and then provide a set-point for that controller. Upon nominating the

preferred controller, the other controllers (ICP and/or SDP respectively) will revert to their

override (protective) set-points. These protection set-points are editable from the SCADA

(e.g. for slackline protection) but will be limited to the upper SDP limit for line protection and

the lower ICP limit for pump protection (these limits are hardcoded in the PLC per pump

station). Note that if the Flow controller is disabled at this station, the operator will not be

able to nominate this controller as the preferred controller.

An External Speed Set-point will be provided by the Set-point Controller to drive the VSDs to

a certain set-point during Startup conditions (note: protective controllers are still active).

Once the Duty Controller is in Running state, this input will be disabled.

Manual: Refer to Section 6.15.4.2.2 Manual Entry of Speed below.

The Speed Controller will either be in Line Wide Control, Station Wide Control or Manual

modes of operation. It will not be possible to have a mixture of set-point sources.

The Set-point Management component will allow the changing of the mode of operation from

both the Line Wide Controller and the Station operator (last one wins).

All set-point changes to the PID controllers shall be ramped to the new value. The ramp rate

will be individually configurable per PID controller.

In LWC mode, the set-point from the SWC shall be tracked to match the LWC set-point.

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6.15.4.2.2 Manual Entry of Speed

The “Operator Speed Set-point” will be entered as a percentage of drive speed and will be

limited to the minimum (site depend) and maximum (100%) of the VSD with visual feedback

to the operator that the entry is out of bounds.

When active, the Operator’s Speed Set-point will be included by the Override Controller. The

ICP and SDP protective PID loops are still active, but their set-points are governed at the

respective protective values. The Flow PID loop will be set to track.

Transitions from Manual Mode of Operation back to LWC or SWC Modes of Operation will

result in set-points being ramped and the output remaining bumpless.

6.15.4.2.3 Gain Scheduling

All PID controllers support gain scheduling. The PID gain parameters change in response to

the number of pumps running “At Station Set-point”.

The update of PID settings will match the number of pumps currently running “At Station

Set-point” (controlled by the station controller).

Starting and stopping pumps will be seen as a disturbance. Upon completion of the startup

ramp the Drive Control will switch to “At Station Set-point” and the PID gain parameters will

be changed. Upon detecting a pump stop event (number of “At Station Set-point” pumps will

decrease on event), the PID gain parameters will be changed.

6.15.4.2.4 Flow PID Controller

This is a PID controller which ensures the station is achieving its desired flow rate. This PID

controller is disabled if it is not required.

The flow PV is the summation of the individual pump flows or from common flowmeter (site

depend).

The Flow loop is always in Automatic and cannot be set to manual.

The Flow PID’s set-point and set-point mode will be handled by the Set-point Management

component detailed above.

By factoring in “Station Speed Set-point” from the Override Controller, the Flow PID will

prevent integral windup when it is not the active controller.

6.15.4.2.5 ICP PID Controller

This is an override control which ensures the pump ICP is within limits. Depending on the

chosen set-point, this controller may operate as the preferred controller under normal control

mode.

The ICP loop is always in Automatic and cannot be set to manual. This loop cannot be

disabled.

The set-point will have a lower limit clamp to prevent the trip limit set-point being exceeded.

The output of the ICP PID is adjusted by a linearization function to account for the non-linear

characteristic of pressure to pump speed.

The ICP PID’s set-point and set-point mode will be handled by the Set-point Management


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By factoring in “Station Speed Set-point” from the Override Controller, the ICP PID will


6.15.4.2.6 SDP PID Controller

This is an override control which ensures that the overall station delivery pressure is

controlled away from a trip point. Depending on the chosen set-point, this controller may

operate as the preferred controller under normal control mode.

The SDP loop is always in Automatic and cannot be set to manual. This loop cannot be

disabled.

The set-point will have an upper limit clamp to prevent the trip limit set-point being

exceeded.

The output of the SDP PID is adjusted by a linearization function to account for the non-

linear characteristic of pressure to pump speed.

The SDP PID’s set-point and set-point mode will be handled by the Set-point Management


By factoring in “Station Speed Set-point” from the Override Controller, the SDP PID will


6.15.4.2.7 PID Controller Summary of Operation

The following table details each PID controller’s operation:

Property ICP Loop SDP Loop Flow Loop

Auto/Manual (1) Auto only Auto Only Auto Only

Enable/Disable Always Enabled Always Enabled Allow to be disabled

LWC Set-point Yes Yes Yes

Station Set-point Yes Yes Yes

Set-point Clamped

(but configurable)

Yes at minimum Yes at maximum No

Set-point Deviation

alarm on active loop

(only enabled for

the active station

controller, disabled

for the override

controllers)

Yes Yes Yes

Output Linearized Yes Yes No

Gain Scheduling

Supported

Yes Yes Yes

Prevents Integral

Wind-Up

Yes Yes Yes

Set-points Ramped Yes Yes Yes

Allows Override

Control

Yes Yes Yes

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Table 6.15-1: PID Controller Modes of Operation

Note (1): This refers to the PID Control Function and not the control loop, which has three Modes of Operation: LWC, SWC, Manual.

6.15.4.2.8 Linearization Function

The output of the ICP and SDP PID controllers will be linearized using an inverse function.

This will be a static function and the co-efficient will be calculated during implementation.

6.15.4.2.9 Override Controller

The Override Controller nominates the most critical input (PID controller’s output) by means

of minimum selection. Due to the minimum selection, the output to the drive is inherently

bumpless.

The output is fed back to PID controllers to prevent integral windup.


The Drive Controller is responsible for ramping a pump from minimum speed to “Station

Speed Set-point”, managing the pump within its operating window, and interfacing to the

VSD typical.

The following figure depicts the envisaged control loop for the Drive Controller:

Drive Control

(DrC)

Px Speed SPPx Running

Feedback Mask

Station SP

Px Speed FB

Px Flow FB

Px SDP FB

To / From VSD Pump x Typical, where 1 <= x <= 8

C1

C2

C3

C4

From Speed Control

Hydraulic Envelope

MUX

Ramp Rate

SR Flip-

Flop

S = Px Tripped

R = NrRunFB = NrRunSp

OR 5 min timer expire

SR Selection

Slow Ramp Rate

Fast Ramp Rate

At Station SP

Ramping

Clamp Max Flow

Clamp Min Flow

Bypass Hydraulic Envelope

From Duty Controller

VSD Local FB

Figure 6.15-7 Drive Controller Loop

Note: the “Bypass Hydraulic Envelope” allows an engineer to disable the hydraulic envelope

calculations from within the PLC, should this be required.

The Drive Controller will comprise the following constituent components which are detailed in

subsections below:

Operating Window Management

Drive Ramping

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Drive Control

6.15.4.3.1 Operating Window Management

Each pump will be controlled within its “operating window” where possible.

They “operating window” will be characterized and defined by four curves. The speed set-

point sent to the VSD typical will be clamped based on:

Maximum flow rate

Minimum flow rate

Pump maximum speed

Pump minimum speed

When the speed set-point of all operational pumps is limited due to the “operating window”,

the PID controllers will be clamped to ensure they do not windup.

During startup and shutdown, the “operating window” will be ignored for the individual

pump.

Note that if the drive’s Flow Transmitter fails, the “operating window” will be ignored for the

individual pump.

The “operating window” will be visible from the SCADA and the operating point of each pump

will be plotted on it.

6.15.4.3.2 Drive Ramping

Upon starting a pump, the following sequence of events will occur:

1. Upon receiving a start command, the VSD will ramp to minimum speed (site depend) at

the VSD’s internally configured ramp rate (R0).

2. Upon reaching minimum speed, the Drive Controller will ramp the VSD to the Speed

Controller’s “Station Set-point” at a preconfigured ramp rate (R1).

3. When the VSD’s speed feedback is greater than or equal to the Speed Controller’s

“Station Set-point”, then the pump is switched over to the Speed Controller’s “Station

Set-point” and is considered On Duty.

There will be two ramp rates (R1) configured. A ‘fast’ ramp rate will be used when

recovering from a pump trip. The ‘slow’ ramp rate will be used for all other conditions to

minimize hydraulic disturbances. The ramp rate selection will revert from fast to slow upon

the following conditions:

Upon the number of required pumps running being reached and all pumps are

running “At Station Set-point”

Upon a five minute (configurable) timer elapsing.

Upon stopping, the pump coasts (freewheels) to standstill.

If a VSD is started in Local and switched to either Automatic or Manual, its speed set-point

will be ramped toward the “Station Set-point” at the ramp rates described above. Upon

exceeding the Station Set-point, the drive will be switched to “Station Set-point”.

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6.15.4.3.3 Drive Control

Once the Drive Controller has switched over to Station Set-point, the Drive Controller will

follow the Speed Controller’s “Station Set-point”.

While running “At Station Set-point”, the Operating Window Management is active.

Note that a drive that is started in local or is switched to local cannot be controlled by the

Drive Control and will hence fall out of “At Station Set-point”, or not achieve “Station Set-

point”. Upon being placed back in either Manual or Automatic, the drive will be ramped to

“Station Set-point” and then switched over to Station control again.

6.15.5 Device Group Availability


The Duty Controller is only available if at least one pump set is Ready. The Duty Controller

will not have its own availability state but will depend on the availability of the pump sets

under its control. If it is not able to run pump sets to achieve the “Number of Running

Pumps Required”, it will automatically go to Stopped state and will have to be restarted by

the operator once the condition is no longer prevailing.


The Speed Controller is always available. The Speed Controller will be active as soon as at

least one pump is “At Station Set-point”. When inactive, the Speed Controller will be set to

minimum speed.


The Drive Controller is available whenever its VSD is not in local.

6.15.6 Inter-PLC Communication

6.15.6.1 Signals from Station PLC to Line Wide Control PLC

Heartbeat (for Watchdog)

Number of Running Pumps Feedback (pumps running, irrespective of mode of

operation)

Number of On Duty Pumps Feedback (pumps running At Station Set-point)

Number of Pumps Ready to Stop

Number of Pumps Ready to Start

Number of Tripped Pumps

Number of Stopped Pumps

Station Flow Feedback

Station ICP Feedback

Station SDP Feedback

Actual Flow Set-point

Actual ICP Set-point

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Actual SDP Set-point

Duty and Speed Controller Mode of Operation

6.15.6.2 Signals from Line Wide Control PLC to Station PLC

Heartbeat (for Watchdog)

LWC Number of Running Pumps Required

ICP Set-point

SDP Set-point

Flow Set-point

Duty and Speed Controller Mode of Operation

6.15.7 Actions in Event of Communication Failure

In the event of Communication Failure:

If the Duty Controller is in LWC Mode of Operation and the Auto Load Matching is

disabled, the Duty Controller will re-enable AutoLoadMatching upon detection of

communication failure. The operator will have to disable AutoLoadMatching again

later.

The Speed Controller set-points and mode of control will remain where they currently

are. Upon re-establishing communication, it will resynchronize with the Line Wide

Controller and respond to mode and set-point updates if in LWC mode.

It will be possible for an operator to change the mode of control to SWC and then

change the set-points if required. Upon re-establishing communication, it will

resynchronize with the Line Wide Controller but will not respond to mode and set-

point updates until it is placed back in LWC mode by the operator.

6.15.8 Event Strategies

6.15.8.1 Speed Controller Event Strategies

6.15.8.1.1 Speed Controller Manual Mode Selected

This event will be generated when the Speed Controller’s Mode of Operation has changed

from SWC to Manual Mode.

6.15.8.1.2 Speed Controller SWC Mode Selected


from Manual to SWC Mode.

6.15.8.1.3 Speed Controller ICP Active

This event will be generated when the ICP controller becomes active.

6.15.8.1.4 Speed Controller SDP Active

This event will be generated when the SDP controller becomes active.

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6.15.8.1.5 Speed Controller Flow Active

This event will be generated when the Flow controller becomes active.

6.15.8.1.6 Speed Controller Operator Input Active


from SWC to Manual Mode.

6.15.8.1.7 Override Active

This event will be generated when the Override Controller will become active.

6.15.8.1.8 Speed Controller – Contention

This event will be generated when the Drive Controller detects that any of the pumps is

operating outside its “operating window”, the output of the Speed Controller is at minimum

or maximum and the ICP / SDP controllers are requesting a value outside the minimum /

maximum (i.e. SDP / ICP protection not achievable).

6.15.8.2 Drive Controller Event Strategies

6.15.8.2.1 Drive x Operating Window Clamp Active

This event will be generated when a Pump is operating outside its “operating window” where

"x" is a number of the Pump.

6.15.8.2.2 Drive x Operating Window Calculation Error

This event will be generated when one of the linearization curves are not defined properly i.e.

x-axis values at GenCurve10Pt blocks must be increasing.

6.15.8.3 Duty Controller Event Strategies

6.15.8.3.1 Duty Controller - Mode Selection

This event will be generated when the following Duty Controller’s Mode of Operation has

changed:

Duty Controller Manual Mode Selected

Duty Controller LWC Mode Selected

Duty Controller SWC Mode Selected

6.15.8.3.2 Duty Controller – Startup Matrix State

This event will be generated whenever the operator changes a following Startup Mode:

Startup Matrix Normal Line State Selected

Startup Matrix Tight Line State Selected

Startup Matrix Slack Line State Selected

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6.15.8.3.3 Duty Controller – State

This event will be generated whenever the following Duty Controller state changes:

Duty Controller Stopped

Duty Controller Startup

Duty Controller Running

6.15.8.3.4 Duty Controller – Startup Matrix Triggers

This event will be generated whenever the following Duty Controller startup matrix triggers

activate:

Startup Matrix Time Trigger Occurred

Startup Matrix Flow Trigger Occurred

Startup Matrix SDP Trigger Occurred

Startup Matrix ICP ROC Trigger Occurred

6.15.8.3.5 Duty Controller – Commands

An event is triggered when the Duty controller issues a pump start or stop command:

Duty Controller Pump x Start Command Active

Duty Controller Pump x Stop Command Active

where x is a number of current Pump (started or stopped).

6.15.8.3.6 Duty Controller – No Standby Exist

This event will be generated when the number of available pump is equal or less to the

number of required pump.

6.15.8.3.7 Duty Controller – Change State

This event will be generated when Duty Controller is working in Load Matching Mode and

DuC will change number of required pumps (increase or decrease).

6.15.8.3.8 Duty Controller – Comms Fail

This event will be generated when Duty Controller will recognize communication failure.

6.15.9 Alarm Strategies

6.15.9.1 Speed Controller Alarm Strategies

6.15.9.1.1 Speed Controller – Loop Control Deviation

This alarm will be generated when the active PID loop’s error is greater than a configurable

value (default 5 %) for a configurable time (default 60 seconds). This alarm will be

suppressed for a configurable time (default 120 seconds) after detection of a pump start /

stop and set-point change. Only the active PID Loop will be alarmed. There are three

possible alarm messages:

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Speed Controller Process Deviation High (ICP PID Err: xxx* kPa)

Speed Controller Process Deviation High (SDP PID Err: xxx* kPa)

Speed Controller Process Deviation High (Flow PID Err: xxx* L/min)

* where xxx is triggered value

6.15.9.2 Drive Controller Alarm Strategies

None defined.

6.15.9.3 Duty Controller Alarm Strategies

6.15.9.3.1 Duty Controller Upstage

This alert will be generated when the “Number of Running Pumps Required” is greater than

the sum of the “Number of Running Pumps” and the “Number of Ready Pumps" i.e. an

Upstage Request cannot be initiated. This alert will stop the Duty Controller but will not

trigger a pumps offline sequence.

6.15.9.3.2 Duty Controller Downstage

This alert will be generated when the “Number of Running Pumps” is greater than the sum of

the “Number of Running Pumps Required” and the “Number of Ready Pumps” i.e. a

Downstage Request cannot be initiated. This alert will stop the Duty Controller but will not

trigger a pumps offline sequence.

6.15.10 Interlocking Strategies


None defined.


None defined.


In addition, the following will be displayed on WinCC:

All run hours and associated resets will be displayed on a faceplate.

The current duty selection of pumps will be displayed, including “next to start” and

“next to stop”.

The active PID controller will be evident from the display.

The graphical pump curves and efficiency loci with associated operating point,

including the operating window will be available on the operator display on request.

The efficiency (optimal) lines shall be highlighted in this display. This curve display

will be static, and will include all actual pump loci on a single display.

Commands, set-points and modes of operation will be configurable from the operator

stations with appropriate security level. These include the following:

Duty Controller:

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Start / Stop command

Manual Number of Pumps Required

Minimum and Maximum Speed set-points

Stabilization Timer Set-point

Run Hour initial values and resets

LWC, SWC Manual mode of control

Speed Controller:

Active (preferred) controller

Station Flow / ICP / SDP / Operator Speed set-points

LWC, SWC, Manual mode of control

Drive Controller:

Fast and Slow Ramp Rate set-points

Reset Timer Set-point

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6.16 Safety Instrumented System (Line Over-pressure

Protection)

This device group is associated with the control and monitoring of the Safety Instrumented

System (SIS) (Line Over-pressure Protection) Device Group.

SIS LOP Protection is installed on all stations with Mainline Pump Sets installed and where

this requirement has been identified by HAZOP and LOPA Studies.


The ‘SIS (Line Over-pressure Protection)’ Device Group will display all SIS devices associated

with Line Over-pressure Protection related to the IVW Mainline Pumps, along with their

associated “health” statuses, maintenance support and event timestamps. Time stamping is

done in the process control system.

Pipeline Over-pressure Protection adheres to the following protection philosophy:

1. An alarm will be issued when the Station Discharge Pressure exceeds a high-alarm set-

point. This set-point is usually set 200 kPa lower than the maximum allowable operating

pressure (MAOP) of the pipeline.

2. Station Discharge Pressure interlock will provide the first level of protection against over

pressurisation. In parallel pump configurations, this interlock will trip all running Mainline

Pumps simultaneously, based on high-trip set points. In series pump configurations, this

interlock will trip the last running Mainline Pump in sequence until all the pumps are

tripped or the station discharge pressure falls below the high-trip set point.These set-

points are usually set to the maximum allowable operating pressure (MAOP) of the

pipeline.

3. Line Overpressure Protection SIL will provide the second level of protection, and will trip

all Mainline Pump-sets simultaneously, based on a SIL protection set point to be set high

to act as last resort. This set-point is usually set at the maximum allowable working

pressure (MAWP) or design pressure of the pipeline.

The following SIS interface signals are applicable to this group:

Instruments connected to SIL

Station Discharge Pressure (SIL) PT 12xA

Instruments connected to PLC

Station Discharge Pressure (SIF) PY 12xA _SIF Station Dis charge Pressure (SIL) PY 12xA _AI

Station Discharge Pressure* PT 12x

PLC03 Panel Power Supply Fail* G5x.K11_FA MV01 FX Open* MV01FxxOP


6.16.1.1 Station Line Over-pressure Protection

An independent SIL-rated safety system is installed to perform the following functionality:

On detection of a high trip Station Discharge pressure as detected by the independent

SIL-rated station discharge pressure transmitter, all Mainline Pumps will be interlocked off

simultaneously via the TVR input to the VSD/EPR (Electrical Protection Relay). This system is

not configured for fail-safe operation on an instrument failure.

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SIS LOP may be controlled from the PCS either locally at the Station or remotely from the

MCC.


This group cannot be controlled and hence there is no Mode of Operation defined.


6.16.4.1 SIS Diagnostic Failure

Should the signal G51.K11_FA indicate a single 24V power supply failure, the SIS diagnostic

failure flag is triggered and an associated alarm is raised. This flag is reset when the

G5x.K11_FA signal returns to a healthy state.

Note: This is common to all SIS device groups and is repeated on each associated SIS device

group for consistency. This flag indicates that one of the redundant power supply modules

has failed and the system is operating in a non-redundant mode.

6.16.4.2 Line Over-pressure Protection (LOP)

The trip as issued by the SIL Relay is latched in the VSD/EPR via the mechanical trip (TVR)

issued from the SIF relay. The function is executed within 2 seconds from a physical

overpressure to trip.

The function is hard-wired and interfaced to the control system for monitoring via the signal

PY 12xA_SIF. On receipt of a SIF trip (PY 12xA_SIF) the PLC shall remove the run command

(P0x_IRC) from the VSD/EPR drives to prevent a control error.

This trip function is also latched in the PLC. While latched, the SIF trip indication on the

overview is shown (dotted line on graphic). A SIF reset button on the SIS page becomes

available under the latched trip condition and, when selected, performs the following

functions:

Reset each of the VSD/EPR latched trips AND

Reset the latched trip flag in the PLC

This button is shared with the MTBF trip function.

The SIF Reset button is coloured red under the following conditions:

SIF Trip Function latched within PLC

SIF Failed to Trip is active

6.16.4.3 LOP Proof Test Interval (Mitigation of Undetected Dangerous Failures)

The period between successful SIF trips is monitored and timed by the PLC. If the period

exceeds a PLC configurable time, a ‘Proof-test Interval Exceeded’ flag is set in the PLC. The

default time period is 180 days.

A successful proof test requires the following signals to be actuated (in order):

PT 12xA_AI Trip High Set point (kPa)

PY 12xA_SIF

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MV Mainline Pump Supply Breaker/s Open Status. In the case of DOL Motors, this will

be the motor supply breaker status (hardwired from the breaker). In the case of

VSDs, this will be the motor supply breaker status (hardwired from the breaker) OR

the VSD MCB Open status (via Profibus).

(This condition requires all MV Pump MCB's to be Not Closed, and at least one MCB to have

moved off its closed limit)

A proof test is credited as successful if all conditions are received within 5 seconds of the

trigger (PT 12xA Alarm High), as measured by PY 12xA_AI event in the PLC. A successful

proof test will reset the "Time since last proof" countdown timer.

The required proof test interval and the elapsed time since the last proof test will be visible

on the SCADA.

The elapsed time since the last proof test will be reset when a successful proof test has been

executed. Note that a trip event resulting in the above signals being activated within the

configured time will also be considered a proof test and will hence reset this timer.

An event is raised when the SIF transmitter value PY 12xA_AI exceeds the predefined SIF

Trip value. This event will be used for trip evaluation during proof test procedures. The text

to be displayed is "PY 12xA_AI LOP Trip Value Exceeded".

Note: The validity of this monitoring timer cannot be guaranteed. It relies on proper

procedures in place to validate the execution of the proof test.

6.16.4.4 LOP SIF Diagnostic (Detected Dangerous Failures - DDF)

For the Line Over-pressure SIF, the following signals form part of DDF diagnostics:

PY 12xA_AI Fault (PLC configurable time delay, default 5 minutes), hardware fault,

sensor fault and under-range.

LOP SIF Fail-to-Trip (instantaneous setting of the diagnostic flag). SIF Function Failed

to Trip is reset when the trip relay (PY 12xA_SIF) is healthy.

The above two functions are alarmed independently as detailed in alarm strategies below.

The SIF diagnostic failure flag set includes a time filter to ensure that glitches do not set and

reset the flag spuriously. This timer should be set to a default of 5 minutes on instrument

failure/recovery only.

The following functions are to occur on detection of a SIF diagnostic failure:

Start an MTTR timer

Generate a SIF Diagnostic Failure alarm (Medium Priority)

PY 12xA_AI may not be put into simulation by an operator.

The operator should inform maintenance of the failure immediately and rectification action

should start.

6.16.4.4.1 SIF Function Failed to Trip

Calculation of SIF Function Failed to Trip alarm is as follows:

The sensing element value has initiated a trip (PY 12xA_AI Trip Set point Exceeded)

AND

The VSD has not opened the associated MV breaker within 3 seconds

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OR

The trip relay (PY 12xA_SIF) tripped AND

The VSD has not opened the associated MV breaker within 3 seconds

Note: It is possible that some comparison signals will have to be calculated over more than

one scan to allow for signal propagation within the SIS and associated equipment. SIF

Function Failed to Trip is reset on a successful Proof Test (PY 12xA_SIF).

On failure of PT 12x, including simulation or override, all pumps are tripped via the PTR LOP

interlock, if the MTTR is active.

6.16.4.5 Operation Under LOP SIF Diagnostic Failure

After the MTTR timer has started, the station is operating with the following functions active:

PT 12x (SDP) is configured to trip the pumps at the same set-point as the PY

12xA_SIF function would have acted

If PT 12x be in a fault state/simulation state when entering MTTR, all the pumps are

tripped.

If an associated pressure deviation high alarm is enabled on entering an MTTR

condition all the pumps are tripped. Refer to Section 6.12.6.1.1 (The comparison

alarm is averaged over 5 minutes to prevent spurious activation of the function). The

comparison also only occurs if both sensors are healthy, i.e. the alarm and trip is

suppressed under sensor failure conditions. (This condition is not possible for LOP

SIF since the only device able to place the SIF into MTTR is the SIF Pressure

Transmitter, PY 12xA_AI)

The LOP SIF Diagnostic Alarm is repeated every 5 hours after the MTTR time starts.

An Imminent Shutdown Alarm in 1 hour is activated 1 hour before expiry of the

MTTR.

An Imminent Shutdown Alarm in ½ hour is activated ½ hour before expiry of the

MTTR.

If the MTTR timer expires, the pump off-line sequence will be initiated and pumps

interlocked off using the PTR LOP interlock.

The SIF credited MTTR value is available (and editable) on the SIS graphic. It is

editable by Maintenance staff only. The value is adjustable between 0 and 72 hours.


Not required.

6.16.6 Group Status

The following status indications are to keep the Operator informed of the status of the SIS

Group.




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Alarm Configuration Database (3) for details, including the text to be used for the alarm

messages.


SIF Diagnostic Failure

HP SIF Diagnostic Failure

Refer to Section 6.16.4.4

SIF Failure Time Exceeds MTTR

HP SIF MTTR Exceeded Trip

The SIF Diagnostic Failure alarm has been present longer than the MTTR credited for that SIF

SIF Function Spurious Trip

HP SIF Spurious Trip

The PY 121A_SIF is active and the PT 121 pressure remains below the Alarm High set-point. (after a configurable delay of 2 secs)

SIF Proof Test Interval Exceeded

HP SIF Proof Test Exceeded

The SIF Proof Test Interval Exceeded status indicates that the Proof Test time has exceeded the required time period

SIF Function Failed To Trip

HP SIF Failed to Trip


SIF Fault and in MTTR Trip (SDP)

HP PT121 Fault & in MTTR Trip


SIF MTTR Imminent Shutdown 1 hour

HP SIF MTTR Imm Shut 1h


SIF MTTR Imminent Shutdown 1/2 hour

HP SIF MTTR Imm Shut 1/2h


SIS Diagnostic Failure

HP SIS Diagnostic Failure


Table 6.16-1: SIS Group – Group Alarm Status


None defined.


None defined.


The interlocks listed here are implemented in other groups and are listed here for reference

purposes only. For more information, consult the relevant groups.


6.16.7.1.1 Line Over-pressure Protection

The SIF trip signal from the trip amp is directly wired into the TVR trip of the VSD, this TVR

trip is latched within the VSD.

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6.16.7.2.1 P0x: Line Overpressure Protection activated

The pump will be interlocked off using the IRT signal and the pump run Offline if in

Automatic when a SIF trip is active.

6.16.7.2.2 P0x: SIF Failure Time exceeds MTTR


Automatic when a SIF Failure Time exceeds MTTR.

6.16.7.2.3 P0x: PT 12x Fault and in MTTR Trip, Pressure Deviation High and in

MTTR Trip


Automatic when a PT 12x Fault and in MTTR Trip or a Pressure Deviation High and in MTTR

Trip occurs.


If the VSD trip reset is unsuccessful due to communications failure, a local VSD reset is

required.


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6.17 Sumps and Intermix Transfer

This section is associated with the control of the Sump and Intermix Transfer Device Group

and its associated devices.

Sump and Intermix Transfer facilities are installed on most Stations.


Where multiple Intermix tanks are installed on a station, transfer to both intermix tanks

simultaneously is generally not permitted. Simultaneous transfer from multiple sump tanks

to a single intermix tank is permitted.


Valves

Intermix Tank Txx Inlet Valve XV TxA

Sump Outlet Valve XV GxE

Instruments

Intermix Tank Txx Level LT 75x

Sump Tank Level LT 13x (LP Manifold Sumps) LT 99x (HP Manifold Sumps)

Sump Pump Xxx Flow FS 13x (LP Manifold Sumps) FS 99x (HP Manifold Sumps)

Pumps

Sump Pump Xxx Xxx



HP Manifold Sump and Intermix Transfer device groups are usually handed over separately

from HP Routing device groups.

LP Manifold Sump and Intermix Transfer device groups are usually handed over together with

the LP Routing device groups.


All devices related to the Sump and Intermix Transfer Group shall have the following three

modes of operation:

Local

Manual

Automatic (station dependent)


6.17.4.1 Sump and Intermix Transfer Routing Matrix

Where automatic transfer of intermix from the sump to intermix tanks is provided for on a

station, transfer is will be automated using a Routing Matrix (Refer to section 4.9 for details).

If available, selecting the sequence online button will start the sequence, opening all the

valves required for that route. The online button will be disabled if the selected route is not

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available or if a conflicting route is online already. Each sump transfer has its own offline

sequence. Selecting the offline will run that specific transfer route offline. The offline

sequence button will not be linked to availability.

6.17.4.1.1 Offline Indication (Sequencer)

All Routing valves Closed AND

Sump Pump Stopped

6.17.4.1.2 Matrix Online Indication (Green Solid Circle/ Sequencer)

All Routing valves Opened AND

Sump Pump Running

6.17.4.1.3 Matrix Route Closed Indication (Red Solid Circle)

Any Routing valve Closed

6.17.4.2 Intermix Transfer Online Sequence

Intermix Transfer online sequence is activated on receipt of:


A check is undertaken to ascertain if the Intermix Transfer Online Sequence is "Ready". If so,

the associated Routing valves are opened as required. Once the route is open, the sump

pump is started. If the group is not “Ready”, the sequence cannot be initiated.


7.2.9.1: Intermix Transfer Online Sequence

The following conditions during the running of the online sequence shall result in the

sequence aborting, complete with all associated alarming and event logging:

Any associated Routing Valves Not Available OR

Sump Pump Xxx Not Available OR


6.17.4.3 Intermix Transfer Offline Sequence

Intermix Transfer offline sequence is activated on receipt of:


a sump low level-trip (LT 13x or LT 99x)

a sump no flow trip (FS 13x or FS 99x)

an Intermix Tank high level-trip (LT75x) and route open into the tank (as determined

by routing valves Not closed status)

A check is undertaken to ascertain if the Intermix Transfer Offline Sequence is "Ready". If so,

the sump pump is stopped. Once the pump has stopped, associated Routing valves are

closed as required. If the group is not “Ready”, the sequence cannot be initiated.


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7.2.9.2: Intermix Transfer Offline Sequence


continuing to completion. Device faults during offline shall be used to continue the Sequence,



Not required.

6.17.6 Route availability

6.17.6.1 Intermix Transfer Sequence Availability

The following conditions render the Online Sequence “Not Available”. The offline sequence

button will not be linked to availability.


Xxx Not Available Xxx Not Avail or Intlk Refer to [3]

LT 75xx High Tank Txx Level High Refer to [3]

XV TxA Not Available Or Interlocked Closed

XVTxA Not Avail or Intlk Refer to [3]

XV Gxx Not Available XVGxx Not Avail Refer to [3]

Table 6.17-1: Intermix Transfer Sequence Availability

6.17.7 Group Status


None defined.


None defined.


None defined.


The following alarms are used to configure the message text on existing alarms in the device

typical:

6.17.8.1 Sump Level Rate of Change

Condition Text Priority Info Text

LT 99x/LT13x ROC High

Sump Level Rate of Change High

Warning Conduct on site investigation

Table 6.17-2: Sump Additional Device Alarm

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None defined.


6.17.9.2.1 Xxx: Intermix Tank Txx Level High Trip

The running Sump Pump (Xxx) shall be interlocked off if a high level trip is detected (LT 75x)

and the route is Not Closed.

6.17.9.2.2 Xxx: Sump Tank Level Low Trip

If the low-low level (LT 13x/99x) is reached the Sump Pump (Xxx) shall be interlocked off.

This interlock's associated alarm will be suppressed if the route is closed or sump pump (Xxx)

not running.

6.17.9.2.3 Xxx: Sump Pump No Flow

If a low flow (FS 13x/99x) is detected while the Sump Pump (Xxx) is running, after a

predefined time (10 seconds) after the pump has been started, the Sump Pump is interlocked

off. This interlock and associated alarm is blocked if the pump is not running.


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6.18 Road Loading

This section is associated with the control of Road Loading facilities and its associated

devices. Road Loading forms part of the Sumps and Intermix Transfer device group.

Sump and Intermix Transfer facilities are installed on most Stations.


The Road Loading Transfer Pump (Xxx) is used to transfer intermix from one or more

intermix tanks to the Road Tanker Loading facility for transport to an Intermix Refractionator

Plant.

Product cannot be received into and dispatched from intermix tanks at the same time.

Intermix transfer to the road tanker involves opening a flow-path from one intermix tank in

either manual or local before the Road Loading Transfer Pump (Xxx) can be started.

The road loading is automated but requires the local operator input.

The strainer valve, XV SxA, has been identified as a safety shutoff valve in terms of API 1004

and is interlocked closed until a start request from the batch controller is received.


Instruments

Intermix Tank Txx Level LT 75x

Road Loading Transfer Pump Xxx Current IT 71x

Valves

Intermix Tank Txx Outlet Valve XV TxE Strainer S0x Inlet Valve XV SxA

Drives

Road Loading Transfer Pump Xxx

Road Loading

Road Loading Pump Start Request FQIC 71x_IRC

Road Loading Signal Permissive FQIC 71x_RDY


Control is from the batch controller locally at the station.


All devices related to the Road Loading Group shall have the following Mode of Operation:

Intermix Tank Outlet valves locked in manual Mode of Operation

Road Loading Transfer Pump and Strainer S0x Inlet Valve is locked in Automatic

Mode of Operation

Local (from batch controller 50-FQIC 71x)


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6.18.4.1 Road Tanker Loading – Batch Controller

Tanker loading has its own batch controller. This is a standalone device and handles Load

Bay safety and delivery volumes. The batch controller will interface to a printer in the control

room for printing of Bill of Lading (BOL) dockets.

The batch controller has a hard-wired interface to the PLC as follows:

A Load permissive/grant (FQIC 71x-RDY) signal is sent from the PLC to the batch

controller, indicating that the associated process conditions are met.

The PLC receives a start request (FQIC 71x_IRC) signal from the batch controller if

all of its safety interlocks are met and a START delivery is requested. This signal is

high for the duration of the delivery. The start request signal is displayed on the

SCADA graphic.

On receipt of a "Start Request", the Strainer valve XV SxA interlock is removed and the valve

opened. When the valve is open the Transfer pump Xxx is started.

Should the "Start Request" signal be removed, the Transfer pump Xxx is stopped and the

Strainer valve XV SxA is closed.

The operator will need to close the associated intermix tank outlet valve/s (XV TxE).


6.18.5.1 Load Grant

The following conditions will render the Road Loading Device Group “Not Available”.


XV SxA Not Available XVSxA Not Avail Refer to [3]

Xxx Not Available Xxx Not Avail Refer to [3]

XVTxE not Open XVTxE Not Open Routing valves are required to be open.

LT 75x low level if XV TxE Not Closed

Tank T0x Level Low Trip If T0x Intermix outlet valve XVTxE not closed and T01 indicates a low level LT 75x.

XV TxA Not Closed if XV TxE Not Closed

XVTxA Not Closed Prevents intake and dispatch of product from a tank simultaneously.

Table 6.18-1: Road Loading Availability

6.18.6 Group Status


None defined.


None defined.

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None defined.


The following Group Interlocks have been defined for the Road Loading Device Group.


An independent overfill and earth monitor relay will remove the start request from the batch

controller under an overfill or no-earth condition.


6.18.7.2.1 XV SxA: No Load Start Request

The strainer valve, XV SxA, is interlocked closed if the preset start request signal (FQIC

71x_IRC) is removed.

6.18.7.2.2 Xxx: Tank T0x Low Trip

If the Intermix Tank T0x Level (LT 75x) Low Trip is reached and XV TxE is Not Closed, the

Road Loading Pump (Xxx) is interlocked off.

The low alarm and low alarm trip message is suppressed if Xxx is Not Running or if XV SxA is

Closed.


None defined.


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6.19 Road & Rail Loading

This section is associated with the control of Road/Rail Loading facilities and its associated

devices. Road/Rail Loading facilities are located at the Tarlton Terminal Depot.

6.19.1 Group Description Rail and Road Loading facilities are designed and operated in accordance with API1004

recommended practises. Facilities include transfer pumps, strainer de-aerator combinations,

flow metering, control valves, load arms, batch controllers, earth monitoring and Overfill

Protection Systems.

The road loading facility at TLR consists of three islands and four bays with products being

fed to the bays from dedicated product Accumulator Tanks. Each loading bay is equipped

with three bottom-loading arms. Preset Controllers (Contrec 1010) are used to control and

meter the fuel into road tankers at these bays. Civacon Overfill/Earth Monitor systems are

used for earth- and overfill monitoring and are dedicated one per bay. There are 12 Preset

Controllers for road loading. Additive Dosing facilities for up to six additives are installed on

each load arm.

Rail loading consists of two loading bays, one dedicated to each product. The Diesel loading

bay contains three top loading arms and the ULP loading bay four top loading arms. Unlike

Road Loading, all Rail loading is top-loading and no additive injection facilities are available.

Control of the transfer process is directly and independently controlled and monitored by the

batch controller. To this end, the control valve, flow meter, associated instrumentation and

Overfill/Earth Monitoring Systems are directly connected to the batch controller.

The loading pumps are dedicated to specific loading arms in both road and rail and will be

operated on a rotational basis as determined by duty controllers in the PLC.

Road and Rail loading is automated but also requires manual and local operator input. Only

tanks placed in WORKING status (one per Product at a time) are available for loading

operations. Note that tanks may only be placed in WORKING status when QC has been

successfully completed and the tank released for distribution.

Prior to and during a delivery, the PLC ensures that the associated route to the tanker is open

and that no process interlocks are active. The Tank Outlet valve is opened by the operator

once the tank is placed in WORKING state and is no longer interlocked. The load pump and

associated load valve is opened by the PLC (Duty Controller) on receipt of a START request

from the Contrec 1010.

In the case of Rail loading/offloading an additional check is made to ensure that the RMD

Device is not being controlled.

If the route is open and no process interlocks are active, the PLC sends a permit signal to the

Contrec 1010, which coupled with the Civacon Overfill and Earth Monitoring Signal, ensures

that the transfer is performed safely. If all safeties are ‘healthy’, and a START Request button

is activated on the Preset Controller, a start request is issued to the PLC. The PLC then sends

a start request to a duty controller which opens the associated loading valve/s and starts the

associated pump/s. If the start signal falls away, the PLC will stop the pump and close the

valve automatically.

One Loading pump is started for every two START requests received for ULP Road and Rail

Loading. A Loading pump is started for every START request received for DIE Road and Rail

Loading.

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If the one or more load operations for a particular product is active, the associated load

pump and valve are kept running/open by the PLC. The load pump is only stopped and valve

is only closed once all product specific loading operations are completed within the gantries.

6.19.1.1 Devices and Instrumentation Control and Monitoring functionality shall be achieved via the following devices:

[Only Road Loading of one product (Diesel) is detailed herein. Details of Road/Rail Loading of

other products cab be found in the Tarlton EDS.]

General

Accumulator Tank A1 Outlet valve XV A1F* Accumulator Tank A2 Outlet valve XV A2F*

Tank Group 2: A1, A2 (fed from LP Manifold 2) Road and Rail Loading

Valves

Road/Rail Transfer Pump X10 Outlet Valve XV X10E Road/Rail Transfer Pump X11 Outlet Valve XV X11E Road/Rail Transfer Pump X12 Outlet Valve XV X12E Road/Rail Transfer Pump X13 Outlet Valve XV X13E Road/Rail Transfer Pump X14 Outlet Valve XV X14E Road/Rail Transfer Pump X15 Outlet Valve XV X15E Road Loading Bay 2 to IRP Tank 4 transfer valve ZV T4B

(indication)

Pumps

Road/Rail Transfer Pump X10 X10 Road/Rail Transfer Pump X11 X11 Road/Rail Transfer Pump X12 X12 Road/Rail Transfer Pump X13 X13 Road/Rail Transfer Pump X14 X14 Road/Rail Loading Pump X15 X15

Instrumentation

Road/Rail Transfer Pump X10 Flow FS 721 Road/Rail Transfer Pump X11 Flow FS 722 Road/Rail Transfer Pump X12 Flow FS 723 Road/Rail Transfer Pump X13 Flow FS 724 Road/Rail Transfer Pump X14 Flow FS 725 Road/Rail Transfer Pump X15 Flow FS 726 Road/Rail Transfer Pump X10 Current IT721 Road/Rail Transfer Pump X11 Current IT722 Road/Rail Transfer Pump X12 Current IT723 Road/Rail Transfer Pump X13 Current IT724 Road/Rail Transfer Pump X14 Current IT725 Road/Rail Transfer Pump X15 Current IT726

Tank Group 2: A1, A2 (fed from LP Manifold 2) Road Loading

Instrumentation

Road Loading Bay 1 Preset controller FQIC 712 Road Loading Bay 2 Preset controller FQIC 721 Road Loading Bay 3 Preset controller FQIC 732 Road Loading Bay 4 Preset controller FQIC 741

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FQIC712 Start request FQIC712A_IRC FQIC712 Load Grant FQIC712B_RDY FQIC721 Start request FQIC721A_IRC FQIC721 Load Grant FQIC721B_RDY FQIC732 Start request FQIC732A_IRC FQIC732 Load Grant FQIC732B_RDY FQIC741 Start request FQIC741A_IRC FQIC741 Load Grant FQIC741B_RDY

Tank Group 2: A1, A2 (fed from LP Manifold 2) Rail Loading

Instrumentation

Rail 1 Loading Preset controller FQIC 705 Rail 1 Loading Preset controller FQIC 706 Rail 1 Loading Preset controller FQIC 707 FQIC705 Start request FQIC705_IRC FQIC705 Load Grant FQIC705_RDY FQIC706 Start request FQIC706_IRC FQIC706 Load Grant FQIC706_RDY FQIC707 Start request FQIC707_IRC FQIC707 Load Grant FQIC707_RDY FQIC 705 High Level LSH 705 FQIC 706 High Level LSH 706 FQIC 707 High Level LSH 707

6.19.1.2 Functional Layout of the Road and Rail Loading

A1

A2E-11

E-15

E-5

E-6

E-4

E-13

XVX10EXVX10E XVA1FXVA1F

XVA1GXVA1G

XVA2FXVA2F

XVA2GXVA2G

XVX11EXVX11E

XVX12EXVX12E

XVX13EXVX13E

XVX14EXVX14E

XVX15EXVX15E

FT712FT712

FT721FT721

FT732FT732

FT741FT741

FT705FT705

FT706FT706

FT707FT707

Tank Group 2 (fed from LP Manifold 2) Road Loading

Tank Group 2 (fed from LP Manifold 2) Rail Loading

Figure 6.19.1 – Road and Rail Loading (Diesel)

6.19.2 Modes of Control Road and Rail Loading may only be controlled from the Station. Mode of Control for all devices is set

to Station Mode of Control.


All devices shall have the following Modes of Operation:

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Local

The Transfer pumps’ Transfer Pump Outlet valves are always in automatic mode. The Accumulator

Tank Outlet valves are always in manual mode of operation and need to be controlled by the

operator.


6.19.4.1 Preset Controller As per the Transnet Pipelines Automation Standard document with modifications as listed.

Once permission to load has been authorised by the Dispatch Clerk, Load

data is automatically sent down to the correct preset controller from the

SAP System. Note that Load data can be manually entered into the preset

controller under supervision, should the SAP System not be available. The operator enters his Driver ID, PIN and Transaction Number into the

preset controller to initiate a particular load.

If all safety interlocks wired into the preset controller are healthy (PLC

Ready, Earth and Overfill Monitoring), then the operator is able to commence the load by pressing the start button on the preset controller.

After the Load has been completed, Bill of Lading data is automatically

uploaded to the SAP System for processing.

6.19.4.2 Loading Pump and Valve Control Loading Pumps are controlled by the PLC. The number of running Loading Pumps depends on the

number of start requests received from associated Preset Controllers. One Loading pump is started

for every two START requests received for ULP Road and Rail Loading. A Loading pump is started for

every START request received for DIE Road and Rail Loading.

Loading Pumps are controlled by a duty standby controller. Each Duty Standby Controller will be

managed by start requests (FQIC7xxx_IRC) received from the Preset Controllers.

When the start signal is received and provided the load grant/ready status (FQIC 7xxB_RDY) is

healthy, the Duty Standby Controller will open the pump Outlet valve and, after a configurable time,

start the corresponding loading pump. When the start signal is removed, the PLC will stop the

loading pump via the duty controller and then close the loading valve.

The duty controller manages the number of pumps to run per product while loading.

No Duty Standby switching on running hours will occur whilst loading is in progress.

6.19.4.3 Transfer Shutoff/Isolation In the event that the Rail Tanker indicates a high level (LSH 70x), the overfill protection system

interfaced into the preset controller will ensure that the control valve is closed and the transfer

terminated.


6.19.5.1 Road Loading Batch Controller Ready The Batch Controller Ready (FQIC7xxB_RDY) is given if the following conditions are met:

An Associated Route is Open (Loading valve open)

Tank in “Working” state

The “Working” Tank has no Low Level Trip, coming from the Tank Gauging

System Any one Transfer Pump available and associated Transfer Pump Outlet valve

available

Rail Loading Plant E-Stop (UA296) healthy

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Road Loading Plant E-Stop (UA297) healthy

Fire Detection Alarm not activated UA193 or UA194

6.19.5.2 Rail Loading Batch Controller Ready The Batch Controller Ready (FQIC7xxB_RDY) is given if the following conditions are met:

An Associated Route is Open or Available

Tank in “Working” state

The “Working” Tank has no Low Level Trip, coming from the Tank Gauging

System Any one Transfer Pump available and associated Transfer Pump Outlet valve

available

Rail Moving device is not running (QStopped)

Rail Loading Plant E-Stop (UA296) healthy

Road Loading Plant E-Stop (UA297) healthy

Fire Detection Alarm not activated UA193 or UA194

6.19.6 Group Status The following status indications are available to keep the Operator informed of the status of the Road

and Rail Loading Group:

6.19.6.1 Group Alarm Status Indications The following Group Alarm Statuses are configured using display LEDs which are grey in the inactive

condition and red in the active condition, with an associated alarm. Refer to the Alarm Database for

details, including the text to be used for the alarm messages.

None defined.

6.19.6.2 Group Error Indications The following Group Error Statuses are configured using display LEDs which are grey in the inactive

condition and red in the active condition, with an associated event. Refer to the Alarm Database for

details, including the text to be used for the event messages.

None defined.

6.19.6.3 Group Information Indications The following Group Information Statuses are configured using display LEDs which are grey in the

inactive condition and green in the active condition, with an associated event. Refer to the Alarm

Database for details, including the text to be used for the event messages.

None defined.

6.19.7 Group Interlocks The following interlocks have been defined for the Receiver Group:

6.19.7.1 Hard Wired Interlocks The batch controller provides the following protection functionality, by removing the START Request:

Tanker Overfill and Earth monitoring via an independent overfill and earth monitor relay

Low Flow protection.


6.19.7.2.1 Road Loading Bay E-Stops Plant E-Stops installed on the Road Loading gantries will be wired in series and interfaced to PLC02 as

a single Road Loading Plant E-Stop UA297.

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When any of the E-Stops are activated, the PLC will perform the following functionality:

Interlock all loading pumps off. Both road and rail loading pumps are

stopped to avoid confusion as to which are shared between road and rail and which are not.

Interlock closed all open working tanks outlet and routing valves.

Remove ready signals from 1010’s (FQIC_7xxB_RDY) in both Road and Rail

Enable siren UA 291.

Text to be displayed is “Plant Emergency Stop”

6.19.7.2.2 Rail Loading E-Stops Plant E-Stops installed on the Rail Loading gantries will be wired in series and interfaced to PLC02 as

a single Rail Loading Plant E-Stop UA296.

When any of the E-Stops are activated, the PLC will perform the following functionality:

Stop all loading pumps running. Both Road and Rail loading pumps are

stopped to avoid confusion as to which are shared between road and rail and which are not.

Interlock Close all open working tanks outlet and routing valves.

Remove ready signals from 1010’s (FQIC_7xxB_RDY) in both Road and Rail.

Enable siren UA 292

Text to be displayed is “Plant Emergency Stop”

6.19.7.2.3 Pump Low Flow Each Loading Pump is interlocked to the Low Flow Switch. The pump will be tripped if there is low

flow after the pump has been running for a configurable time in the PLC. When a low flow is detected

the PLC will start the next available pump (via a Duty Controller). Note: If no-flow is detected within

the preset controller (based on configurable set-point set up within the preset controller), the preset

controller will remove the start request to the PLC, independently of this interlock.

Text to be displayed is “Road/Rail Transfer Pump No Flow”

6.19.7.2.4 Product Load Valves (API 1004) The API1004 requirement to interlock product load valves closed on loss of start request has not been

implemented at Tarlton due to the complexity of multiple load pumps being able to feed individual

load arms.


None defined.


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6.20 Sump Injection (Venturi)

This section is associated with the control of the Sump Injection (Venturi) Device Group and

its associated devices.

Sump Injection facilities are installed on most RPP and COP Stations.


Sump Injection facilities may be used to inject intermixure from the sump at a controlled flow

rate back into the mainline. Injection of the contents of the Sump is based on the venturi

principle, by which a pressure differential across the venturi causes the product from the

sump to be injected into the mainline. Motorised actuators are installed on the Injection Inlet,

Sump Outlet and Injection Outlet Valves for control purposes. Reverse flow into the Sump

Tank is prevented by means of a non-return valve in the Sump Outlet Line.

Sump Injection facilities may be installed on multi-product pipelines and single product

pipelines. Flushing of Sump Injection piping is not required for either multi-product or

dedicated-product pipelines.

In multi-product pipelines, a Control Valve is installed on the main injection line before the

venturi on all multi-product lines and is used to control the sump injection flow rate to two

set points – coarse and fine. This valve is used in open loop control (not PID) with position

feedback. In manual the valve position can be set between 0 – 100 % throttling. In

automatic there are only two preset positions that can be selected (i.e. coarse or fine).


Valves

Sump Injection Inlet valve XV GxA Sump Injection Discharge valve XV GxE

Sump Outlet valve XV GxB Sump Injection flow control valve CV GxJ (Multi-product lines only)

Instruments

Sump Tank Level LT 13x (HP Manifold Sumps)




All devices related to the Sump Injection Group shall have the following three modes of

operation:

Local

Manual

Automatic (station dependent)

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6.20.4.1 Sump Injection States

6.20.4.1.1 Sump Injection Online

Sump Injection is in an Online state if:

XV GxA Opened AND

XV GxB Opened AND

XV GxE Opened AND

6.20.4.1.2 Sump Injection Offline

Sump Injection is in an Offline state if:

XV GxA Closed AND

XV GxB Closed AND

XV GxE Closed

6.20.4.2 Sump Injection Sequences

6.20.4.2.1 Sump Injection Online Sequence

The Sump Injection Online Sequence is activated, if Ready, on receipt of:


If Ready, the Sump Injection Inlet and Injection Outlet valves are opened simultaneously

and on successful completion the Sump Outlet valve is opened.



Any actuated Sump Injection valve Not Available (XV GxA, XV GxB,

XV GxE) OR



7.2.10.1: Sump Injection Online Sequence

6.20.4.2.2 Sump Injection Offline Sequence

The Sump Injection Offline Sequence is activated, if Ready, on receipt of:


Sump Level low-trip

Intermix Transfer Route online

If Ready, the Sump Outlet valve is closed and on successful completion, the Sump Injection

Inlet and Outlet valves are closed simultaneously.

Any faults encountered whilst the sequence is running will result in the sequence continuing

to completion, complete with all associated alarming and event logging:

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7.2.10.2: Sump Injection Offline Sequence


6.20.5.1 Sump Injection Availability

The following conditions render the Sump Injection Device Group “Not Available”.

Table 6.20-1: Sump Injection Availability

6.20.6 Group Status


None defined.


None defined.


None defined.


None defined.



None defined.


6.20.8.2.1 XV GxB: Sump Tank Level Low Trip

If the low-trip level (LT 13x) is reached the Sump Outlet valve (XV GxB) shall be interlocked

closed. This interlock's associated alarm will be suppressed if the route is closed.

6.20.8.2.2 XV GxB: Intermix Routing

An Intermix delivery will take precedence over Sump Injection, by interlocking the Sump

Outlet valve closed.


XV GxA Not Available XVGxA Not Avail Refer to [3]

XV GxB Not Available XVGxB Not Avail Refer to [3]

XV GxE Not Available XVGxE Not Avail Refer to [3]

LT13x Low LT13x Low Sump level at low-trip level

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6.21 Purge Air Fans – RPP & COP Stations

This section is associated with the control of the Purge Air Fan Device Group and its

associated devices.

Purge Air Systems are installed on Mainline Pump Sets on stations associated with the RPP

Pipeline.


Where installed on mainline pump sets, Purge Air Fan Systems are used to for both cooling of

the motor windings as well as purging of product vapours for hazardous area classification

purposes. A single purge air system caters for all mainline pump sets installed on a respective

station. Mainline pump sets may only be run with purge air circulation active.

Two Purge Air Fans are used (duty and standby), with dedicated flow switches per pump set

indicating the presence of purge airflow. Purge Air Fans, after running for a certain time-

period (configured in the PLC) are alternated to achieve equal run hours (duty and standby).


Instruments

Mainline Pump P0x Purge Air Flow FS 0x1 Purge Air Fan Current IT14x

Equipment

Purge Air Fan Q0x, Q0y




All devices related to the Purge Air Group shall have the following three modes of operation:

Local

Manual

Automatic



No sequences have been defined for the Purge Air system but the two fans are controlled

according to the duty/standby controller typical. Automatic selection of duty and standby

status of fans is based on Run Hour differentials [Configurable in the PLC – Default 100

hours]. Note that each fan will run for a period of twice the set point, i.e. 200 hours.




and will start and stop the Purge Air fans accordingly.


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Manual mode

Group not available

6.21.4.2 Purge Air Flow

Mainline pumps can only run if the purge air flow switch is active. If the duty controller is

running and the flow switch is not active, after a delay of 5 seconds the standby fan is also

started and the duty controller is switched off (duty control not active). The operator needs

to investigate the problem and restart the duty controller or stop the standby fan in manual

mode.

If no flow is detected after 15 seconds, the mainline pumps are interlocked off.




Xxx Not Available Xxx Not Avail or Intlk Purge Air Pump Not Available

Table 6.21-1: Purge Air DuC Availability

6.21.6 Group Status


None defined.


None defined.


None defined.


None defined.



None defined.


None defined.

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6.22 Ventilation Fans – 24” MPP Stations

This section is associated with the control and monitoring of the Pumphouse Ventilation Fans

Device Group.

Ventilation Fans are installed on all pump stations associated with the 24” MPP Pipeline,

where the mainline pumps are installed in enclosed Pump House buildings.


The main pumphouse ventilation fan system comprises six (6) individual fans.

Note: It is acknowledged that the main pumphouse temperature will follow the trend of the

outside ambient temperature.


Main Pumphouse Fans

Ventilation Fan Q22 Q22






Instruments

Ventilation Fan Q22 Temperature TT 142







The Pumphouse Ventilation Fans Device Group shall be controllable both locally from the

SCADA System installed at the Pump Station as well as remotely from the MCC.


All devices related to the Ventilation Fan Device Group shall have the following three Modes

of Operation:

Local

Manual

Automatic

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There are six (6) DOL ventilation fans installed inside the main pump house, each with a

dedicated temperature sensor.

6.22.4.1 Main Pumphouse Ventilation Control

One of the functions of the main pumphouse ventilation fan system is to provide adequate

ventilation, ensuring safe access for personnel. When detected gas levels are above

occupational safety levels (typically 3.6% LEL – AT 184_TH), two (2) fans will automatically

start. The fans will remain running until stopped by the operator.

Automatic selection of duty and standby fans is based on run hours, as per the duty/standby

controller typical.

Note: The gas level (typically 3.6% LEL – AT 184_TH) input for this function is provided

from the Fire and Gas System as a digital input to the PCS (refer to Section Error!

Reference source not found.). This input is different from the gas level signal (typically

20% LEL – AT 184_H) from the Fire and Gas System that is used for the hardwired start

interlock to the six (6) fans. This input is also different from the gas level signal (typically

40% LEL – AT 184_HH) from the Fire and Gas System, which will interlock the Station Inlet

Isolation valve XV I1A.

6.22.4.2 Main Pumphouse Ambient Temperature Control

A second function of the main pumphouse ventilation fan system is to maintain main

pumphouse ambient temperature within a desirable range. Upon the starting of the Duty

Controller, two ventilation fans will be started regardless of the ambient conditions inside the

pumphouse.

Starting of additional fans is based on the standard operating temperature setpoint (25˚C).

The process variable (PV) will be a derived temperature measurement, based on the average

of temperatures associated with fans running. That is, if two fans are running, then the

average of the two temperature sensors will be used as PV by the process control system. If

the derived process variable exceeds the standard operating temperature setpoint by more

than a configurable temperature (typically 2˚C) for a configurable time (30 minutes) and the

duty controller is running, an additional fan will be started. The PV will then be re-calculated

based on the average of the number of temperature sensors associated with the running

fans.

Note: The ambient temperature averaging calculation will use substitute values when

temperature probes fail.

The average temperature will be calculated using all vent fan temperature sensors regardless

of whether the temperature sensors are displaying a real or substituted value.

If the PV is greater than a configurable temperature (typically 2˚C) below the standard

operating temperature setpoint for a configurable time (default 30 minutes) one of the

running fans will be stopped.

Whenever a fan has been started or stopped, the timer is reset such that multiple fans are

not started or stopped simultaneously as a function of temperature.

Automatic selection of duty and standby fans is based on run hours, as per the duty/standby

controller typical.

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6.22.4.3 Start/Stop Ventilation Fans Duty Controller

The ventilation fan duty controller will be started on receipt of any of the following

conditions:

A Start Request from the Duty Controller.

A Start Request from the Station Line-up Sequencer.

A Rising edge of Combined Pump Room HC Gas Detector signal AT 184_TH (3.6%

LEL), for Ventilation Control and when in automatic.

The ventilation fan duty controller will be stopped on receipt of any of the following

conditions:

A Stop Request from the Duty Controller.

A Stop Request from the Station Isolation Sequencer.

When the Ventuilation Fans device group becomes Not Available.

The Duty Controller remains running, until a device fault occurs which causes it to stop

running, or it is stopped by the operator. Placing the group in manual mode while the

sequence is running will leave the Ventilation Fans in their current state.


6.22.5.1 Pumphouse Ventilation Fans Group Availability

The following conditions will render the Pumphouse Ventilation Fans Device Group “Not

Available”.

Table 6.22-1: Pumphouse Ventilation Fans Availability

Condition Logic

Less Than Two Fans Avail or Intlk If less than two fans are available or

Interlocked.

Less Than Two Fans Rdy for Duty If less than two fans are ready for duty (DuC).

6.22.6 Group Status

6.22.6.1 Pumphouse Ventilation Fans Group Status

6.22.6.1.1 Group Alarm Status Indications



ACDB [6] for details, including the text to be used for the alarm messages.

Table 6.22-2: Pumphouse Ventilation Fans Group Alarm Status

Condition Logic

Less Than Two Fans Running

If less than two fans are running

and one or more mainline pump set is running.

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6.22.6.1.2 Group Error Status Indications

Not Required.

6.22.6.1.3 Group Information Status Indications

Not Required.



A hardwired start interlock (pulsed start signal) will be provided from the Fire and Gas

System to start all fans following detection of gas in the pumphouse. A hardwired stop signal

(pulsed signal) will be provided from the Fire and Gas system when the condition is reset in

the Fire and Gas System.

A hardwired stop interlock (pulsed stop signal) will be provided from the Fire and Gas System

to stop all fans following detection of fire (i.e. double knock, from Combined Fire Detector

signal UA 192).


6.22.7.2.1 Q22 \ Q23 \ Q24 \ Q25 \ Q26 \ Q27: AT184_H Pump House Gas Detected

The hardwired interlocks will be duplicated in the PCS. [This interlock ensures that a control

error is not generated when the fans are controlled from the Fire and Gas System].

A start interlock will be provided from the PCS to start all fans following detection of gas at

20% LEL in the pumphouse (i.e. from Combined Pump Room HC Gas Detector signal AT

184_H).

6.22.7.2.2 Q22 \ Q23 \ Q24 \ Q25 \ Q26 \ Q27: BA184 Pumphouse Fire Detected

A stop interlock will be provided from the PCS to stop all fans following detection of fire (i.e.

double knock, from Combined Fire Detector signal UA 192), or when gas is no longer

detected within the pumphouse (i.e. from Combined Pump Room HC Gas Detector signal AT

184_H).

Note: BA 184 takes precedence over AT 184_H interlock.


Not Required.

6.22.9 Inter-PLC Communications Interface

Not Required.


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6.23 Pressurisation Fans - RPP Stations

This section is associated with the control of the Pressurisation Fan Device Group and its

associated devices.

Pressurisation Systems of this type have been installed on certain stations associated with the

RPP Pipeline (where Control and Equipment Rooms have been installed within Hazardous

Areas).


Pressurisation Fans are used to pressurise control rooms situated within hazardous areas for

the purposes of altering the classification of the control rooms to that of safe areas.

Two Pressurisation Air Fans are used (duty and standby), with a differential pressure switch

mounted in the control room and used to indicate whether the room is pressurised.

Pressurisation Air Fans, after running for a certain time-period (configured in the PLC) are

alternated to achieve equal run hours (duty and standby).

Pump sets may only be run with Pressurisation circulation active.


Instruments

Room Differential Pressure PDS 15x

Pressurisation Fan Current IT 15x

Equipment

Pressurisation Fans 1, 2 Q0x, Q0y




All devices related to the Pressurisation Fan Group shall have the following three modes of

operation:

Local

Manual

Automatic



No sequences have been defined for the Pressurisation system but the two fans are

controlled according to the duty/standby controller typical. Automatic selection of duty and

standby status of fans is based on Run Hour differentials [Configurable in the PLC – Default

100 hours]. Note that each fan will run for a period of twice the set point, i.e. 200 hours.



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and will start and stop the Pressurisation fans accordingly.



Manual mode

Group not available

6.23.4.2 Pressurisation Pressure

If the duty controller is active and the room differential pressure switch is not active after a

delay of 10 minutes (indicating a differential pressure within the Control/Equipment Room

<60Pa), the standby fan is also started, and the duty controller is switched off (duty control

not active). The operator needs to investigate the problem and restart the duty controller or

stop the standby fan in manual mode.




Xxx Not Available Xxx Not Avail or Intlk Pressurisation Pump Not Available

Table 6.23-1: Pressurisation DuC Availability

6.23.6 Group Status


None defined.


None defined.


None defined.


None defined.



None defined.

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6.23.8.2.1 Q0x: Station Isolation

Should no fan be running, the station is isolated after a pre-configured time (Configurable in

the PLC- default 15 mins). All PLC outputs are disabled and will only be enabled once a fan

has been started in local and has run for a pre-configured time (Configurable in the PLC-

default 15 mins).


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6.24 Inhibitor & DRA Injection

This section is associated with the control of the Inhibitor & DRA (Drag Reducing Agent)

Injection Device Group and its associated devices.

Rust Inhibitor Systems have been installed on various stations associated with the RPP and

COP Pipelines.

DRA Injection Systems have been installed on various stations associated with the RPP

Pipeline.


Inhibitor injection is used to deliver a predetermined amount of rust inhibitor into the

mainline upstream of the pump sets, for the purposes of prohibiting corrosion of the

pipelines. A variable stroke-dosing pump with a variable speed motor is used to inject

inhibitor into the mainline, dependent on the mechanical pump stroke setting and speed of

the variable speed drive. Injection rates may be set to vary between 4 ppm to 8 ppm.

Inhibitor injection into Avtur is not permitted.

Drag Reducing Agent injection is used to deliver a predetermined amount of drag reducing

agent into the mainline downstream of the mainline pump sets and control valves, for the

purposes of reducing drag and increasing flowrate. A variable stroke-dosing pump with a

variable speed motor is used to inject DRA into the mainline, dependent on the mechanical

pump stroke setting and speed of the variable speed drive. DRA injection into Avtur is not

permitted.

Separate variable stroke dosing pumps with variable speed motors are used to inject inhibitor

and DRA into the mainline.


6.24.1.1 Inhibitor Injection Systems

Instruments

Inhibitor Tank Level LT 17x

Inhibitor Injection Pump Speed Output SC17x Inhibitor Injection Pump Speed Feedback ST17x

Equipment

Inhibitor Injection Pump X0x

6.24.1.2 DRA Injection Systems

Instruments

DRA Tank Level LT 17x

DRA Injection Pump Speed Output SC17x DRA Injection Pump Speed Feedback ST17x

Equipment

DRA Injection Pump X0x



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All devices related to the Inhibitor/DRA Injection Group shall have the following three modes

of operation:

Local

Manual

Automatic


6.24.4.1 Inhibitor/DRA Flow Control

If the group is in automatic, Inhibitor/DRA flow is calculated according to the injection rate

set point and mainline flow.

The following formula is used to calculate the required Dosing Pump Speed Set point for the

variable speed drive:

Dosing Pump Speed (revs) = Constant x Mainline Flow rate x Injection Rate

1 000 000

Each pump will have its own calculation with a separate Injection rate set point. Injection

rate set points will have upper and lower limits configured.

Inhibitor Injection rates may be set to vary between 4 ppm to 8 ppm, with limits of 5 to 8

ppm, included in the formula as a variable.

The Constant is defined as pump displacement expressed as the number of revolutions per

litre of product, and is calculated as follows:

Constant (revs/litre) = No. of Revs/stroke

Stroke Displacement (litres) x Mechanical Stroke Setting

No. of Revs/Stroke is defined in the Dosing Pump Manual

Stroke Displacement is defined in the Dosing Pump Manual

Mechanical Stroke Setting as set on the pump

The actual pump speed is indicated. In manual mode the operator has to set the speed set-

point to the required speed. The speed is not calculated.

6.24.4.2 Inhibitor/DRA Injection States

6.24.4.2.1 Inhibitor/DRA Injection Online

Inhibitor/DRA Injection is in an Online state if:

X0x is Running

6.24.4.2.2 Inhibitor/DRA Injection Offline

Inhibitor/DRA Injection is in an Offline state if:

X0x is Stopped

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6.24.4.3 Inhibitor/DRA Injection Sequences

6.24.4.3.1 Inhibitor/DRA Injection Online Sequence

The Inhibitor/DRA Injection Online Sequence is activated, if Ready, on receipt of:


If Ready, the Inhibitor/DRA Injection Pump will start if the HP flow rate (FTxxx) is greater

than 500l/min (configurable) and will stop when the flow-rate drops below 400 l/min

(configurable).

The following conditions while the sequence is running will result in the sequence stopping,



Inhibitor/DRA Level low-trip

Associated HP Route closed



Inhibitor/DRA Injection pump Not Available (X0x) OR



7.2.11.1: Inhibitor/DRA Online Sequence


6.24.5.1 Inhibitor/DRA Injection Availability

The following conditions render the Inhibitor/DRA Injection Device Group “Not Available”.

Table 6.24-1: Inhibitor/DRA Injection Availability

6.24.6 Group Status






Inhibitor/DRA Active Inhibitor/DRA ActivePossible Hotspot

If inhibitor/DRA is running and an interface is detected an alarm “Inhibitor/DRA active” is triggered.


X0x Not Available X0x Not Avail Refer to [3]

LT17x Low LT17x Low Inhibitor/DRA level at low-trip level

HP Route Closed HP Route Closed As determined by valve status

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Table 6.24-2: Inhibitor/DRA Injection Group Alarm Status


None defined.


None defined.


None defined.



None defined.


6.24.8.2.1 X0x: Inhibitor/DRA Tank Level Low

If a Inhibitor/DRA Tank low-trip level (LT 17x) is detected while the Inhibitor/DRA Injection

Pump (X0x) is running, the pump is interlocked off. This interlock and associated alarm is

blocked if the pump is not running.


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6.25 General

This section is associated with the control and monitoring of the General Device Group.

The General Device Group consists of status and tripping signals related to various systems

installed on each station, including:

PLC and ET200 24 VDC Power supplies (monitoring only)

HVAC System (monitoring only)

Fire System (monitoring only)

Siren (control only)


The control and monitoring functionality is achieved via the following devices (typically):

6.25.1.1 PLC and ET200 Power Supplies

LV01 ET Panel Power Supply Fail G10_FA PLC01 Panel Power Supply Fail G51_FA

RR01 ET Panel Power Supply Fail G52_FA Metering Panel Power Supply Fail G60_FA

Comms Panel 01 Power Supply Fail G80_FA

6.25.1.2 HVAC Systems

‘Building’ HVAC1 Fail HVACx_FA ‘Building’ HVAC1 Run HVACx_ON

Server Panel 1 Temperature TT 191

VSD Room Temperature TT 192 Metering Panel Temperature TT 193

6.25.1.3 Fire Systems

Fire Systems, consisting of a Fire Water (manifolds) and Gas Suppression (buildings) systems

will be controlled locally from the fire panels located in the Fire Pump-house and Control

Room, as well as remotely from the Situation Management System installed in the National

Operating Centre (NOC). Limited interface will be provided between the Fire System and the

Process Control System, and will be used for alarming purposes only.

Note that Fire System interface is site specific – the signals listed below should be used as a

guideline only. [Note that Fire Systems installed pre-2009 and all associated equipment have

been assigned an Instrument Group Identifier of 19. Fire Systems installed post- 2009 and all

associated equipment has been assigned an Instrument Group Identifier of 18].

Fire Detection - Plant UA 181A Plant Fire System Healthy UA 181B

Fire Detection - Building UA 182

Fire Water Tank Low Level (90%) 50-LS 181

Fire Foam Concentrate Tank Low Level (90%) LS 182 Tank Bund xx HC Liquid Detection LS 18xA

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The Fire Detection – Plant and Fire Detection Building signals are usually composite signals of

all flame detectors/sensors using double knock detection.

6.25.1.4 Others

Terminal Siren (Alarm) 50-UA 191


The General Device Group be controlled from the PCS either locally at the Station or remotely

from the MCC.


All devices related to the General Device Group shall have the following two Modes of

Operation:

Local

Manual


6.25.4.1 LP Station Statuses

Station status bits will be generated and sent to the Line-wide PLC on receipt of the following

conditions:


LP Routing No Valid Flow-path PRDx

LP No Valid Flow-path PRDx Applies only whilst a delivery is in progress. Refer to Section 6.31.4.3

Prover No Valid Flow-path

Prover No Valid Flow-path Applies only whilst a delivery is in progress. Refer to Section 6.36.4.4

Strainer Sxx Blocked Strainer S01 Blocked Applies only whilst a delivery is in progress. Refer to Section 6.31.4.2.1

LP Manifold Over-pressure

LP Manifold Over-pressure Applies only whilst a delivery is in progress. Refer to Section 6.30.7.3

Tank Txx Level High Tank A01 Level High Applies to Accumulator and Intermix Tanks, only whilst a delivery is in progress to the tank.

Tank Txx Overfill Protection Activated

Tank A01 Overfill Protection Applies to Accumulator and Intermix Tanks. Refer to Section 6.35.8.2.1

Sump Txx High Level Intake Sump T31 Level High

Applies to all Sump Tanks.

Table 6.25-1: General - LP Station Statuses

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6.25.4.2 HP Station Statuses

Station status bits is generated and, together with those generated on the Dispatch Control

System, sent to the Line-wide PLC on receipt of the following conditions:


Receiver No Valid Flow-path

Receiver No Valid Flow-path Refer to Section 6.2.4.3

Receiver Fault Receiver Fault Refer to Section 6.2.4.8.9

HP No Valid Flow-path HP No Valid Flow-path Refer to Section 6.12.4.5

P0x No Valid Flow-path P0x No Valid Flow-path As per Section 6.8.4.5

HP Line Overpressure Protection

HP Line Overpressure Protection


Sump Txx High Level Sump Txx Level High

Strainer Sxx Blocked Strainer Sxx Blocked Applies only when route is online. Refer to Section 6.13.4.2.4

Fire Detected - Plant Fire Detected - Plant Refer to Section 6.25.1.3

Fire Detected - Building Fire Detected - Building Refer to Section 6.25.1.3

Station Emergency Stop Station Emergency Stop Refer to Section 6.26.7.1.1

Table 6.25-2: General - HP Station Statuses


Not required

6.25.6 Group Status


None defined.


None defined.


None defined



None defined.


None defined.

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None defined.


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6.26 Electrical Distribution

This section is associated with the control and monitoring of the Electrical Distribution Device

Group.

The Electrical Distribution Device Group consists of status and tripping signals related to the

electrical distribution on a station, including:

HV and MV Electrical Breakers (monitoring and control)

LV Electrical Breakers (monitoring only)

HV, MV and LV Power Fail statuses (monitoring only)

MV Generators (monitoring and control )

LV Generators (monitoring only)

UPS (monitoring only)

The Electrical Device Group includes the MV Gensets as well as the Diesel Offloading for, and

diesel supply to, the MV Gensets which are addressed in the following sections within this

document:

MV Gensets Device Group (section 6.27)

MV Generator Diesel Supply Device Group (section 6.28)

Diesel Offloading Device Group (section 6.29)

[MV Gensets are only installed on stations associated with the 24” MPP Pipeline.]



6.26.1.1 HV/MV Links

Typical electrical interface for HV/MV Links installed on stations is as follows:

MV01 L5x Closed MV01L5x CL

MV01 L5x Earthed MV01L5x EL

6.26.1.2 HV/MV Incomer Breakers

Typical electrical interface for HV/MV Electrical Breakers installed on stations associated with

the 24” MPP Pipeline is as follows:

MV01 F5x Closed MV01F5x CL

MV01 F5x Open MV01F5x OP MV01 F5x In Local MV01F5x SLO

MV01 F5x Electrical Non-Latched Trip MV01F5x ETP MV01 F5x Electrical Latched Trip MV01F5x ETR

MV01 F5x Power Fail MV01F5x UV

MV01 F5x Open Request MV01F5x O


the RPP and COP Pipelines is as follows (Type 1):

MV01 F5x Closed MV01F5x1 CL

MV01 F5x Open MV01F5x OP

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MV01 F5x In Local MV01F5x SLO

MV01 F5x Trip Circuit Faulty MV01F5x TCF MV01 F5x Master Trip Relay MV01F5x MTR



the RPP and COP Pipelines is as follows (type 2):

MV01 F5x Closed MV01F5x1 CL MV01 F5x Open MV01F5x OP

MV01 F5x In Local MV01F5x SLO MV01 F5x Trip Circuit Faulty MV01F5x TCF

MV01 F5x Master Trip Relay MV01F5x MTR MV01 F5x Overcurrent Trip MV01F5x OCP

MV01 F5x Earth Fault Trip MV01F5x ELP

MV01 F5x Balanced Earth Fault Trip MV01F5x BEF MV01 F5x Electronic Protection Relay Fail MV01F5x ERP

MV01 F5x Breaker Racked Out MV01F5x BRS MV01 F5x Low Gas Alarm (SF6) MV01F5x LGP


MV01 F5x Power Fail MV01F5x UV MV01 F5x Power Out of Spec MV01F5x NRS


6.26.1.3 HV/MV Transformers

Typical electrical interface for HV/MV Transformers installed on stations is as follows:

MV01 F5x Buchholtz Trip MV01F5x BGF

MV01 F5x Oil Temperature High MV01F5x OTP MV01 F5x Tap Changer Out of Step MV01F5x OOS

MV01 F5x Electronic Protection Relay Fail MV01F5x ERP

6.26.1.4 50-LV01 Incomer

Typical electrical interface for LV Switchgear Panels installed on stations is as follows:

LV01 F3x Closed LV01F3x CL LV01 Power Fail LV01 UV

6.26.1.5 LV Generators

Typical electrical interface for LV Generators installed on stations is as follows:

LV Genset E06 Battery Charge Fail E06 BCF LV Genset E06 Mains On Load E06 EOF

LV Genset E06 Running E06 EON

LV Genset E06 Fuel Low E06 FLP LV Genset E06 In Local E06 SLO

LV Genset E06 Mechanical Trip E06 TVR

6.26.1.6 UPS Interface

Typical electrical interface for PCS UPS installations is via hardwired interface as follows:

Control System UPS01 Bypass LV31 BYP Control System UPS01 Fail LV31 FLT

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Note: The LV31_FLT (low battery voltage alarm) is used to alarm the operator that

the UPS has an active fault condition. This signal is a composite of all fault conditions

on the UPS, and includes Warning, General Fault and Low Battery statuses. When

low battery has been detected within the UPS, a shutdown script is initiated on all

PCS Servers which ensures orderly shutdown.

Typical electrical interface for Electrical UPS installations (24” MPP Stations) is via hardwired

interface as follows:

Electrical UPSxx Bypass LV3xBYP

Electrical UPSxx Fail LV3xFLT

Typical electrical interface for Remote Room UPS installations (IVW and JMP Terminals) is via

hardwired interface as follows:

Remote Room UPSxx Bypass LV3x BYP

Remote Room UPSxx On Mains UPSxx FLT

Remote Room UPSxx Warning UPSxx WRN Remote Room UPSxx Static Bypass UPSxx BYP

Remote Room UPSxx Battery Low UPSxx BCF

6.26.1.7 Electrical Status

Battery Charger Fail BATTxx BCF


The Electrical Device Group may be controlled from the PCS either locally at the Station or



All devices related to the Electrical Device Group shall have the following three Modes of

Operation:

Local

Manual

Automatic


Not required.


Not required.

6.26.6 Group Status






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Station Emergency Stop

Station Emergency Stop

[24“ MPP Pipeline stations]

Generated when all incomer breakers and MV Genset breakers show a latched trip status (ETR signal).

[RPP and COP Pipeline stations]

Generated when all incomer breakers show an open MVF5x_OP status.

MV Utility Power Restored

MV Utility Power Restored

Alarm is generated when MV Utility power is restored as detected by MVF5x_UV = 1. [Alarm is only configured for stations with MV Gensets installed.]

Table 6.26-1: Electrical Group Alarm Status


None defined.


None defined.



6.26.7.1.1 Station Emergency Stop

Station Emergency Stop Push Buttons are installed at various locations throughout the site,

notably the guard hut, control centre and MV Building for the purposes of tripping the

Incomer and MV Generator MCB’s in the event of an emergency.

Break glass units are not required to be provided on Station sites supplied from 400VAC

Municipal Supplies, there being no requirement to isolate Incomer supply.


None defined.


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6.27 MV Generator Sets

This section is associated with the control and monitoring of the MV Gensets Device Group.

The MV Gensets Device Group forms part of the Electrical Distribution Device Group, section

6.26

MV Gensets are installed on all stations associated with the 24” MPP Pipeline.


MV backup generators will be installed to provide MV supply power to the site in the event of

a utility power outage. A facility will be provided for these MV generators to be started from

the MCC/SCC or local SCADA system. All electrical interlocking and protection ensuring the

safe starting of these generators remotely will be provided in the electrical protection

schemas and the operator will not be required to evaluate any of these to start/stop the MV

generators. When utility power supply is lost, auxillary power (400V AC) requirements will be

met by the respective site LV generator. However, when running, the MV generators will

meet all power requirements of the respective installed location, negating the need for the LV

and MV generators to run concurrently.

MV generators will each power one half of the MV panel board, and are each sized to handle

auxiliary power requirements as well as the starting and running of a single Mainline Pump, a

single booster pump and the starting of a second booster pump.

It should be noted that when the main utility feed is lost, the Mainline Pumps and booster

pumps in operation will shut down before the MV generators can be started in time to

reinstate power to the pumps to maintain the current pumping operation.

The MV generators are furnished with a self-diagnostic and monitoring system local to the

machine.

MV generators shall be capable of being started up and shut down remotely from the PLC,

without personnel being required to be in attendance on site.

The interface between the PLC and the respective MV Generators will be hard-wired signals

(via ETM).

Control and Monitoring functionality is achieved via the following interface signals:

Digital Inputs

MV Genset E0x Running E0xEON

MV Genset E0x in Local E0xSLO MV Genset E0x Available E0xRDY

MV Genset E0x Warning E0xWRN MV Genset E0x Mechanical Trip E0xTVR

MV Genset E0x Battery Charge Fail E0xBCF

Digital Outputs

MV Genset E0x Start Request E0xIRC MV Genset E0x Stop Request E0xIRT


This device forms part of the Electrical Distribution device group and thus does not have its

own Mode of Control.

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All devices related to the MV Gensets Device Group have the following modes of operation:

Local

Manual

In Local Mode the MV Generator is controlled from the local control panel at the generator.


PLC control (starting/stopping) of the MV generator may only be performed in Manual mode

of operation. In Local mode of operation, the MV generator is controlled from the local

control panel at the generator.

Should the device be placed in Local Mode of Operation, the device status indicates a Local

status on the SCADA. Transfer of a device either from Local to Manual or vice versa is

bumpless i.e. the device shall not change state.

A start command may only be issued if the associated MV Genset has an ‘Available’

(E0x RDY) status and is not in local.

The associated Remote Stop (E0x IRT) command is available in manual of mode of operation

only.

6.27.4.1 Start-up of MV Generators

The initiation of the start-up of an MV generator is determined by the operator (i.e. not

automatic), although the sequence of starting a generator and bringing that generator on line

is automated following the operator initiation command.

When an MV generator is started, the start request output (E0x IRC) is pulsed high until the

respective running feedback (E0x EON) is received or a fault occurs. When an MV generator

is switched off, the stop request (E0x IRT) is pulsed high until the running feedback

(E0x EON) falls away.

6.27.4.2 Pump Selection – Insufficient Power Available

The number of mainline and booster pumps that can be run on emergency supply is limited

by the number and capacity of the MV Gensets installed.

The statuses of utility supply, MV Generators and associated breakers need to be taken into

account when determining the number of pumps that can be run and impacts on both pump

availability (via the Insufficient Power Available condition), and also inhibits pump start-up

(via the Insufficient Pwer Available interlock).

6.27.4.3 Shutdown of MV Genset

On restoration of utility power, the running MV Genset automatically shuts down and restores

power back to the utility in a bumpless manner via the electrical protection system.

The MV generators are also capable of being shut down locally (at site) by an Operator or

remotely by the MCC/SCC Controller via the SCADA system. In either case, no specialist

electrical qualification is required by the MCC/SCC Controller / Operator.

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6.27.4.4 Unplanned Utility Power Outage

In cases of unplanned utility power outage, the mainline and booster pumps stop. The

operator may then select the MV Genset/s he wishes to run, based on the pump sets

required to be placed in operation.

The operator is only able to issue a start command to a MV Genset which has a status

‘Available' (E0x RDY). The start command is only active when the MV Genset is in remote

mode of operation. Operation of the MV Gensets and control of the respective MV Breakers is

automatically controlled within the electrical and MV Genset/s protection systems, and

requires no further operator input, other than issuing of the start/stop command.

When utility power is returned, a check is made by the Electrical Protection controller that

utility power is stable. If the utility power has returned and is stable, the MV Gensets

automatically and bumplessly change over to the utility supply. No operator action is required

to initiate this changeover.

6.27.4.5 Planned Utility Power Outage

In cases of planned Utility power outage, the operator has the ability to start selected MV

Gensets prior to the power outage occurring. In this case, the operator may select the MV

Genset/s he wishes to run, based on the Mainline Pump sets and booster pump sets required

to be maintained in operation.

The operator is only able to issue a start command to a MV Genset which has a status

‘Available' (E0x RDY). The start command is only active when the MV Genset is in remote

mode of operation.

Starting of the MV Genset/s results in the MV Genset/s automatically and bumplessly taking

over supply of power to the selected Mainline Pumps and booster pumps. Operation of the

MV Gensets and control of the respective MV Breakers is automatically controlled within the

electrical and MV Gensets’ protection systems, and requires no further operator input, other

than issuing of the start/stop command.

A configurable timer located in the MV Breakers’ Protection Systems automatically and

bumplessly changes over to Utility Supply, if the Utility supply does not fail within a

preconfigured time (default 60 minutes). No operator action is required to initiate this

changeover. A stop signal is sent to the MV Gensets, and they will shut down after a 5

minute cool down period.

6.27.4.6 Abnormal Operation

During normal operation of the MV Gensets, the bus-coupler MCB (refer to Overall Single Line

Diagram) is always left open – electrically isolating one side of the MV Switchboard from the

other.

In cases where the operator wishes to run pump sets that are not available due to supply

restrictions, operation can be made possible by closing the bus-coupler.

Closure of the bus-coupler can only be executed locally at the station, and is required to be

managed by qualified electrical personnel. Once closed, the operator is able to operate any

available MV Genset, and run any available pump set.

In cases where more pump sets are started than the MV Genset/s can supply, electrical

protection automatically load sheds pumpsets based on predefined set-points within the MV

Switchgear protection system. There is no consequential PLC action.

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A Genset is available and a Start Request be issued via the PLC if the associated MV

Generator has an ‘Available' status and is in Remote mode of operation.

6.27.6 Group Status


None defined.


None defined.


None defined.


The following interlocks are defined for the MV Gensets Group:


None defined.


6.27.7.2.1 E0x: Mechanical Trip

Note: This trip is part of the typical.

The Mechanical Trip signal (E0x TVR) will trip the respective generator (E0x) off.

6.27.7.2.2 E0x: Bay Controller Stop

Note: This trip is part of the typical.

The bay controller stop request provides trip detection for when the generator was running

and was stopped by the bay or GenSet controllers. This is detected via a falling edge of the

run feedback (E0x EON).


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6.28 MV Generator Diesel Supply

This section is associated with the control and monitoring of the MV Generator Diesel Supply

Device Group.

The MV Generator Diesel Supply Device Group forms part of the Electrical Distribution Device

Group, section 6.26.

MV Generator Diesel Supplies are installed on all stations equipped with MV Gensets (i.e.

associated with the 24” MPP Pipeline).


The Diesel Storage Tank provides diesel for the MV backup generators.

The Diesel Supply to the generators is responsible for diesel transfer from the Diesel Storage

Tank (T0x) to the individual Generator Day Tanks (T6x). Two Diesel Transfer Pumps (X0x

and X0y) are available for this task and are run in a duty/standby operation.

Control and monitoring functionality shall be implemented for the following devices:

Valves

Diesel Storage Tank T0x Outlet Valve XV TxE

Diesel Storage Tank T0x Outlet Valve XV TxF MV Genset E0x Day Tank Inlet Valve XV T6xA

MV Genset E0y Day Tank Inlet Valve XV T6yA

Instrumentation

Diesel Transfer Pump X0x/0y Flow FS 19x MV Genset E0x Day Tank T63 Level LT 19x

MV Genset E0y Day Tank T64 Level LT 19y MV Genset E0x Day Tank Leak Detect LSH 300A

MV Genset E0y Day Tank Leak Detect LSH 300B

Pumps

Diesel Transfer Pump X0x X0x Diesel Transfer Pump X0y X0y





All devices related to the MV Generator Diesel Supply Device Group have the following modes

of operation:

Local

Manual

Automatic

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The two diesel transfer pumps, one for operation and the other for standby, are used to

transfer diesel between the Diesel Storage Tank (T0x) and the respective MV backup

generators (day tanks). Each diesel transfer pump is sized to feed both day tanks

simultaneously at a higher delivery rate than the consumption rate of the two MV generators

combined.

A flow switch on the common diesel transfer pumps' discharge line is used to protect the

diesel transfer pumps against low flow and consequent over-heating.

In automatic mode, and with the Duty Controller running, the diesel transfer pumps

automatically control the filling and maintain the level of the day tanks based on high level

and low level set-points derived from the respective day tank level transmitters. A

configurable control level low (default 25%) inside one of the day tanks will:

Set the number of pumps required in the duty controller to 1.

Open the associated day tank inlet valve.

Start a diesel transfer pump and open the tank outlet valve.

Note: The pump and diesel tank outlet valve are operated in the following sequence: Open

the valve, and when opened, start the pump.

On reaching a configurable control level high (default 80%) inside the respective day tank:

Set the number of pumps required in the duty controller to 0.

The diesel transfer pump is stopped and the associated diesel tank outlet valve is

closed.

The day tank inlet valve will close.

The duty/standby controller will rotate the duty of the pumps.

The diesel transfer pump is stopped and diesel tank outlet valve is closed only if a transfer is

not online to the other MV GenSet day tank at the same time.

Cycling of supply pumps is disabled for this duty controller.

6.28.4.1 Start / Stop Diesel Supply Duty Controller

The Diesel Supply Duty Controller starts a transfer, if Ready, on receipt of:

A Start Request on the duty controller from the SCADA OR

A low signal from any of the day tanks level (LT 19x or LT 19y), provided the Duty

Controller is running.

When the duty controller is started for the first time by the operator, both tanks are filled

until the high level is reached (default 80%). When the level is reached in both tanks, the

duty controller set-point is set to 0.

When one day tank level reaches the low limit, the duty controller fills only the tank with the

low level. The other day tank is not filled.

6.28.4.1.1 Day Tank Filling Sequence

The tank filling sequence is completed in the following order:

The relevant day tank inlet valve (XV T6xA OR XV T6yA) is opened.

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One supply leg (XV TxE AND X0x) OR (XV TxF AND X0y) is brought online by first

opening the diesel tank outlet valve and then starting the relevant pump.

When the day tank indicates a high level on both tanks, the diesel supply is stopped

(duty controller set-point set to 0).

The Duty Controller remains running until a device fault occurs, or until it is stopped

by the operator.

Placing the Group in Manual mode while the sequence is running will put the duty controller

into Stopped mode and leave devices in their current state.

The duty controller can be stopped by:

A Stop Request on the duty controller from the SCADA

When the Diesel Supply Group becomes Not Available

Note: The duty controller stops/closes all devices in the group on a stop command if in

Automatic (In Manual mode of operation, the devices remain in their current state). The duty

controller also transmits a one shot command to devices to ensure that they stop/close.

6.28.4.2 Duty Controller Response to Failure

The following failure modes exist in the duty controller when it is running.

6.28.4.2.1 Pump Trip

If one diesel transfer pump is running and trips or their respective valves are in

control error, the standby pump will start automatically, provided the group is in

Automatic mode.

If two pumps trip (or their respective valves are in control error), the duty controller

will go to stopped mode and retain its current state.

6.28.4.2.2 Diesel Tank Outlet Valve Failure

If the diesel tank outlet valve fails to open during Pump Start, the duty controller

switches to the other pump.

If the diesel tank outlet valve is in wirebreak, the duty controller switches, and relies

on the pump interlocks to stop the pump as needed.

6.28.4.2.3 Day Tank Inlet Valve

If one day tank inlet valve fails to open, the duty controller takes no action and

continues to run.

If both day tank inlet valves fail to open, the duty controller goes to a stopped state

due to Availability.

If any valve fails to close, the duty controller carries on running as the tank is

protected by level interlocks.

6.28.4.2.4 Level Transmitter Hardware Fault While Transferring to a Tank

A Level Transmitter hardware fault causes the duty controller to go to a stopped state when

the day tank valve opens. This is protected by setting the hardware fault substitute value to

88%.

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6.28.4.2.5 Level Transmitter Hardware Fault While Not Transferring

A Level Transmitter hardware fault removes Availability and stops the pumps running through

the interlock from the substitute value of 88%.

6.28.4.3 Diesel Supply Flags

6.28.4.3.1 Tank Inlet Valve Not Available OR Tank Level High

The "Tank Inlet Valve Not Available OR Tank High Level" availability indicates as follows:

Tank High Trip Level (LT 19x) OR

Tank Level (LT 19x) Fault OR

Inlet Valve (XV T6xA) Not Available

AND

Tank High Trip Level (LT 19y) OR

Tank Level (LT 19y) Fault OR

Inlet Valve (XV T6yA) Not Available

6.28.4.3.2 Pump and Valve Not Available

T0x Outlet Valve (XV TxE) OR

Transfer Pump (X0x) Not Available

AND

T0x Outlet Valve (XV TxF) OR

Transfer Pump (X0y) Not Available


6.28.5.1 Diesel Supply Availability

The following conditions render the Diesel Supply group “Not Available”:


Tank Inlet Valve Not Available or Tank High Level

Day Tk Vlv Not Avail or Lvl High Refer to Section 6.28.4.3.1

Pump and Valve Not Available Pump and Vlv Not Avail or Intlk Refer to 6.28.4.3.2

Table 6.28-1: Diesel Supply Availability

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6.28.6 Group Status

6.28.6.1 MV Generator Diesel Supply Group Status


None defined.


None defined.


None defined.


The following interlocks have been defined for the Diesel Supply Group:


None defined.


6.28.7.2.1 X0x / X0y: Diesel Storage Tank Level Low Trip

If a low level trip (LT 19x) is reached, the Diesel Transfer pumps (X0x and X0y) are

interlocked off. This interlock’s associated alarm will be suppressed if the route is not online

and pump not running.

6.28.7.2.2 X0x / X0y: Diesel Transfer Pump No Flow

If a low flow (FS 19x) is detected for a configurable time (2 seconds) while a Diesel Transfer

pump is running, both Diesel Transfer pumps (X0x and X0y) are interlocked off. This interlock

and associated alarm will be blocked if the pump is not running.

6.28.7.2.3 X0x / X0y: MV Generator E0x Day Tank Level High Trip

If a high level trip (LT 19x) is reached, both pumps (X0x and X0y) are interlocked off.

6.28.7.2.4 X0x / X0y: MV Generator E0y Day Tank Level High Trip

If a high level trip (LT 19y) is reached, both pumps (X0x and X0y) are interlocked off.

6.28.7.2.5 XV T6xA: MV Generator E0x Day Tank Level High Trip

If a high level trip (LT 19x) is reached, the Day Tank Inlet valve (XV T6xA) is interlocked

closed.

6.28.7.2.6 XV T6yA: MV Generator E0y Day Tank Level High Trip

If a high level trip (LT 19y) is reached, the Day Tank Inlet valve (XV T6yA) is interlocked

closed.

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6.28.7.2.7 XV T6xA: MV Generator E0x Day Tank Leak Detect Trip

If a high level (LSH 300A) is reached, the Day Tank Inlet valve (XV T6xA) is interlocked

closed.

6.28.7.2.8 XV T6yA: MV Generator E0y Day Tank Leak Detect Trip

If a high level (LSH 300B) is reached, the Day Tank Inlet valve (XV T6yA) is interlocked

closed.

6.28.7.2.9 X0x: No Valid Flow-path Trip

A Flow-path exists if the following conditions are met:

X0x Running AND

(XV TxE AND (XV T6xA OR XV T6yA))

Note that the "Open" state is required from each device.

6.28.7.2.10 X08: No Valid Flow-path Trip

A Valid Flow-path exists if the following conditions are met:

X0y Running AND

(XV TxF AND (XV T6xA OR XV T6yA))

Note that the "Open" state is required from each device.


None defined.


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6.29 MV Generator Diesel Offloading

This section is associated with the control and monitoring of the MV Generator Diesel

Offloading Device Group.

The MV Generator Diesel Offloading Device Group forms part of the Electrical Distribution

Device Group, section 6.26.

MV Generator Diesel Offloading is installed on all stations equipped with MV Gensets (i.e.

associated with the 24” MPP Pipeline).


The Diesel offloading facilities are used to transfer diesel from a road tanker to a dedicated

Diesel Storage Tank T0x. The Diesel Storage tank provides the diesel for the MV backup

generators. No custody transfer or volume measurement is provided.

The Tank Inlet valve (XV TxA) has been identified as a safety shutoff valve in terms of API

1004 and will be kept closed by means of an Automatic Close command until a start request

from the batch controller is received.

Control and monitoring functionality shall be implemented for the following devices:

Valves and Pumps

Diesel Storage Tank T0x Inlet Valve XV TxA

Diesel Offloading Pump X0x X0x

Instrumentation

Diesel Storage Tank T0x Level LT 19x Diesel Offloading Pump X0x Flow FS 71x

Diesel Offloading Earth Monitor FQY 71xB Diesel Offloading Pump X0x In Field Local X0x_FLO

Diesel Offloading Pump X0x Field Start Request X0x_FRC




All devices related to the Diesel Offloading shall only be controllable locally in the field at the

terminal.


All devices related to the MV Generator Diesel Offloading Device Group have the following

modes of operation:

Local

Manual

The transfer pump X0x and Safety Shut-off valve (XVTxA) are always in automatic mode.

They are controlled by sequences triggered from the LOP. No manual control from the

control system is permitted.

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6.29.4.1 Diesel Offloading Pump

A ground switch (FQY 71xB) is used to earth the road tanker prior to offloading. The ground

switch is interlocked with the Diesel Off-loading pump (X0x) and Diesel Storage Tank T0x

Inlet valve (XV TxA) via the PLC. This caters for the scenario where the road tanker pump is

used to transfer product.

A Diesel Offloading pump (X0x) is used to transfer diesel from the road tanker to the Diesel

Storage Tank T0x in cases where the road tanker does not have its own offloading pump. If

the Road Tanker Pump selector switch (X0x_FLO) = 0, the road tanker’s own pump is used.

A bypass around the Diesel Offloading pump (X0x) is used where the road tanker is equipped

with its own offloading pump.

Field Switches enable the operator to select between Diesel Offloading Pump (X0x) and the

road tanker pump, as well as to issue a start command to the PLC. Transfer is stopped via

the E-STOP located in the field.

6.29.4.2 Diesel Offloading Start Request

On receipt of a Field Start Request (X0x_FRC = 1) and with the Diesel Offloading Pump

selected (X0x_FLO = 1), the PLC will open the Diesel Tank Inlet valve XV TxA if available.

When the valve is Open the Transfer pump X0x is started. Should the pump E-Stop

(X0x_RES) be activated, the Transfer pump will be stopped and the Diesel Tank inlet valve is

closed.

On receipt of a Field Start Request (X0x_FRC = 1) and with the Road Tanker Pump selected

(X0x_FLO = 0), the PLC will open the Diesel Tank Inlet valve XV TxA. Should the E-Stop be

activated, the Diesel Tank inlet valve (XV TxA) is closed, and therefore the pump will stop.

The start request signal is displayed on the SCADA graphic

The PLC prevents the Diesel Offloading Pump (X0x) from starting and the Diesel Storage

Tank T0x inlet valve (XV TxA) from opening via the Offloading Grant Availability, if the

following conditions are met:

Tank level high LT 19x

Ground switch not connected FQY 71xB

A flow switch on the diesel offloading pump discharge is used to protect the pump against

low flow by stopping the pump.


6.29.5.1 Offloading Grant

The following conditions render the Device Group “Not Available” and automatic sequences

will be inhibited:


No FQY71xB Earth Offload Earth Monitor Not Conn

The No FQY71xB Earth availability status indicates that Diesel Offloading Earth monitor signal indicates an unhealthy state

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X0x Not Available X0x Selected and Not Avail

X0x Not Available AND Selected for operation. If NOT selected for operation, this is always True.

XVTxA Not Available XVTxA Not Avail Refer to [3]

LT19x Tank Level High Tank T0x Level High The Diesel Storage Tank T0x Level is above the configured high level alarm set-point

Table 6.29-1: MV Generator Diesel Offloading Availability

6.29.6 Group Status


None defined.


None defined.


None defined.


The following interlocks are defined for the Diesel Offloading Group:


None defined.


6.29.7.2.1 XV TxA: Diesel Storage Tank Level High Trip

If a Level High Trip (LT 19x) is detected, the Diesel Storage Tank T0x Inlet valve (XV TxA) is

interlocked closed.

6.29.7.2.2 X0x: Diesel Storage Tank Level High Trip

If a Level High Trip (LT 19x) is detected, the Diesel Offloading Pump (X0x) is interlocked off.

6.29.7.2.3 X0x: Diesel Offloading No Flow Trip

If a low flow (FS 71x) is detected for a configurable time (2 seconds), the Diesel Offloading

Pump (X0x) is interlocked off. This interlock and associated alarm is blocked if the Pump is

not running.

6.29.7.2.4 XV TxA: Diesel Offloading Earth Switch Not Connected

If the Earth switch (FQY 71xB) is not connected, the Diesel Storage Tank T0x Inlet valve

(XV TxA) is interlocked closed.

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6.29.7.2.5 X0x: Diesel Offloading Earth Switch Not Connected

If the Earth switch (FQY 71xB) is not connected, the Diesel Offloading Pump (X0x) is

interlocked off.


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6.30 LP Routing – General

This section is associated with the control and monitoring of the LP Routing – General Device

Group.

The LP Routing – General Device Group contains devices and instrumentation that are

common to all LP manifolds.

Product-specific LP Routing is addressed as separate device groups, in Section 6.31.

LP Routing flow control is addressed as a separate device group, in Section 6.33.


The device group enables the control and monitoring of devices and instrumentation common

to LP Manifolds installed at all intake and delivery stations.

Control and monitoring functionality is achieved via the following devices, which are all

common to the LP Product Routing Groups:

Valves

LP Header Valve XV HxA/B

Instrumentation

LP Manifold Over-Pressure Protect PS 801 (RPP/COP Installations)

LP Manifold Over-Pressure Protect PT 801 (24” MPP Installations)

LP PRV Flow Detection FS 80x

LP Routing Switching Panel DH 80

6.30.1.1 LP Strainers

Dual LP Strainers form a separate device group enabling local operation of strainers outside

of the LP Routing device group. Refer to Section 6.13 for details.

Single Strainers form part of the LP Routing device group.


LP Routing – General device group may be controlled from the PCS either locally at the


This device group has the same Mode of Control as all LP Routing – Product device groups

i.e. they are handed over as one.


All devices related to the Prover shall have the following three Modes of Operation:

Local

Manual

Automatic

The LP Routing Switching Panel DH 80 shall only be able to be accessed locally from within

the Density Hut.

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6.30.4.1 Common Header Valves

Where Header valves have been installed that are common to all products and must

therefore be controlled by all product groups from the respective product routing screens,

these valves shall remain in manual mode of control unless required by a sequence.

Sequences (notably the stop intake/delivery sequence) will interlock the relevant header

valve for the duration of the control request.


A LP Routing No Valid Flow-path status is determined by any of the valves on the route being

in a Not Open OR Wirebreak state. This status is used for mainline pump interlocking

purposes.

6.30.4.3 Product Identification: SCADA Line Colouring

Product Identification and the associated SCADA Line coloring for common LP manifolds

handling multi-products will be determined by valve status and interface detection. Line

coloring will not differentiate between different grades of the same product where the

product is determined by interface detection.

Product Identification and the associated SCADA Line coloring for dedicated product

manifolds will be fixed (dedicated) and will differentiate between different grades of product

where possible.

6.30.4.4 Density Hut DH80

LP switching facilities within the Density Hut is no longer supported by the PCS (switching

between LP primary and transition routes is supported using Routing Matrix functionality).


The statuses of the valves and strainers within this group will be used to implement route

availabilities as defined in the LP Routing Sections.

6.30.6 Group Status






LP Manifold Over-Pressure Protect

LP Manifold Over-Pressure Protect


Strainer Sxx Blocked Strainer Sxx Blocked Refer to Section 6.30.6.1.2

Table 6.30-1: LP Routing Group Alarm Status

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6.30.6.1.1 LP Manifold Over-Pressure Protect

If over-pressure in the LP Manifold is detected (PS 80x or PT 80x), an alarm shall be issued.

This alarm is reset once the pressure falls below the high-trip set-point.

6.30.6.1.2 Strainer Blocked (Single Strainers)

If the duty strainer indicates a high differential pressure, an alarm shall be issued. This alarm

is reset once both the strainer valves are closed.


None defined.


None defined.



None defined.


The following interlocks are part of this device group:

6.30.7.3 XV HxA: Line Over-Pressure Protection

On high-trip pressure within the LP Manifold as detected by PT 80x, interlock close XV HxA.

[Note: Where pressure switches are installed for detection of Line Over-Pressure, these are

used for alarming purposes only.]


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6.31 LP Routing - Product

This section is associated with the control of LP Routing – Product device groups and their

associated devices.

Dedicated product LP manifolds are installed on all intake and delivery stations and are used

to take product in from client tanks on intake stations, and to deliver product to client tanks

on delivery stations. In most instances, dual meter manifolds have been installed on

dedicated product manifolds to facilitate open switching of the same product between clients.

Single meter manifolds have been installed on intermix manifolds.

All product transfers to and from clients are custody metered to API Manual of Petroleum

Measurement Standards, and in accordance with RSA Trade and Legal Metrology Act

requirements. Custody Metering Systems are installed on all intake and delivery stations, and

utilize dedicated flow computers interfaced to turbine flow meters for volumetric

measurement of product transfers. Volumes are compensated for pressure, temperature and

density.


LP Product (Metering) manifolds installed on TPL sites comprise of de-aerators, strainers,

turbine meters, flow conditioners where required, proving systems, consignee/nor valves and

metering instrumentation (temperature, pressure and density measurements). On intake

sites, product passes from the consignor valve to the meter and then to the prover; whilst on

delivery sites, product passes through the prover followed by the meter and lastly the

consignee valve.

Backpressure is maintained on the turbine flow meters by means of pressure-sustaining

valves where necessary. Meters are calibrated regularly using permanent on-site large

volume pipe prover facilities, comprising of bi-directional provers with flow direction

controlled by means of four-way valves.

LP Routes are able to be controlled both manually and automatically from the PCS. In

automatic, routing sequences are controlled from a LP Routing Matrix, and comprise of Open

Route, Start Intake/Delivery, and Stop Intake/Delivery sequences.

Batch limit alarms, standard volumes, flow rates, temperature and pressure values will

however be interfaced from the CMS to the PCS for monitoring purposes.

The PCS shall only support open and closed switching operations (CMS does not support fly-

switching).

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XVH3A

CLIENT 2

CLIENT 1XVM1E ZVM1AFT811

XVM2E ZVM2AFT812 XVCC2

XVCM2

XVH1A XVCC1

XVCM1

XVH5A

CVH0J XVH0A XVY1KHP

MANIFOLD

PROVER

Figure 6.31-1: Typical LP Product Routing Manifold Layout (Intake Station)

Figure 6.31-2: Typical LP Product Routing Manifold Layout (Delivery Station)

Control and monitoring functionality is typically achieved via the following devices:

6.31.1.1 Field Signals hard-wired to the PLC

Valves

Common Header Valve XV H0A

Manifold x Header Valve XV HxA

Strainer Sxx Inlet Valve XV SxA Strainer Sxx Outlet Valve ZV SxE

Manifold x Meter Inlet Valve XV MxA Manifold x Meter Outlet Valve ZV MxE

Manifold x Distribution Valve XV Dxx Consignor/Consignee Valve XV Cxx

Tank Txx Inlet Valve XVTxA

Instrumentation

Manifold x Sample Flow FS 8xx

Consignor/Consignee Feeder Line Pressure PT 8xx Strainer Sxx Diff Pressure PDT 8xx

XVH3B

CLIENT 2

CLIENT 1

XVCM1

XVCC1

XVT2A

XVM1AZVM1E FT811

XVM2AZVM2E FT812XVDM2

XVDC2

XVT2C

ZVS1E ZVS1A XVH1B

A01

XVDM1

XVDC1

XVT2BT2T2

XVH5B

CVH0J XVH0A

XVH1C CVA1J

XVH5A

XVH3A

XVH1AHP

MANIFOLD

XVT2EZVA1A

S01

X01XVG1E CVG1J

T1T1XVT1EZVX1A

T2T2

BLEND

ACC TANK

TRANSFER

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* Devices form part of another group / PLC

6.31.1.2 Field Signals hardwired to CMS Flow Computer (FC)

[These signals are not interfaced to the PCS, but are listed here for information]

Instrumentation

Manifold x Metering Flow FT 8xx

Manifold x Metering Pressure PT 8xx

Manifold x Metering Temperature TE 8xx Manifold x Metering Density DT 8xx (Not Used)

6.31.1.3 Signals hardwired between the Flow Computer (FC) and PLC

FC to PLC

Manifold x Metering Flow - Uncompensated FT 8xx_S1 Manifold x Metering Flow - Compensated FT 8xx_S2

FC-PLC Communication failure UA 8xx

PRD1 Batch Limit 1 MxxBL1 PRD1 Batch Limit 2 MxxBL2

PLC to FC

PRD1 Raw Pulse Enable Mxx MxxRPE

Logical Consignor/Consignee Valve status XV CxxA

6.31.1.4 Modbus Signals between the Flow Computer (FC) and PLC

FC to PLC

Manifold x Metering Pressure PT 8xx

Manifold x Metering Temperature TT 8xx


LP Routing – Product device groups may be controlled from the PCS either locally at the


These device groups have the same Mode of Control as LP Routing – General device group

i.e. they are handed over as one.


All devices related to the LP Routing – Product device groups shall have the following three

Modes of Operation:

Local

Manual

Automatic


6.31.4.1 Metering / Flow Computer Interface (Hardwired)

[The following hardwired interface relates to Emerson Spectratech S600 Flow Computers]

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6.31.4.1.1 Compensated Flow

Flow compensation of Metering Flow is done in the CMS Flow computer, and is hardwired to

the PLC as FT 8xx_S2. The compensated flow is used for flow control.

6.31.4.1.2 Uncompensated Flow

An uncompensated flow signal is also available in the CMS Flow computer, and is hardwired

to the PLC as FT 8xx_S1.

6.31.4.1.3 Supervisory communication failure (FC-PLC)

This digital input is send to the control system for alarming purposes and indicates when

communications between the FC and PLC is lost. Loss of communications will have an impact

on the standard volume, metering pressure and temperature displays on the PCS.

6.31.4.1.4 Batch limit 1 and 2

These digital inputs are sent to the control system for alarming purposes and are used to

alarm the operator when the calculated time remaining for completion of a product transfer is

less than the respective batch limits configured i.e. nearing completion.

6.31.4.1.5 Raw pulse enable

The PLC sends a signal (digital output) to the specific metering flow computer depending on

the following conditions:

LP route online for that meter

Prover online for that product

Prover content correct for that Product to be proved.

Prover available (refer to Section 7.2.13.1)

The purpose of this signal is to tell the relevant stream computer to enable its raw pulse bus

output, to enable proving for that stream. Only one raw pulse enable per prover, can be high

at any one time.

6.31.4.1.6 Logical Consignor/Consignee Status

Logical valves (PLC digital outputs) are hardwired to the respective Flow Computers and act

as consignee valves by giving feedback when a route is changed from closed to not closed

status. In order to ensure that metering is initiated when a consignee valve is opened in the

field, PLC Interlocking ensures that an associated logical valve is opened when the consignee

valve moves off its closed limit.

The PLC sends a signal (digital output) to the specific metering flow computer indicating from

which consignor a delivery is online. There are a maximum of twenty consignor valves per

flow computer. Logic “1” indicates a logical consignee valve is closed.

Midnight-switching is implemented as an End-Of-Day Report as detailed in the Custody

Metering System URS [13].

6.31.4.2 Single Strainer Flags

Where dual strainers have been installed, refer to Section 6.13.

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These flags are raised by the process control software as configured on the Strainer block.



detail.

Single strainers are usually installed per meter manifold.

6.31.4.2.1 Strainer Sxx Blocked

Set strainer Sxx blocked if:

PDT 8xx high for 5 seconds

Reset strainer Sxx blocked if:

PDT 8xx Not high AND

XV SxA is Closed AND

ZV SxE is Closed

The Strainer Blocked flag is indicated on the SCADA per strainer.

Alarm and trip set points on PDT 8xx shall be configured so as to give the operator enough

time to take corrective action on receipt of the alarm.


A LP Routing No Valid Flow-path status is determined by any of the valves on the route being

in a Not Open OR Wirebreak state. This status is used for mainline pump interlocking

purposes.

6.31.4.4 CMS – PCS Interface

Primary and Transition Route concepts (including route numbers) are no longer supported in

the PCS.

Automatic switching based on Batch limits (BL2) will no longer be provided; alarms generated

on batch limits will still be issued.

Control of open route, start intake/delivery, stop intake/delivery will be provided in a Routing

matrix form in the PCS environment. Volumes will be entered directly into the CMS and will

be downloaded to the flow computer for triggering of configurable batch limit alarms.

Flow set-points will be entered directly into the Control valve faceplate in the PCS

environment.

The following metering information will be displayed on the PCS System: standard volumes,

flow rate, batch limit alarms, temperature and pressure.

6.31.4.5 LP Routing Matrix

Control of Open Route, Start Intake/Delivery and Stop Intake/Delivery sequences will be

controlled in a LP Routing Matrix. For Routing Matrix details refer to Section 4.9.

Routing availability will be indicated on the LP Routing Matrix by means of colour. Start

Intake/Delivery Sequences are only available to be run when the associated route has been

successfully opened. Stop Intake/Delivery Sequences are always available to be run,

regardless of the associated sequence availability.

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Switches may either be open or closed switches, depending on the order in which the

operator chooses to run the various sequences. The requirement for closed switching may be

encoded using sequence availability based on route status.

The practice of fly-switching within the same flow computer will no longer be permitted at

any of TPL custody metering stations or supported by the Custody Transfer Metering Flow

Computers. To facilitate this requirement, Start Intake/Delivery sequences to the same

destination through the same meter may never be run simultaneously (this is encoded using

sequence availability based on route status).

6.31.4.6 LP Open Route Sequence

An Open Route Sequence is initiated from:

an Open Route Request from the SCADA

If Ready, the route is opened by simultaneously opening/closing all appropriate valves.

The purpose of the Open route sequence is to prepare the LP Manifold for an intake/delivery.

The Open Route Sequence will be available if the associated valves are available.

See LP Routing Tables for details:

Table 6.31-1: LP Routing Tables (Intake Manifold)

Table 6.31-2: LP Routing Tables (Delivery Manifold)

Open Route indication will be given once all valves associated with the route that are

required to be open are open, all valves associated with the route that are required to be

closed are closed, and flow paths exist through the relevant strainer/s and prover.

See LP Open Route flow diagrams for details:

7.2.12.3: Typical LP Open Route Sequence (Intake Manifold)

7.2.12.8: Typical LP Open Route Sequence (Delivery Manifold)

Any faults during the Open Route sequence will result in the sequence continuing, complete

with all associated alarming and event logging. Placing the Group in Manual mode while the

sequence is running results in the sequence aborting.

6.31.4.6.1 Intake Stations

This sequence is based on dual meter manifolds to a single HP destination and is station

dependent.

Note: Step (i) is not executed if a delivery of the same product is already in progress

(selected product header valve is open).

i) First: Close product meter outlet valve on the second meter manifold

(same product)

Close all product consignor valves and associated logical consignor

statuses (same product) ii) Then:

Close selected meter outlet valve

Close selected product consignor valve and associated logical

consignor status (to ensure a new delivery is started)

iii) Finally:

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Open selected product consignor valve and associated logical

consignor status

Open destination (common) header valve

6.31.4.6.2 Delivery Stations

Route from HP to Consignee:

This sequence is based on dual meter manifolds and is station dependent.

Note: Step (i) is not executed if a delivery is already in progress to any destination (any

product header valve is open).

i) First:

Close common header valve

Then:

Close selected product header valve/s and interlock closed other

product header valves

Interlock closed selected product blend valve

Enable Strainer software (where dual strainers have been installed)

Note: Step (ii) is not executed if a delivery of the same product is already in progress

(selected product header valve is open).

ii) Then: Close product meter inlet valve, distribution valves on the second

meter manifold (same product)

Close all other product consignee valves and associated logical

consignee statuses (same product)

iii) Then: Close selected product meter inlet valve and other distribution valves

on the selected meter manifold

Close selected product consignee valve and associated logical

consignee status (to ensure a new delivery is started) iv) Finally:

Open selected product distribution valve

Open selected product consignee valve and associated logical

consignee status Open common header valve

Close selected tank outlet valves, open other valves on the route to

the tank (for deliveries into a Tank)

Route from Accumulator Tank to Consignee:

This sequence is based on dual meter manifolds and is station dependent. This route is

only available when all routes from HP are closed i.e. a closed switch.

i) First: Close selected product header valve/s and interlock closed other

product header valves


Enable Strainer software (where dual strainers have been installed)

ii) Then: Close product meter inlet valve, distribution valves on the second

meter manifold (same product)

Close selected product meter inlet valve, distribution valves on the

selected meter manifold

Close all product consignee valves and associated logical consignor

statuses (same product) iii) Finally:

Open selected product distribution valve

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Open selected product consignor valve and associated logical

consignor status

Close selected tank inlet valve, open other valves on the route from

the tank (for deliveries from a Tank)

6.31.4.7 Start Intake/Delivery Sequence

A Start Intake/Delivery Sequence is initiated from:

A Start Intake/Delivery Request from the SCADA

If Ready, the route is opened by simultaneously opening/closing all appropriate valves.

The Start Intake/Delivery Sequence will in certain instances close other intake/delivery routes

that are open once the selected intake/delivery is Online, as part of the sequence (e.g. The

primary route on cross-product switches and switches from intermix should close as soon as

an associated route is online, station dependent).

The Start Intake/Delivery Sequence will be available only if the associated route is open, and

associated valves are available.

See LP Routing Tables for details:

Table 6.31-3: LP Routing Tables (Intake Manifold)

Table 6.31-4: LP Routing Tables (Delivery Manifold)

Start Intake Route indication will be given once all valves associated with the route that are

required to be open are open, all valves associated with the route that are required to be

closed are closed, and flow paths exist through the relevant strainer/s and prover.

See LP Start Intake/Delivery flow diagrams for details:

7.2.12.4: Typical LP Start Intake Sequence (Intake Manifold)

7.2.12.9: Typical LP Start Delivery Sequence (Delivery Manifold)

All faults occurring whilst opening or closing a route during a Start Intake/Delivery Sequence

shall result in the following action being taken, complete with all associated alarming and

event logging procedures:

Close Switch Open Switch

Close

Primary

Open

Transition

Open

Transition

Close

Primary

Single Manifold Continue Continue Abort Continue

Dual Manifold Continue Continue Abort Continue



dependent.

i) First:

Open selected product header valve

ii) Then: Open selected product meter outlet valve

The intake is now online.

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All faults during this stage of the Start Intake sequence will result in the

sequence aborting complete with all associated alarming and event logging

procedures.

iii) Finally, close all other open routes, including cross product routes (station dependent):

Close product meter outlet valve on the second meter manifold

(same product) Close all other selected product consignor valves and associated

logical consignor statuses (same product)

Interlock closed other product manifold header valves (different

products)

Any faults during this stage of the Start Intake Route sequence will result in the

sequence continuing, complete with all associated alarming and event logging.

Placing the Group in Manual mode while the sequence is running results in the

sequence aborting.




i) First: Open selected product metering inlet valve

Close selected product header sacrificial ball valve (to protect EPV

Header, where installed)

ii) Then: Open selected product header EPV valve

iii) Then:

Open common header valve

Open selected product header sacrificial ball valve (where installed)

The delivery is now online.

All faults during this stage of the Start Delivery sequence will result in the


procedures.

iv) Finally, close all other open routes, including cross product routes (station

dependent):

Close product meter inlet valve, distribution valves on the second

meter manifold (same product) Close other distribution valves on the selected meter manifold.

Close all other selected product consignor valves and associated

logical consignor statuses (same product)

Interlock closed other product manifold header valves (different

products)

Any faults during this stage of the Start Delivery sequence will result in the

sequence continuing, complete with all associated alarming and event logging.

Placing the Group in Manual mode while the sequence is running results in the

sequence aborting.

Route from Accumulator Tank to Consignee:

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This sequence is based on dual meter manifolds and is station dependent. This route is

only available when all routes from HP are closed i.e. a closed switch.

i) First: Open selected product metering inlet valve

ii) Then:

Open selected product header valve

iii) Finally: Start Accumulator Pump

The delivery is now online.

All faults during this stage of the Start Delivery sequence will result in the


procedures.

6.31.4.8 Stop Intake/Delivery Command

A Stop Intake/Delivery Sequence is initiated from:

A Stop Intake/Delivery Request from the SCADA

If Ready, the route is closed by simultaneously closing all associated valves.

The Stop Intake/Delivery Sequence will close all intake/delivery routes associated with a

particular product. Other different product routes that are open will need to be closed using

the respective product Stop Intake/Delivery sequences.

Note that availability is not a prerequisite for running a Stop Intake/Delivery sequence.

See LP Stop Intake/Delivery flow diagrams for details:

7.2.12.5: Typical LP Stop Intake Sequence (Intake Manifold)

7.2.12.10: Typical LP Stop Delivery Sequence (Delivery Manifold)

Any faults during the Stop Intake/Delivery sequence will result in the sequence continuing,

complete with all associated alarming and event logging. Placing the Group in Manual mode

while the sequence is running results in the sequence aborting.



dependent.

Note: Step (i) is not executed if a delivery of a different product is already in progress

(different product header valve is open).

i) First:

Close destination (common) header valve ii) Then:

Close selected product header valve

iii) Finally close all valves on both same product manifolds (dual meter manifolds):

Close selected product meter outlet valve

Close product meter outlet valve on the second meter manifold

(same product) Close all product consignor valves and associated logical consignor

statuses (same product)

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Note: Step (i) is not executed if another delivery is already in progress to any other

destination (any other product header valve is open).

i) First:

Close common flow control valve (set to auto and close)

Then:

Close common header valve

ii) Then:

Close selected product header valve/s

iii) Finally close all valves on both same product manifolds (dual meter manifolds):

Close both same product meter inlet valves Close all product distribution valves common to the meter manifolds

(same product)

Close all consignee valves associated with the same product

Close selected tank inlet valve and other valves on the route to the

tank (for routes into Tanks)


Route from Accumulator Tank:


i) First: Stop Accumulator Pump

Then:

Close accumulator flow control valve (set to auto and close)

Close product header valve from tank

ii) Finally close all valves on both same product manifolds (dual meter manifolds): Close both same product meter inlet valves

Close all product distribution valves common to the meter manifolds

(same product)

Close all consignee valves associated with the same product

Close selected tank outlet valve and other valves on the route from

the tank (for routes from Tanks)

6.31.5 Route Availability

Availability for the LP Routing (Product) group is done on a per route basis and is indicated

on the LP Routing matrix for the respective routing sequences. When available the box will

display a green background and when not available it displays a yellow background.

Automatic control via the PLC will not be inhibited if the route is not available for Open Route

and Stop Intake/Delivery sequences only.

Upon clicking on the individual route, an additional faceplate will be invoked indicating the

availability of the devices relevant to this route.

6.31.6 Group Status


None defined.

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Alarm Configuration Database (3) for details, including text to be used for the event

message.


LP No Valid Flow-path Mxx LP No Valid Flow-path Mxx Refer to Section 6.31.4.3

Table 6.31-5: LP Routing - Group Error Status


None defined.



6.31.7.1.1 Tank Overfill Protection Interlocks

An independent SIL-rated tank Overfill Protection System has been installed on each tank.

Refer to Section 6.35.8.1.1 for details.


6.31.7.2.1 Logical Valve – Consignee/nor Valve Interlock

If the consignee/nor valve is open and no route has been selected, then the first (default)

logical valve is forced open.

If the consignee/nor valve is open and a route has been selected, then the associated logical

valve is forced open. In dual meter manifolds, this forces the operator to open the logical

consignee/nor on the second manifold before closing the original consignee/nor on the first

manifold when switching.

If the consignee/nor valve is closed, then the associated logical valve is closed. The logical

valve may be opened or closed by the operator thereafter.

In automatic, the logical consignee/nor is opened from the sequences in automatic before

the product delivery valve is opened.

6.31.7.2.2 XV TxxA/B/C/D: Tank Txx Overfill Protection

Associated tank inlet valves (and header valves for blow-off tanks) will be interlocked closed

when a SIF trip is active (Refer to Section 6.35.8.2.1).

6.31.7.2.3 XV HxxA/B/C/D: Header valve Interlock

Associated Header valve/s will be interlocked closed when another header to the same

destination meter is not closed, OR if the station is only able to receive multi-product from

one source.

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None defined.


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6.33 Flow Control – LP Application


part of the LP Routing – General or Product device groups (depending on the installation).


The Flow Control Valve installed on the LP manifold (either on a common section or on

dedicated product manifolds) is used for closed loop control, to control Station Suction

Pressure ICP (Set point configurable by the operator via SCADA) or Manifold Flow (Set point

configurable by the operator via SCADA). The Operator can select to control either flow

(default) or suction pressure.


Valves

LP Flow Control Valve CV HxJ

Instrumentation

LP Manifold Compensated Flow FT 8xx_S2



LP Flow Control may be controlled from the PCS either locally at the Station or remotely from

the MCC.

This device forms part of the LP Routing – General or Product device groups, and thus does

not have its own Mode of Control.



Local

Manual

Automatic


This control valve has a mode of operation that is independent of the LP routing group to

which it is associated.



Not applicable to this device group.


The control valve position is determined by a 4-20mA analogue output signal.

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xxx

PT

xxxCV

xxxCV

FT

xxx

xxxPT

PT

xxxFIC

xxxPT

xxxPIC

xxxOVR

xxxOVR xxx

PICxxx

OVR

ICP

Route

dependant

SDP

Not UsedFLOW

xxxMAN

SP SPOR

SP

SP

CONTROL VALVE

SPOR

SPOR

0%

100%

SPOR

ICP

Va

lve

Ove

rrid

e

Po

stio

n

0%

100%

Flow/SDP

Va

lve

Ove

rrid

e

Po

stio

n

SPOR

OVERRIDE FUNCTIONS


FT xxx_S

>

Figure 6.33-1: Flow Control – LP Application

Control valves are part of the respective LP Device Group and do not have their own graphic.

Hence the PV’s and control loop are not visible to the operator.

The Control Valve typical has two PID loops configured, each with a hard coded override. In

this application, the configured PID loops are as follows:

Flow PID

ICP PID

The operator can choose to control on any of two pre-configured PV’s (pre-configured in the

PLC depending on the application):

Flow (Default)

ICP


When a control parameter is chosen, the other parameters are in override control. The set-

points for override control revert back to the override set-points (not operator settable). Note

that the operator set-points are not overwritten and are reverted to should the operator

change back to the original control parameter. The PID loops are not active in manual.

Override Curve

A hard ramp override curve exists for each PID loop. This is enabled when the PID is too

slow to catch transients. This is especially true if the PID loop is tuned for slow response to

reduce wear on the valve. In this application, flow and ICP override functions are enabled.


Not required.

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6.33.6 Group Status


None defined.


None defined.


None defined.


None defined.



None defined


6.33.8.2.1 CV HxJ: Tank High Trip


will ramp closed) when a LP Route is Not Closed and the associated Tank level (LQT/LT 75x)

has a High Trip value.

6.33.8.2.2 CV HxJ: All LP Routes Closed


will ramp closed) when all associated LP Routes are Closed (and not in Wirebreak).

6.33.8.2.3 CV HxJ: LP Routing Sequence


will ramp closed) by the Stop Delivery Sequence until the Route is Offline.


On instrument failure, the instrument goes into last good value, complete with alarming.

Operator action will be required to prevent control loop wind-up.


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6.34 Tank Farms

This section is associated with the control and monitoring of Tank Farms where installed on

stations and terminals.

This section is not a device group on its own, but these devices and associated control form

part of the associated LP Routing - Product device groups.


This section details control and operating facilities related to tank farms that are owned and

operated by Transnet Pipelines. In these cases, pipeline operations and distribution

operations are divided on the following basis:

1. Pipeline Operations:

Pipeline Deliveries into and out of tanks (accumulator and intermix tanks)

Quality Assurance of product within tanks

Inter-tank Transfer and Circulation (where required)

Tank Farm Management

2. Distribution Operations:

Road and Rail Tanker Distribution

In cases where Transnet Pipelines delivers or intakes product from tankage owned and

operated by other parties (companies), these transactions will be performed ‘across the

fence’. In other words, line-up into the relevant tanks will remain the responsibility of the

client, as will all other tank farm management functions.

6.34.1.1 Automation Concepts

Custody Metering facilities are provided at all intake and delivery stations to meter product

volumes delivered into both accumulator and intermix tanks in accordance with API Custody

Metering standards. Prover facilities are provided to accurately establish meter factors to be

used in the metering of product to API Standards (products only, not intermix).

Tank Gauging Systems are installed on all Accumulator Tanks on Terminals (IVW, JMP and

TLR).

Where the requirement is identified, tanks are equipped with Overfill Protection Systems in

accordance with API 2350 and Buncefield Final Report recommendations [16].

Process interlocks will be installed on tank inlet and outlet valve/s to prevent delivering into

and out of a tank simultaneously. Tank handover will be proceduralised.

Tank dipping (capturing and reporting) will be supported by SAP/MES. Product quality

capturing and reporting will not be supported on the PCS, but will be supported by SAP/MES.

Where inter-tank transfer facilities are installed on sites, inter-tank tank transfer will be

facilitated by means of a routing matrix.


Instruments

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Tank Txx Level LT 75x (Tank Guaging not installed) OR

LQT 75x (Tank Guaging installed)

Where Tank Gauging Systems are installed, an uncompensated analogue level will

be wired from the TGS Head to the PLC for the purpose of indicating level within

the tank. In addition, compensated volumes and other information will be

interfaced from the TGS into the PCS for monitoring purposes (Refer to Section

6.34.4.5).


Tanks form part of the LP Routing - Product device groups and thus do not have their own

Mode of Control.


All devices related to Tanks have the following modes of operation as derived from the LP

Product Routing device groups:

Local

Manual

Automatic


6.34.4.1 Tank Level Control and Over-Fill Protection

Tank Level Control and Over-fill Protection conforms to the following protection philosophy

(in accordance with API 2350 and Buncefield Final Report recommendations):

1. A high level alarm is issued when the level within a tank that has an open route into it

exceeds a high-alarm level. This set-point is set at the normal operating level, and is set

at a level that is two minutes of full flow below the High-trip level set-point. Full flow is

determined as the highest possible flowrate from any individual source.

[At the IVW and JMP Terminals, the time between AH and AT is set more conservatively

at five minutes.]

2. A LP Control Valve interlock will provide the first level of protection against over-fill. This

interlock will interlock the control valve closed on the route that is open into the tank,

based on a tank high-trip level set-point. This set-point is set at a level that is two

minutes of full flow below the Tank Over-fill Protection (SIL) level set-point. Full flow is

determined as the highest possible flowrate from any individual source.

[At the IVW and JMP Terminals, the time between AT and SIL is set more conservatively

at five minutes.]

3. For tanks with Tank Overfill Protection Systems (SIF) installed:

A Tank Over-fill Protection SIF (independent of the PCS) will provide the second level of

protection, and will interlock all tank inlet valves (and associated header valves for blow-

off tanks) closed simultaneously, based on a SIL protection set-point to be set high to act

as last resort. This set-point is set at a level that is two minutes of full flow below the

tank overflow level. Full flow is determined as the highest possible flowrate from any

individual source.

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[At the IVW and JMP Terminals, the time between SIL and tank overflow is set more

conservatively at five minutes.]

4. For tanks without Tank Overfill Protection Systems (SIF) installed:

A high level switch will provide the second level of protection, and will interlock all tank

inlet valves (and associated header valves for blow-off tanks) closed simultaneously,

based on high level detection in the tank. The level switch is set at a level that is two

minutes of full flow below the tank overflow level. Full flow is determined as the highest

possible flowrate from any individual source.

6.34.4.2 Tank States

Tank States will not be implemented on tanks. Process interlocks will however remain on the

tank inlet and outlet valves, depending on whether tanks are receiving or distributing product

(Refer to Section 6.34.8.2.1).

Product Quality Control and Tank Handover between operations will be proceduralised.

6.34.4.3 Tank Product Management

Tank Dip capturing and reporting will be supported within SAP/MES.

Product Quality capturing and reporting will be supported within SAP/MES.

6.34.4.4 Inter-Tank Transfer

On sites where tank farms comprising of multiple tanks exist, inter-tank transfer facilities

comprising of transfer pumps, flow meters and actuated routing valves may exist. These

facilities enable the transfer of products between various tanks, for the purposes of product

quality control (between tanks) and circulation (to the same tank).

Inter-tank transfer may be controlled in local, manual or automatic Modes of Operation. A

Inter-tank Transfer Routing matrix and associated transfer sequences will be implemented on

the PCS to facilitate automated control of inter-tank transfer at the varuious stations, where

required.

6.34.4.5 Tank-Gauging System (TGS) Interface

The data interface between TankMaster (SAAB) System (OPC Server) and the Intake OS

Server (OPC Client) will be implemented via OPC communication using the Terminal Bus.

Tank strapping is to be performed in both the MES Metering and Tank Master Software.

The following data is transmitted to PCS via OPC tags.

6.34.4.5.1 OPC Tag Descriptors

Product Information

Status

Symbol PCS7 Tag Unit

Level Current Value TK-xxx.LL.CV ILevel m

LL Status Healthy = False

TK-xxx.LL.ME ILevelQCBad

Average Temperature TK-xxx.AT.CV IAvgTmp °C

AT Status Healthy =

False

TK-xxx-

AT.ME

IAvgTmpQCBad

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Product Information Status


Reference Density - is the density

of the product at the Standard Reference Temperature 20°C. It

can either be manually entered, or automatically calculated from the

Average Temperature and the

Observed Density.

TK-

xxx.DREF.CV

IRefDens kg/L

DREF Status Healthy = False

TK-xxx-DREF.ME

IRefDensQCBad

Volume Correction Factor - is used

to convert the volume at the current temperature to the

corresponding volume at the Standard Reference Temperature

20 °C. The VCF is automatically

calculated according to API Standard 2540 if the Reference

Density and the Average Temperature of the product are

known.

TK-

xxx.VCF.CV

IVCF

VCF Status Healthy = False

TK-xxx.VCF.ME

IVCFQCBad

Free Water Level - can be manually

entered or measured by a Water Interface Sensor.

TK-

xxx.FWL.CV

IFWL m

FWL Status Healthy =

False

TK-

xxx.FWL.ME

IFWLQCBad

Free Water Volume - calculated on

the basis of the Free Water Level and the Tank Strapping Table

(TST).

TK-

xxx.FWV.CV

IFWV L

FWV Status Healthy = False

TK-xxx.FWV.ME

IFWVQCBad

Total Observed Volume - is

calculated from strapping tables. It is the total volume at the Observed

Temperature of the product.

TK-

xxx.TOV.CV

ITOV L

TOV Status Healthy = False

TK-xxx.TOV.ME

ITOVQCBad

Gross Standard Volume. TK-

xxx.GSV.CV

IGSV L

GSV Status Healthy = False

TK-xxx.GSV.ME

IGSVQCBad

Gross Observed Volume TK-

xxx.GOV.CV

IGOV L

GOV Status Healthy = False

TK-xxx.GOV.ME

IGOVQCBad

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Product Information Status


Flow rate Flow rate can

be positive or negative

TK-xxx.FR.CV IFlowrate L/min

FR Status Healthy =

False

TK-xxx.FR.ME IFlowrateQCBad

Available Room – Volume left to completion

TK-xxx.AVRM.CV

IAvailRoom L

AVRM Status Healthy = False

TK-xxx.AVRM.ME

IAvailRoomQCBad

Pumpable volume TK-xxx.PV.CV IPmpVol L

PV Status Healthy =

False

TK-xxx.PV.ME IPmpVolQCBad

Table 6.34-1: Tank Farm TGS OPC Tag Descriptors

6.34.4.5.2 OPC Global Alarm Acknowledge

Alarm Acknowledge

External Alarm Acknowledge

On acknowledgement of any of the alarms on a tank, the EXT_ALARM_ACK.CV tag is set which then sets all unacknowledged alarms in the Tank Gauging system to the acknowledged state.

EXT_ALARM_ACK.CV

Table 6.34-2: Tank Farm TGS OPC Global Alarm Acknowledge

6.34.4.5.3 OPC Interface Watchdog

Value Item ID Description Quality Status

1 xx.ALIVE_PULSE.CV

Tank Master System Running

30 sec pulse Active_Pulse

2 xx.ALIVE.CV Server Running Counter No count on Failure

Table 6.34-3: Tank Farm TGS OPC Watchdog

6.34.4.5.4 OPC Qualities

The Used OPC qualities are as following:

OPC quality

Meaning, usage Short Names

OPC_QUALITY_GOOD_NONE_SPECIFIC

Quality of tags are good. Good

OPC_QUALITY_GOOD_NO

Any other OPC Quality is considered as Bad

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NE_SPECIFIC

bad.

Table 6.34-4: Tank Farm TGS OPC Qualities

In addition to the data detailed above, the following additional information will be displayed

to the operator on the PCS System:

Tank State (as derived from Tank State Machine)

Tank level = LQT xxx, hardwired from TGS head

Gross Observed Volume = current volume in the tank, including dissolved sediment

and water

Gross Standard Volume = Gross Observed Volume corrected for pressure and

temperature

Flow rate into/out of tank = calculated from LQT xxx rate of change (positive =

filling, negative = withdrawing)

Available Room = volume available to the normal fill level

Available Product = Gross Standard Volume minus the working bottoms (normal

empty/low level)

Time to Completion = Time remaining to complete an intake/dispatch from the tank

(calculated from metering)

Note: Tank Strapping tables reside within the TGS and MES-Metering systems.


Not required

6.34.6 Group Status




Alarm Configuration Database (3) for details, including the text to be used for the alarm

messages.


Tank Txx Level Deviation

Tank Txx Level Deviation

Comparison between LT/LQT 75x and LY 75xA_AI (SIL).

Table 6.34-5: Tank Farm Group Alarm Status Indication

Note: Deviations greater than a pre-defined percentage (default 1%) will be alarmed as

‘Tank Level A0x Deviation’. This deviation is calculated on the basis of a 5 min first order

filter. When the two signals fall within a configurable percentage (default 0.5%) of each

other, this status is automatically reset.

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None defined.


None defined.


Alarm Priority Message Class Info Text

Tank Txx Level Change Detected

10 Tolerance

Tank A11 Level Change Detected

10 Tolerance

Tank A12 Level Change Detected

10 Tolerance

Table 6.34-6: Tank Farm Additional Device Alarm

When the TGS indicates the tank is active i.e. flow into or out of the tank (flowrate >

threshold), and no tank inlet or outlet valves are not closed, an alarm "Tank Axx Level

Change Detected " is raised.



None defined.


6.34.8.2.1 XVTxxA/B/C/D/E/F/G/H: Tank Valve Interlocks

All Tank Inlet valves (XV TxxA/B/C/D) are interlocked closed when any of the Tank Outlet

valves indicate a Not Closed status. The interlock is removed when all Tank Outlet valves

indicate a Closed status.

All Tank Outlet valves (XV TxxE/F/G/H) are interlocked closed when any of the Tank Inlet

valves indicate a Not Closed status. The interlock is removed when all Tank Inlet valves

indicate a Closed status.

6.34.8.2.2 XVTxxA/B/C/D: Tank High-Trip Level Interlocks

For all tanks fitted with high level switches (in place of SIF TOP Protection):

All Tank Inlet valves (XV TxxA/B/C/D) are interlocked closed when a route is open to the tank

and a high-trip level is detected by the level switch.

6.34.8.2.3 XVTxxE/F/G/H: Tank Low -Trip Level Interlocks

All Tank outlet valves (XV TxxE/F/G/H) are interlocked closed when a route is open from the

tank and a low-trip level is detected by the level transmitter.

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Tank level (50-LQT xxxA as a percentage), Gross Volume, Tank State and Quality status is

displayed on the tank graphic directly.

Tank data detailed in Section 6.34.4.5 above is displayed on a tank faceplate accessed from

the associated tank graphic.

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6.35 Safety Instrumented System (Tank Overfill Protection)

This section is associated with the control and monitoring of the Safety Instrumented System

(SIS) (Tank Overfill Protection) Device Group.

SIS TOP Protection is installed on all storage tanks within TPL facilities, where this

requirement has been identified by HAZOP and LOPA Studies.


An independent SIL-rated safety system is installed to perform the following functionality,

applicable to the following tanks:

Tank Over-fill Protection SIL will provide the second level of protection, and will interlock all

tank inlet valves closed simultaneously, based on a SIL protection set-point to be set high to

act as last resort. This set-point is set at a level that is either two or five minutes of full flow

below the Tank Overflow level (Refer to section 6.34.4.1).

On detection of a high trip tank level as detected by an independent SIL-rated level

transmitter, all associated tank inlet valves are interlocked closed simultaneously via the

emergency trip input to the associated valve actuators. This system is not configured for fail-

safe operation on an instrument failure.

Instrumentation (per tank)

Instruments connected to SIL Relay:

Accumulator Tank Level (SIL) LT xxxA

Signals interfaced to PLC: Accumulator Tank Level (SIF) LY xxxA_SIF

Accumulator Tank Level (SIL) LY xxxA_AI

Tank Inlet Valve Monitor Relay Fail XV xxxA_FA

PLC and ET200 Power Supplies

PLCxx Panel Power Supply Fail G5x.K11_FA



SIS TOP may be controlled from the PCS either locally at the Station or remotely from the

MCC.


This group cannot be controlled and hence there is no Mode of Operation defined.


6.35.4.1 SIS Diagnostic Failure

Should the signal G5x.K11_FA indicate a single 24V power supply failure, the SIS diagnostic

failure flag is triggered and an associated alarm is raised. This flag is reset when the

G5x.K11_FA signal returns to a healthy state.

Note: This is common to all SIS device groups and is repeated on each associated SIS device

group for consistency. This flag indicates that one of the redundant power supply modules

has failed and the system is operating in a non-redundant mode.

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6.35.4.2 Tank Overfill Protection (TOP)

The trip as issued by the SIL Relay will trip the associated tank inlet valves via the actuator

emergency trip input. The trip function is executed to completion within 120s from a physical

overfill (high-trip condition) to all valves confirmed closed.

The function is hardwired and interfaced to the control system for monitoring via the signal

LY xxxA_SIF. On receipt of a SIF trip (LY xxxA_SIF), the PLC will interlock the associated

Tank Inlet valves closed to prevent a control error

This function is also latched in the PLC. While latched, the SIF trip indication on the overview

is shown (dotted line on graphic). A SIF reset button on the SIS page becomes available

under the latched trip condition and, upon selection, resets the latched trip flag in the PLC,

provided that the high trip level trip condition no longer exists. This button is shared with the

MTBF trip function.

The SIF reset button is coloured red under the following conditions:

SIF Trip function latched within the PLC

SIF Failed to trip is active

6.35.4.3 TOP Proof Test Interval (Mitigation of Undetected Dangerous Failures)

The period between successful SIF trips is monitored and timed by the PLC. If the period

exceeds a PLC configurable time, a Proof Test Interval exceeded flag is set in the PLC. The

default time period is 180 days.

A successful proof test requires the following signals to be activated in the following order:

Per Accumulator Tank

LY xxxA_AI Trip High Set-point

LY xxxA_SIF

All associated inlet valves closed feedback

Note: At least one valve must be Open before performing the proof test for a successful

proof test.

A proof test is credited as successful if all conditions are received within 120 seconds of the

trigger as measured by LY xxxA_AI event in the PLC. A successful proof test will reset the

"Time since last proof" countdown timer.

The required proof test interval and the elapsed time since the last proof test will be visible

on the SCADA.

The elapsed time since the last proof test will be reset when a successful proof test has been

executed. Note that a trip event resulting in the above signals being activated within the

configured time (120 seconds) will also be considered a proof test, and will hence reset this

timer.

An event is raised when the SIF transmitter value LYxxx_AI exceeds the predefined SIF Trip

value. This event will be used for trip evaluation during proof test procedures. The text to be

displayed is "LYxxx_AI TOP SIF Trip Value Exceeded".

Note: The validity of this monitoring timer cannot be guaranteed. It relies on proper

procedures in place to validate the execution of the proof test.

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6.35.4.4 TOP SIF Diagnostic (Detected Dangerous Failure - DDF)

The following signals form part of DDF Diagnostics:

LY xxxA_AI fault (PLC config time delayed, default 5 min), hardware fault, sensor

fault and under range. This shall trigger a diagnostic flag after the timer has expired.

(Repeated every 5 hours)

XV xxx_FA active (Actuator SIL Monitor relay) – may be multiple. If more than one

valve, the signals are AND'ed such that any valve failure will trigger a DDF. If this

condition is true for more than a configurable time (default 4 min), the diagnostic

flag is set. The flag shall only be reset after a configurable time (default 4 min) in the

healthy state (separate timer).

SIF Function Failed to Trip - (instantaneous setting of the diagnostic flag) - SIF

Function Failed to Trip is reset when the trip relay (LY xxxA_SIF) is healthy.

The above three functions are alarmed independently as detailed in alarm strategies below.

The SIF diagnostic failure flag set includes a time filter to ensure that glitches do not set and

reset the flag spuriously. This timer is set to a default of 5 minutes on instrument

failure/recovery only.

The following functions are to occur on detection of a SIF diagnostic failure:

Start a MTTR Timer

Generate a SIF Diagnostic Failure alarm (Medium Priority)

LY xxxA_AI shall not be allowed to be put into simulation from the SCADA.

The operator should inform maintenance of the failure immediately and rectification action

should start.

6.35.4.4.1 SIF Function Failed to Trip

Calculation of TOP SIF Function Failed to Trip alarm is as follows:

The sensing element value should have initiated a trip

(LY xxxA_AI trip set-point exceeded) AND

The associated valves did not close within 120 seconds

OR

The trip relay (LY xxxA_SIF) tripped AND

The associated valves did not close within 120 seconds


one scan to allow for signal propagation within the SIS and associated equipment. SIF

Function Failed to Trip is reset on a successful Proof Test (LY xxxA_SIF).

6.35.4.5 Operation under Tank Overfill Protection SIF Diagnostic Failure

After the MTTR timer has started, the station is operating with the following functions active:

LQT xxx is configured to close the valves at the same set-point as the LY xxxA_SIF

function would have acted.

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If LQT xxx is in a fault state/simulation when entering MTTR, the valves shall close as

indicated in point 1 above.

Should the comparison of LQT xxx and LY xxx_AI have been in alarm (level

deviation) on entering a MTTR condition, the valves shall close as indicated in point 1

above. The comparison alarm should be averaged over 5 minutes to prevent spurious

activation of the function. The comparison only occurs if both sensors are healthy,

i.e. alarm and trip is suppressed under sensor failure conditions.

The SIF Diagnostic Alarm is repeated every 5 hours after the start of MTTR timer.

An Imminent Shutdown Alarm in 1 hour is activated 1 hour before expiry of the

MTTR.

An Imminent Shutdown Alarm in ½ hour is activated ½ hour before expiry of the

MTTR.

If the MTTR timer expires, the tank inlet valves are interlocked closed.

The SIF-credited MTTR value is available (and editable) on the SIS graphic. It is

editable by maintenance staff only. The value is adjustable between 0 hours and a

maximum of 72 hours.


Not required

6.35.6 Group Status






SIF Diagnostic Failure

Tank xxx SIF Diagnostic Failure


Tank xxx SIF Failure Time Exceeds MTTR

Tank xxx SIF MTTR Exceeded Trip


Tank xxx SIF Function Spurious Trip

Tank xxx SIF Spurious Trip

The LYxxxA_SIF is active and the LQTxxx level remains below the Alarm High set-point (after a configurable delay of 2 secs).

Tank xxx SIF Proof Test Interval Exceeded

Tank xxx SIF Proof Test Exceeded


Tank xxx SIF Function Failed to Trip

Tank xxx SIF Failed to Trip


LT xxx Fault and in MTTR Trip

LQTxxxA Fault & in MTTR Trip


TRANSNET PIPELINES






Tank xxx SIF MTTR Imminent Shutdown - 1 hour

Tank xxx SIF MTTR Imm Shut 1h


Tank xxx SIF MTTR Imminent Shutdown - 1/2 hour

Tank xxx SIF MTTR Imm Shut 1/2h


Tank xxx Level Deviation and in MTTR Trip

Tank xxx Lvl Dev & in MTTR Trip


yyy SIS Diagnostic Failure

yyy SIS Diagnostic Failure


Table 6.35-1: SIS Group Alarm Status

xxx is the relevant tank for that product, yyy is the relevant product.


one scan cycle to allow for signal propagation within the SIS and associated equipment.


None defined.


None defined.


None defined.



6.35.8.1.1 Tank Overfill Protection

If a tank high trip level is detected, the associated tank inlet valves are tripped closed by an

independent SIL 1-rated Overfill Protection System.


6.35.8.2.1 XV xxx: Tank Overfill Protection

Associated tank inlet valve will be interlocked closed when a SIF trip is active.

Tank Overfill Protection Trip (LYxxxA_SIF), OR

SIF Failure Time Exceeds MTTR, OR

LQTxxx Fault and in MTTR Trip, OR

Level Deviation High and in MTTR Trip

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None defined.


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6.36 Prover

This section is associated with the control of the Prover Device Group and its associated

devices.

Provers are installed on all Intake and Delivery Stations with custody metering installed.


Prover loop facilities at delivery and intake stations are utilized to accurately establish meter

factors to be used in the custody metering of product, to API Manual of Petroleum

Measurement Standards. Bi-directional provers are installed at Transnet Pipelines sites.

The Proving Cycle (and control of the prover 4-way valve) will be controlled and monitored

from the Custody Metering System via interface to the Prover Flow Computer/s. Visualization

and status information relating to the prover 4-way valve and proving functions will not be

provided on the PCS.

Facilities to fill and empty the Prover prior to and after proving are provided and consist of

transfer tanks, transfer pumps and associated inlet and outlet piping. Filling and draining of

Provers may be either manually or automatically controlled on multi-product Provers or

locally controlled on single product Provers. Automation of these operations require

automatic control of all associated transfer, drain and vent valves and transfer pumps, as well

as the continuous level measurement of the transfer tanks.

The following sequences are provided on the PCS:

Prover On Line Sequence

Prover Off Line Sequence

Prover Fill & Drain Sequences

Prover Sequences are accessed from a Prover Matrix. Prover availability is based on devices

required for individual sequences.


6.36.1.1 Field to PLC Interface

Control of the Prover Device Group by the PLC is achieved via interface to the following

equipment:

Valves

Manifold x Prover Inlet Valve XV YxA

Manifold x Prover Outlet Valve XV YxE Manifold x Prover Bypass Valve XV YxK

Prover Y0x 4-way Valve XV YxR

Prover Y0x Vent Valve XV YxV

Prover Y0x Transfer Valve XV FxA

Prover Y0x Transfer Valve XV FxB Prover Y0x Transfer Pump 4-way Valve XV FxR

Transfer Tank Outlet Valve XV FxE

Instrumentation

Prover Y0x Transfer Pump Xxx Flow FS xx1

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Prover Y0x Sphere Detector ZI xx1

Prover Y0x Sphere Detector ZI xx6

Prover Y0x High Level LSH xx1

Prover Y0x Low Level LSL xx2 Prover Y0x High Level LSH xx3

Prover Y0x Low Level LSL xx4

Transfer Tank Level LT xx1

Pumps

Prover Y0x Transfer Pump Xxx

6.36.1.2 Sphere Indication

Home and away sphere detectors are mounted on a Prover and interfaced to the PLC to

indicate the position of the sphere on the SCADA, as follows:

Home - Set if ZI xx1 is detected, reset if ZI xx6 is detected

End - Set if ZI xx6 is detected, reset if ZI xx1 is detected

Volume detectors (ZI xx2, ZI xx3, ZI xx4, ZI xx5) are also indicated on the PCS graphics.


The Prover may be controlled from the PCS either locally at the Station or remotely from the

MCC.


All devices related to the Prover shall have the following three Modes of Operation:

Local

Manual

Automatic


6.36.4.1 Metering System Interface

No signals shall be interfaced between the Prover Flow Computer and the PCS.

6.36.4.2 4-Way Valve Control (S600 Flow Computer)

Initiation and control of the Proving Cycle (and control of the prover 4-way valve) shall be

done from the Metering System or directly from the Flow Computer. The 4-way valve will be

reflected as a static icon on the PCS.

6.36.4.3 Prover States

6.36.4.3.1 Prover Online

The Prover is in an Online state if:

XV YxA Opened AND

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XV YxE Opened AND

XV YxK Closed

6.36.4.3.2 Prover Offline

The Prover is in an Offline state if:

XV YxA Closed AND

XV YxE Closed AND

XV YxK Opened

6.36.4.4 Prover No Valid Flow-path Status

A Valid Flow-path for the Prover exists if the following conditions are met:

(XV YxA Open OR Wirebreak AND

XV YxE Open OR Wirebreak) OR

XV Y1K Open OR Wirebreak

6.36.4.5 Prover Flags

These flags are raised by the process control software as configured on the Prover block. The

flags are used to generate Group Status Indications, Group Availability Indications and for

Group Event and Group Alarm logging. The triggering of each flag is described here in detail.

6.36.4.6 Possible Hotspot

A Possible Hotspot is indicated if the Prover is moved from the offline state and the Prover

product differs from that of the product route that is online. Prover online and offline status is

determined by device status.

This alarm is cleared when the Prover goes Online.

6.36.4.7 Product Mismatch

This alarm is triggered if a LP manifold route moves from closed to not closed status and

differs from the product currently in the prover.

The alarm is cleared after 30 seconds.

6.36.4.8 Level Indication

The prover has two low level switches and two high level switches. Both the low and high

level switch indicates if the level is made i.e. high level. [Note that some provers depending

on the physical construction may have only one high level switch.]

The following logical conditions are determined by the level switches:

Empty - All level switches are off

Not Empty - At least one of the low level switches.

Full - All level switches are On

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Fault - A fault indicates if there is a conflict between the high and the low levels i.e. if

none of the conditions above is true. If a switch is in hardware fault or signal out of

range, the switch automatically defaults to the override value of 7.77mA (low level).

The logic condition for "Not full" is not required.

LSHxx4 LSHxx3 LSLxx2 LSLxx1

0 0 0 0 Empty

0 0 0 1 Not Empty

0 0 1 0 Not Empty

0 0 1 1 Not Empty

0 1 0 0 Fault

0 1 0 1 Fault

0 1 1 0 Fault

0 1 1 1 Not Empty

1 0 0 0 Fault

1 0 0 1 Fault

1 0 1 0 Fault

1 0 1 1 Not Empty

1 1 0 0 Fault

1 1 0 1 Fault

1 1 1 0 Fault

1 1 1 1 Full

Table 6.36-1: Prover Diesel Level Indication

6.36.4.9 Prover Primed

The Prover is primed for a particular product when:

Prover Y0x Transfer Valves XVFxA AND XV FxB are closed AND

Prover Y0x Vent Valves XVYxV are closed AND

Prover is full (Refer to Section 6.36.4.8)

6.36.4.10 Prove Enable is SET (RPE)

The Prover is enabled for a particular product when:

Prover Y0x Transfer Valves XVFxA AND XV FxB are closed AND

Prover Y0x Vent Valves XVYxV are closed AND

Prover is full (Refer to Section 6.36.4.8)

Prover content matches the LP product online.

6.36.4.11 Prover Sequences

6.36.4.11.1 Prover Sequence Matrix

Control of Prover Online, Offline, Drain and Fill Sequences will be controlled from a Prover

Sequence Matrix. For Sequence Matrix details refer to Section 4.9.

6.36.4.11.2 Prover Online Control Sequence

The Prover Online Sequence is activated on receipt of:

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an Online request from the SCADA

If Ready, the Prover Inlet and Outlet valves are opened and on successful completion the




Any actuated valve Not Available (XV YxA, XV YxE, XV YxK)

Prover Drain valves not closed

Prover Level not full



7.2.13.2: Prover Y01 Online Sequence

6.36.4.11.3 Prover Off-line Control Sequence

The Prover Offline Sequence is activated, on receipt of:


If Ready, the Prover Bypass valve is opened and on successful completion, the Inlet and

Outlet valves are closed.



Any actuated valve Not Available (XV YxA, XV YxE, XV YxK)



7.2.13.3: Prover Y01 Offline Sequence

6.36.4.11.4 Prover Drain sequences

The Prover Drain Sequence is activated on receipt of:

a Drain request from the SCADA

If Ready, the transfer valves for the other products are closed and once closed, the

associated transfer and vent valves are opened and the transfer routing valve is forwarded.

On completion the Prover transfer pump is started.

When all low level switches on the Prover indicate that the Prover is empty or if the Prover

Transfer pump has tripped on no flow, a timer is started. After a configurable time has

elapsed, a further check is made to determine whether all low level switches on the Prover

indicate that the Prover is empty. If not, the cycle commencing with starting the transfer

pump is rerun.

If the Prover is empty, the Prover transfer valves are closed. Once closed, the transfer

routing is reversed, Prover vent valves are closed and the transfer pump stopped. Note that

product will overflow to the sump in the event that the Prover transfer Tank is full.

While the Drain sequence is running, the no flow trips are counted. If the pump tripped on a

no flow for more than 3 times, the sequence will close the prover transfer valves. Once

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closed, the transfer routing is reversed, Prover vent valves are closed and the transfer pump

is stopped.

Any faults encountered during the running of the Drain sequence will result in the sequence

aborting during the open route portion and continuing to completion during the close route

portion, complete with all associated alarming and event logging.


aborting.


7.2.13.5: Prover Y01 Drain Sequence

6.36.4.11.5 Prover Fill Sequences

The Prover Fill Sequence is activated on receipt of:

a Fill request from the SCADA

If Ready, the transfer valves for the other products are closed and once closed, the

associated transfer and vent valves are opened and the transfer routing valve is reversed. On

completion the Prover transfer pump is started.

When the associated transfer tank indicates a low level or if the transfer pump has tripped on

no flow, the Prover vent valves are closed. Once closed, the Prover transfer valves are closed

and thereafter, the transfer routing valve is forwarded and the transfer pump stopped.

Note that product will overflow to the sump in the event that the Prover is full.

Any faults encountered during the running of the Fill sequence will result in the sequence

aborting during the open route portion and continuing to completion during the close route

portion, complete with all associated alarming and event logging.


aborting.


7.2.13.4: Prover Y01 Fill Sequence

6.36.4.12 Product Identification - Prover

Product selection shall be indicated to the operator by means of line fill colours. The Prover

contents can be altered manually from the Prover Screen with overrides.

Where it is not possible to automatically determine the product in the prover (e.g. where

there is only one transfer tank), the operator has to manually set the correct product from

the Prover Screen with overrides.

Product Identification is done in the following manner:

Set Product:

Product in transfer tank if flow path from transfer tank (Transfer valves open and

vent valve open) and

Transfer Four-way valve is reverse and

Transfer pump is running and

Prover is not empty

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OR

LP route for that product is online and

Prover is not empty

OR

Product override and

Prover is not empty

Reset product:

Prover is empty or

Other product override Other products are not isolated or

Other product override

Product unknown:

Product unknown is indicated if no specific product bit is set but the prover is not empty.

When the Prover is empty, as indicated by both the high and low level switches not being

activated, and the low level switch is then activated whilst the Prover is off line and product

type cannot be determined by a flow path from the transfer tank; product in the Prover will

be indicated as unknown.

6.36.4.13 Product Identification - Transfer Tanks

Transfer tank product selection shall be indicated to the operator by means of fill colours.

The transfer tank contents can be altered manually from the Prover Screen with overrides.

When transferring the Prover contents to the Transfer tank, the Transfer Tank contents will

be the same as the transferred Prover contents.

Product Identification is done in the following manner:

Set Product:

Product in prover if flow path from prover (Transfer valves open and vent valve

open) and

Transfer Four-way valve is forward and

Transfer pump is running and

Transfer tank is not empty

OR

Product override and

Transfer tank is not empty

Reset product:

Transfer tank is empty or

Other product override

Product unknown:

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Product unknown is indicated if no specific product bit is set but the transfer tank is not

empty.


The button will indicate the availability is either of the 2 sequences is available.

Online/Offline - Indicate available if either the Online or the Offline sequence is available.

Fill/Drain - Indicate available if either the Fill or the Drain sequence is available.

6.36.5.1 Prover Online Sequence Availability

Prover Online Sequences are configured on a meter manifold/product basis.

The following conditions render the Device Group “Not Available”.

Table 6.36-2: Prover Online Availability

6.36.5.2 Prover Offline Sequence Availability

Prover Offline Sequences are configured on a meter manifold/product basis.


Table 6.36-3: Prover Offline Availability

6.36.5.3 Prover Fill Sequence Availability

Prover Fill Sequences are configured on a product basis.


XV YxA Not Available XVYxA Not Avail Refer to [3]

XV YxE Not Available XVYxE Not Avail Refer to [3]

XV YxK Not Available XVYxK Not Avail Refer to [3]

XV YxA Not Available/Closed

XVYxA Not Avail OR Closed

For valves associated with other meter manifolds connected to the Prover.

XV YxE Not Available/Closed

XVYxE Not Avail OR Closed

For valves associated with other meter manifolds connected to the Prover.

XV YxV Not Closed XVYxV Not Closed Any Prover Vent valve not closed.

XV FxA Not Closed XVFxA Not Closed Any Prover Drain valve not closed

(associated with all products)

XV FxB Not Closed XVFxB Not Closed Any Prover Drain valve not closed


Prover Not Full Prover Not Full Refer to Section 6.36.4.8

Prover Content Not PRDx Prover Content Not PRDx

Prover content does not match the manifold contents.


XV YxA Not Available XVYxA Not Avail Refer to [3]

XV YxE Not Available XVYxE Not Avail Refer to [3]

XV YxK Not Available XVYxK Not Avail Refer to [3]

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Table 6.36-4: Prover Fill Availability

6.36.5.4 Prover Drain Sequence Availability

Prover Drain Sequences are configured on a product basis.



XV YxA Not Closed XVYxA Not Closed All Prover Inlet valves not closed


XV YxE Not Closed XVYxE Not Closed All Prover Outlet valves not closed


XV YxV Not Available XVYxV Not Avail Any Prover Vent valve not available.

XV FxA Not Available XVFxA Not Avail Refer to [3]

XV FxB Not Available XVFxB Not Avail Refer to [3]

XV FxR Not Available XVFxR Not Avail Refer to [3]

XV FxE Not Available XVFxE Not Avail Refer to [3]


Prover Level Low Prover Level Low LSLxx2 AND LSLxx4 Not High Level

Prover Content Not PRDx Prover Content Not PRDx

Refer to Section 0

PRDx Transfer Tank Full PRDx Transfer Tank Full



XVYxA Not Closed XVYxA Not Closed All Prover Inlet valves not closed


XVYxE Not Closed XVYxE Not Closed All Prover Outlet valves not closed


XVYxV Not Available XVYxV Not Avail Any Prover Vent valve not available.

XVFxA Not Available XVFxA Not Avail Refer to [3]

XVFxB Not Available XVFxB Not Avail Refer to [3]

XVFxR Not Available XVFxR Not Avail Refer to [3]

XVFxE Not Available XVFxE Not Avail Refer to [3]


Prover Level High Prover Level High Not LSHxx1 AND LSHxx3 High Level

Prover Content Not Empty

Prover Content Not Empty


PRDx Transfer Tank Empty

PRDx Transfer Tank Empty

Refer to Section 0

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Table 6.36-5: Prover Drain Availability

6.36.6 Group Status






Possible Hotspot Possible Hotspot Refer to Section 6.36.4.6

Level Switches Fault Level Switches Fault


Product Mismatch Product Mismatch Refer to Section 6.36.4.7

Table 6.36-6: Prover Group Alarm Status




Alarm Configuration Database (3) for details, including text to be used for the event

message.


Prover No Valid Flow-path

PRDx

Prover No Valid Flow-path PRDx


Table 6.36-7: Prover Group Error Status






Level Full Level Full Refer to Section 6.36.4.8

Level Not Empty Level Not Empty Refer to Section 6.36.4.8

Level Empty Level Empty Refer to Section 6.36.4.8

ZI861 Active ZI861 Active Refer to [3]


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Table 6.36-8: Prover Group Information Status


None defined.



None defined.


6.36.8.3 Xxx: Prover Transfer Pump No Flow

If a low flow (FS xx1) is detected for a configurable time (default 5s) after the pump is

started, the Prover Transfer Pump (Xxx) will be interlocked off. This interlock and associated

alarm is blocked if the Pump is not running.


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6.37 Intermix Blend Control This section is associated with the control and monitoring of the Intermix Blend Device

Group.

Intermix Blend facilities are installed on all delivery stations within TPL facilities.


Intermixture blending facilities at the pump stations comprise dedicated intermix tanks,

metering and pumping facilities. Accurate control of blending into product being delivered is

required in order to ensure that product is not delivered out of specification. The flow control

loop Auto / Manual can be selected independently of the Intermix Blending group. The

volume injected is measured by means of a counter module that counts the pulses per unit

volume coming from the flow meter.

Pressure and temperature compensation of Intermix blend volumes is not required and thus

pressure and temperature compensation need not be installed.

Control and Monitoring functionality shall be achieved via interface to the following devices:

Valves

Blend Inlet valve XV GxE

Blend Recirculation valve XV GxR Blend Routing valves XV Gxx

INT Tank Txx Outlet valve XV TxE

Blend Control Valve CV GxJ

Pumps

Blend Pump Xxx Xxx

Instrumentation

Blend Flow FT 84x Blend Pressure PT 84x (where applicable)

Blend Pump Xxx Flow FS 84x

Blend Pump Xxx Current IT 84x


The Intermix Blend device group may be controlled from the PCS either locally at the Station

or remotely from the MCC.


All devices related to the Intermix Blend Control and Transfer shall have the following three

modes of operation:

Local

Manual

Automatic


6.37.4.1 Blending Functionality

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Blending may only be initiated to an online LP route. Blending shall continue during

transitions across consignees of like product and the blending system will proportion the

transition volumes. Blend pulses will be ignored whilst blend outlet valves are closed, to cater

for blend recirculation and inter tank transfer through the blend meter.

A PLC high-speed counter card counts the turbine flow meter pulses used for volume

calculations. When blending is initiated (blend valve is not closed) a counter is started which

in turn count pulses from the flow meter. (1 pulse * variable factor = 1 litre of intermix).

Blend volumes, batch volumes, etc are all reset and the counter starts from zero for a new

delivery, when both the consignee and blend outlet valves are opened for the first time.

Blending will remain active for the duration of a delivery i.e. the blend valve may be closed

and opened without the volumes being reset and with the blend totals continuing to add up.

Blend meter factor cannot be changed whilst blending is in progress.

6.37.4.2 Blend Flow Control Flow rate will be controlled via the Blend Control valve (CV GxJ) if (XV GxE) is open for

blending. The Flow Control Loop shall have separate auto/manual modes of operation.

The operator, prior to initiating blending, is required to enter the contaminant value. This

value is used along with compensated blend and delivery flow rates (as measured by the

respective flow meters) to control the Blending rate automatically, provided the Blend Flow

Control Loop has been placed in Automatic. Contaminant values for the various products may

be altered in the online reports.

Desired Blend Flow Rate Set-point is calculated from the formula:

Desired Blend Flow Rate Set-point = (Blend Percentage/Contaminant percentage) x Delivery

Flow Rate

where

Blend Percentage is limited to a maximum of 0.25% into Diesel and 0.5% into Petrol.

If neither product is identified, the default is set to 0.25%.

Contaminant Percentage entered is derived from Lab results e.g. If blending into

Petrol is required, and the associated Intermix Tank sample indicates a 30% Diesel

component and 70% Petrol component, then the Contaminant Percentage is 30%.

6.37.4.3 Blend Compensation Compensation of the blend flow rate is performed using a product specific meter factor.

Meter factors are automatically selected according to the status of the Blend Outlet valve.

Meter Factors are configurable under password access rights.

Liters blended = pulses * 1/K factor.

6.37.4.4 Blending - Operator Interface The following information is displayed on the SCADA:

Blend flow rate

Blend percentage

Blend volume total

Blend meter factor

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6.37.4.5 Recirculation Where re-circulation facilities are installed on a site, re-circulation will be executed as part of

the online sequence. Blend piping product will always be flushed into a designated Intermix

Tank.

The volume of Intermix which needs to be circulated includes the piping from tank to the

Blend re-circulation valve (XV GxR), and the volume of the pumps X0x/y piping. The re-

circulation will start pumps X0x or X0y to flush the piping for a this calculated line volume.

6.37.4.6 Blend Reports Blend Reports will not be supported within the PCS, but will be supported at an MES/MIS

level. The following information will be made available from the PCS for reporting purposes:

Blend Total during previous hour HBlhour

Blend Rate expressed as a percentage of delivery Flowrate BlRate

Blend Total EBlBatch

Average Blend Percentage EBlActPc

6.37.4.7 Blend Volume Calculation A LP Start Delivery route must be online before blending is allowed. If a route is not online

the blend counters will be disabled.

As soon as the blend valve returns a not closed signal the blend counter is reset and started

ready to count the pulses received from the blend flow meter. Additionally the three registers

for Current blend volume, previous delivery and next delivery are also reset.

The current counter value (C) is the actual count from the counter module. This counter

is reset on a ‘start transition (more specifically, when second consignee status shows not

closed)’ or ‘start blend (more specifically, when blend valve shows not closed)’.

The current blend volume register (X) contains the volume blended dedicated to the

original (first) consignee only. The value from counter C is transferred to register X as soon

as a second consignee starts to open. Counter C is reset when this occurs.

The previous delivery register (P) contains the amount of Intermix, which was blended

during a possible transition at the beginning of the current delivery.

The next delivery register (N) will contain the amount of intermix, which was blended

during a possible transition at the end of the current delivery.

When the blending is started for the first time i.e. new blend cycle, the previous delivery

register (P) is 0 (zero). Therefore: Previous = 0.

The current blend volume is derived from the pulses counted until a transition has started

(i.e. the second consignee shows not closed status) or if the blending valve is closed.

During the delivery, the blending may be stopped and restarted without the volumes being

reset and end of hour totals continuing to add up.

If a transition is started, the blend volume counter (C) is stopped as soon as the transition

consignee indicates a not closed feedback. The value from counter C is transferred to the

current blend volume register (X). Thereafter counter C is reset and started, counting the

next delivery volume i.e. when both routes are open during the actual transition.

Once the new route is online i.e. one of the consignees closed again, the blend volume

counter (C) is stopped and the value transferred to the next delivery volume register (N). All

the volumes and percentages are now calculated.

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The formula for calculating the blended volume is:

Delivery blended volume = P / 2 + Current volume + N / 2

EXAMPLE:

Assuming we are online to consignee Caltex with Petrol and start blending. When the

delivered volume is reached we will initiate a transition to consignee Shell without stopping to

blend.

On commencement of blending (Blend valve not closed and delivery in progress), the

registers are all reset and the Previous blend volume (in this case 0) is transferred from

counter C to P? The counter is counting pulses from the flow meter.

Assuming we initiate the transition at the point when the blended volume is 1000 litres.

When the transition consignee (Shell) is not closed the current count (C) 1000, is transferred

to the current blend volume register (X) and the counter C reset and started. The blend

volume during the transition is now totalled in counter C.

Because we are online to two consignees the blended volume must be divided between the

consignees.

When the original consignee is closed the counter value is transferred from counter C to the

next delivery volume register (N) and the counter C reset and restarted ready to count the

current blend volume for the new primary route.

Assume the next delivery-blended volume was 100.

Previous blend volume register (P) = 0

Current delivery blended volume register (C) = 1000

Next delivery blend volume register (N) = 100

At this point all volumes and percentages can be calculated.

From the formula we have: Total blended volume for delivery = 0/2 + 1000 + 100/2.

Therefore the blended volume is 1050.

After the calculation the next delivery blended volume register (N) is transferred to the

previous delivery blended volume register (P), ready to be used for the next calculation.

All blend data for the delivery is entered to the FIFO block for easy retrieval of the MDS.

If we now initiate a transition to Mobil the current counter value (C) will be transferred to the

current delivery volume register (X) e.g. 1900.

The counter (C) is reset and restarted to count the transition volume while both consignees

are open. As soon as the primary consignee is closed the counter value (C) is transferred to

the next delivery volume register (N) and the counter reset and restarted, ready to count the

current blend volume for the transition route.

Assume the next delivery-blended volume was 160.

Previous blend volume register (P) = 100

Current delivery blended volume register (C) = 1900

Next delivery blend volume register (N) = 160

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At this point all volumes and percentages can be calculated.

From the formula we have: Total blended volume for delivery = 100/2 + 1900 + 160/2.

Therefore the blended volume is 2030.

After the calculation the next delivery blended volume register (N) is transferred to the

previous delivery blended volume register (P), ready to be used for the next calculation.

All blend data for the delivery is entered to the FIFO block for easy retrieval of the MDS.

The blend volume for a delivery to one consignee consists of half the volume blended in the

previous transition P, the actual volume blended during the delivery X, and half the volume of

the transition to the next consignee N.

Petrol delivery to Mobil Petrol delivery to Shell Petrol delivery to Caltex

1500 160 1900 100 1000

Docket 102 Docket 101 Docket 100

80 80 50 50

Where:

P = Previous blend volume register

C = Current delivery blended volume register

N = Next delivery blend volume register

Flowchart for Calculating Blending Data

Stop delivery &

End blend

Transition

next/previous

Transition

next/previous

Start blend Start

delivery

Blended total = P/2+C+N/2

= 160/2+1500+0/2

= 180+1500+0

= 1680


= 100/2+1900+160/2

= 50+1900+80

= 2030


= 0/2+1000+100/2

= 0+1000+50

= 1050

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Primary online?

Both in manual and

auto mode of

operation

No

Yes

No

Yes

Yes

Blend valve

Not closed and

blend not active

?

Transition

initiated ?

Transfer C to X,

Reset blend active

Transition

complete ?

Calculate Blended

volume for delivery

= P/2 + X + N/2

Stop delivery

Initiated ?

Reset P, N, X

and C

Start C, set blending active

END

Transfer C to X

Reset C and restart

Transfer C to N

Reset C and restart

Yes

No

Yes

No

Blend calculations

Previous delivery blended volume = P

Next delivery blended volume = N

Current delivery blended volume = X

Current counter value = C

No

Shift all FIFO contents

down and transfer

calculations to FIFO

Transfer N to P

6.37.4.8 Blend Sequences

6.37.4.8.1 Blend Sequence Matrix

Control of Blend Online and Offline Sequences will be controlled from a Blend Sequence

Matrix. For Blend Matrix details refer to Section 4.9.

6.37.4.8.2 Blend Online Sequence

A Blend Online Sequence is initiated by:

A Blend Online Request from the SCADA.

A check is undertaken to ascertain if the Blend Group is "Ready". Blending is placed on line

by simultaneously opening/closing all appropriate valves. Once the route is on line, the Blend

Pump is started, thus completing the sequence.

Where Recirculation facilities have been provided, recirculation will always be performed as

part of the Online Sequence, prior to opening of the relevant Blend outlet valve. Recirculation

will always be performed back to the Intermix Tank designated for Flow Relief.

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Availability will be indicated on a selected route basis, with non-availability being indicated by

the greying out of the Sequence Online button on the SCADA. Availability is determined by

the status of all devices associated with a particular route within the Blending Device Group.

Any faults encountered during the running of the open route sequence will result in the

sequence aborting, complete with all associated Alarming and Event Logging procedures.

The blend flow rate will be controlled by flow control valve CV G1J, if in automatic.

6.37.4.8.3 Blend Offline Sequence

A Blend Offline Sequence is initiated by:

An Offline request from the SCADA

A Stop Delivery Command

Start Delivery sequence for cross product transition

An Intermix Tank low level trip based on route online from that tank

Blend Strainer Blocked status active

All Consignee valves associated with a product being blended into are closed or

selected LP Route not online for that product. (Note that Accumulator and Intermix

tank valves are excluded from this definition – blending into routes open to either

accumulator or intermix tanks is not permitted). Thus blending will be permitted

during same product switches but not during cross product switches.

The Blending Stop Blend Sequence is performed irrespective of route device availability.

Any device failure during the offline sequence will result in the sequence continuing to

completion. Device errors during running off line shall be used to continue the Sequence,



6.37.5.1 Blend Route Availability Availability will be determined on a per route basis and will be displayed on the Matrix

Sequence buttons. Availability is determined by the status of all devices associated with a

selected route within the Blending Device Group.

Route availability is determined as follows:

Selected tank outlet valves available (actuated) and open (ZV)

Other tank outlet valves (XV TxF) available or closed.

Selected blend pump available

Selected blend pump strainer available – ZV’s open and no high PDT

Selected blend valve available

Other blend valves associated with other product blend pumps available or closed

Required Intermix crossover valves available

Other Intermix crossover valves available or closed

LP routing online for selected intermix route

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No low level (LT 85x LL2) based on selected tank

Any route online that requires the crossover valves

Tanker loading from the same tank

No intermix delivery online to the same intermix tank

The offline sequence button is not linked to availability.

6.37.6 Group Status Indications

The following status indications are available to keep the Operator informed of the status of

the Intermix Blend Control and Transfer Group:

6.37.6.1 Group Alarm Status Indications None defined.

6.37.6.2 Group Error Indications None defined.

6.37.6.3 Group Information Indications None defined.


6.37.7.1 Hard Wired Interlocks None defined.


6.37.7.3 Xxx: Blend Pump No Flow The Blend Pump (Xxx) will be tripped if the flow switch (FS 84x) indicates no flow after a

configured time has elapsed. The interlock and alarm is blocked if the pump is not running

Text to be displayed is “Blend Pump No Flow”

6.37.7.4 Xxx: Blend Pump No Flow-path The Blend Pump (Xxx) will be interlocked off if there is no valid flow-path. i.e. valves on route

are not open AND not wirebreak.

Text to be displayed is “No Valid Flow-path”


None defined.


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6.38 System Diagnostics

This section is associated with the monitoring of the System Diagnostics Device Group.

The purpose of the system is to support 1st line diagnostics and periodic surveillance locally

to a site by providing system statuses in support of detailed diagnostics using the tools

provided by the PCS engineering system.


System monitoring will include the following systems and sub-systems:

PCS7 OS Servers (Hardware and PCS7)

PCS7 OS Clients (Hardware)

PCS7 Engineering stations (Hardware)

PLC CPUs (S7-400 and S7-300 as implemented on MBV’s)

Scalance Ethernet network switches for:

Terminal Bus

System Busses

CAS Bus

PCS7 CAS Servers (Hardware)

PCS7 OpenPCS7 Servers (Hardware)

PCS7 WEB Servers (Hardware)

Domain controllers (Hardware)

MES Metering servers (Hardware and Metering software)

MES Metering clients (Hardware)

Tank gauging system (Hardware and heartbeat)

Machine monitoring system (Bently Nevada and System 1 heartbeats)

Any SIMATIC IPC hardware other than those systems already listed

HMI Trainer Servers

The following will be excluded from the system monitoring:

Remote I/O (ET, ETF, ETL, ETM, ETR)

Profibus switchgear and VSDs

Field bus networks

Ethernet networks for:

H1 Bus

PLMS Bus

PCS7 OS Sync Bus

Equipment within DMZs

Firewalls

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UPSs

Electrical SCADA System (Hardware and software)

Printers

Flow Computers

PLMS (Hardware and software)


The Diagnostics screen is viewable from MCC and Station. Only maintenance personal have

the user access rights to modify values. Alarm locality is not required as alarms are only

viewable in the diagnostics channel.


There is no mode of operation for this group.


6.38.4.1 General

The monitoring system shall be part of the process control system

The monitoring system shall be graphically made available on the PCS operator stations

The monitoring system shall be autonomous per site, and not rely on any WAN

communications or off-site located equipment, services or functions to perform the

monitoring function

The system monitoring graphic shall be a symbolic representation of the station hardware

architecture displaying the statuses of the following:

PLCs

OS servers (Additional to the PC hardware status below)

PC Hardware

Network switches

System heartbeats

Where the status display LED is a rollup of statuses, a detailed status display shall be

available, i.e. a second level of statuses.

The monitoring system typicals should be developed such that they are independent of

equipment type, make and model - e.g. by limiting the equipment-specific configuration to

the interface portion only.

6.38.4.2 PLC Statuses

The following status LEDs shall be monitored and rolled up into a single health status

indication per PLC:

Table 6.38-1: PLC Status Monitoring

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PLC LED LED status for a

healthy rolled up

status

PLC Run status LED On

PLC Stop status LED Off

PLC Internal Fault LED Off

PLC External fault status LED Off

PLC Redundancy fault status LED Off

PLC Bus fault LED(s) Off

PLC Interface module fault LED(s) Off

PLC Master LED Not rolled up

The above status LEDs shall be available on a faceplate, accessed from the rolled up health

status indication on the system monitoring graphic. Detailed information is available for each

rollup LED.

Additional to the above, the faceplate to include the following:

Device name

Device description

Device address

6.38.4.3 OS Server Statuses

The following OS server statuses shall be monitored and rolled up into a single health status

indication per OS server pair:

Table 6.38-2: OS Server Status Monitoring

Status Status for a healthy

rolled up status

Server A runtime status Runtime active

Server B runtime status Runtime active

Server A to PLC communication

(detail for each PLC in 2nd level

display,Including redundancy)

Comms healthy

Server B to PLC communication

(detail for each PLC in 2nd level

display, Including redundancy)

Comms healthy

Current Master Not rolled up

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The above statuses shall be available on a faceplate, accessed from the rolled up health


rollup LED.


Device name

Device description

Device address

6.38.4.4 Network Switch Status

The following network switch statuses shall be monitored and rolled up into a single health

status indication per switch:

Table 6.38-3: Network Switch Status Monitoring

Status Status for a healthy

rolled up status

Switch communication Comms healthy

Switch fault status No Fault



rollup LED.


Device name

Device description

Device address

6.38.4.5 PC Hardware Status

The following network PC statuses shall be monitored and rolled up into a single health

status indication per PC:

Table 6.38-4: PC Hardware Status Monitoring

Status State for a healthy

rolled up state

PC communication Comms healthy

Hard drive capacity healthy Healthy

Operating system health Healthy

CMOS Battery status Healthy

Hard drive controller status Healthy

Processor temperature status Healthy

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rolled up state

Internal temperature status Healthy

Memory status (TBC if available) Healthy



rollup LED.


Device name

Device description

Device address

6.38.4.6 Tank Gauging System Status

The following statuses shall be monitored and rolled up into a single health status indication

per TGS:

Table 6.38-5: TGS Status Monitoring


rolled up state

OPC communication Comms healthy

Gross Volume Status Healthy



rollup LED.


Device name

Device description

Device address

6.38.4.7 Machine Monitoring System Status


per TGS:

Table 6.38-6: MMS Status Monitoring


rolled up state

Bently Nevada / System 1

communication

Comms healthy

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rollup LED.


Device name

Device description

Device address

6.38.4.8 Inter PLC Communications Status


per TGS:

Table 6.38-7: Inter PLC Communications Status Monitoring


rolled up state

Communication (Including

redundancy)

Comms healthy

A inter PLC communication link is regarded as a send/receive pair between PLCs. I.e if there

is more than one link per PLC pair, both needs to be monitored and indicated. Indication of

this should be done via a source/destination matrix.

The detailed statuses shall be available on a faceplate, accessed from the rolled up health


rollup LED.


Device name

Device description

Device address

6.38.5 Device Group Availability

None defined.

6.38.6 Group Status

None defined.

6.38.7 Group Events

Alarms/Events shall be generated for all of the above statuses.

Alarms and events shall conform to the standard alarming framework as developed for PCS7

v8 custom typicals.

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6.38.8 Group Alarms

None defined.


None defined.


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6.39 Station Sequences

6.39.1 Introduction

Station Sequences have been developed to automate various operational activities at a

station wide level. Station Sequences are only developed on sites where automation makes

sense, and usually includes the following:

Placing the station into a Lined-Up state

Placing the station into an Online state

Placing the station into an Offline state

Placing the station into an Isolated state

Flushing entire manifolds

These sequences exercise control across multiple device groups, including HP Routing and

Mainline Pump Sets. In most cases, station sequences are only available if the associated

device groups are available, in automatic mode and all affected sub-groups are in the same

mode of control.

Station sequences are designed to line-up a station, place station online, offline and isolate a

station. These sequences are mainly intended for use within the MCC for the start-up and

shutdown of the complete pipeline under Line Wide Control (LWC), but can be used on the

station itself when starting up from a shut-down or wanting to shut down in an emergency

situation.

The Station Line-up, Online and Isolation Sequence buttons are only enabled if the

associated device groups are available, in automatic mode and all affected sub-groups are in

the correct Mode of Control (Refer to Availability tables 6.39.5). The Station Offline

Sequence button will be enabled regardless of device group availability.

In addition to the Station Sequences listed above, Station Flush sequences can be initiated

from the HP Overview page.

6.39.1.1 Line Wide Control

LWC is currently only implemented on the 24” MPP Pipeline and effects control at the

respective stations by issuing the following sequence commands to the local control systems

installed on the respective pump stations on the Trunkline:

Station Line-up

Station Online

Station Offline

Station Isolation

The Line Wide Control PLC will only issue commands to the station’s local control system but

the logic to execute the commands e.g. starting a Mainline Pump will reside in the local

station control system.

In addition to Line Wide control, Station Line-up, Online, Offline and Isolation sequences can

also be initiated by the Station operator.

The statuses that enable and disable these sequences will be made available to the LWC for

determination of the statuses of all pump stations in the Trunkline.

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Note: The Line Wide Startup and Shutdown sequences are detailed in the Linewide Control

Engineering Design Specification for the 24” MPP Pipeline.


There are no Modes of Control for the Station Sequences – the mode follows that of the HP

Routing Screen.


LWC (Line Wide Control) from the MCC / SCC only (24” MPP Pipeline only)

SWC (Station Wide Control) from the MCC / SCC / Station


6.39.4.1 Station Line-up Sequence

[As implemented on 24” MPP Pipeline Pumping Stations TNI, HTP, MBT, as an example]

The Station Line-up sequence is activated on receipt of any of the following:

a Station Line-up request from the SCADA (MCC/SCC or Station)

a Station Line-up request from the Line Wide Control PLC

This sequence will start the following sequences:

HP Routing Online sequence

Lube Oil Online sequence

Pumpset P0x Line-up sequence

Main Pumphouse Ventilation Duty Controller

Segmentation Online sequence

Any sub-sequence failure during the Station Line-up Sequence will result in the sequence

continuing to completion, complete with all associated alarming and event logging

procedures. Placing the HP Routing Device Group in manual mode while the sequence is

running will result in the sequence aborting.


7.2.15.1: Station Line-Up Sequence (TNI)

6.39.4.2 Station Set Lined up

The Station is in a Lined up state if:

HP Routing is online AND

at least one Lube oil system is online (Lube oil pump running) AND

at least one Mainline pump is lined-up (Pump breaker closed and

Pump Discharge valve closed) AND

Segmentation is Online AND

Main Pumphouse Ventilation DuC is running

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6.39.4.3 Station Online Sequence


The Station Online sequence is activated on receipt of any of the following:

a Station Online request from the SCADA (MCC/SCC or Station)

a Station Online request from the Line Wide Control PLC

This sequence will start the following:

Start Station Duty controller

Any sub-sequence failure during the Station Online Sequence will result in the sequence

aborting, complete with all associated alarming and event logging procedures. Placing the HP

Routing Device Group in manual mode while the sequence is running will result in the

sequence aborting.


7.2.15.2: Station Online Sequence (TNI)

6.39.4.4 Station Online

The Station is in an Online state if:

Mainline pump P01 is Online OR

Mainline pump P02 is Online OR

Mainline pump P03 is Online

6.39.4.5 Station Offline Sequence


The Station Offline sequence is activated on receipt of any of the following:

a Station Offline request from the SCADA (MCC/SCC or Station)

a Station Offline request from the Line Wide Control PLC


Segmentation Offline sequence

Any sub-sequence failure during the Station Offline Sequence will result in the sequence





7.2.15.3: Station Offline Sequence (24” MPP)

6.39.4.6 Station Offline

The Station is in an Offline state if:

Segmentation is Offline AND

Mainline pump P01 is Offline AND

Mainline pump P02 is Offline AND

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Mainline pump P03 is Offline

6.39.4.7 Station Isolation Sequence


The Station Isolation sequence is activated on receipt of any of the following:

a Station Isolation request from the SCADA (MCC/SCC or Station)

a Station Isolation request from the Line Wide Control PLC


HP Routing offline

Lube Oil offline

Open Pump breakers

Stop Main Pumphouse Ventilation Fan DuC

Any sub-sequence failure during the Station Isolation Sequence will result in the sequence





7.2.15.4: Station Isolation Sequence (24” MPP)

6.39.4.8 Station Isolated

The Station is in an Isolated state if:

HP Routing is offline AND

All Lube Oil systems are Offline AND

Mainline pump 50-P01 breaker not closed AND



All Main Pumphouse Ventilation Fans are stopped

6.39.4.9 Station Flush Sequence


The Station Flush is activated on receipt of:

a start request from the SCADA (MCC/SCC or Station)


Receiver Online

Launcher Online

Mainline Pump P01-P03 Flush

Strainer Flush

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Any sub-sequence failure during the Station Flush Sequence will result in the sequence

continuing to completion, although with the individual flush sequence being aborted,

complete with all associated alarming and event logging procedures. Placing the HP Routing

Device group in manual mode while the sequence is running will result in the sequence

aborting.


7.2.15.5: Station Flush Sequence (TNI)

6.39.4.10 Mainline Pump Flush Sequence


The Pump Set P01-P03 Flush Sequence is activated, if ready, on:

Receipt of a Station Flush Request from the HP Routing Overview Screen.

The Station Duty/Speed controller is placed into ‘Flush Active’ state during flushing, which

inhibits the Duty/Speed Controller from controlling the mainline pumps.

Pump sets are only flushed if the flowrate through the dispatch manifold, as measured by the

sum of the mainline pump flowmeters (FT0x1), is greater than a configurable amount

(default 9000 L/min).

A minimum flowrate of 12000 L/min is achieved by running three pumps at minimum speed

of 1600 rpm (4000 L/min per pump). This is used to flush all the Mainline Pumps.

The Station Duty/Speed controller will always flush the maximum number of “available for

flushing” pump sets, but is limited by flow rate (FT 121) as per the following conditions:

Flow rate > 12000 L/min, limited to maximum of three (3) pump sets.

Flow rate <= 12000 L/min and >= 9000 L/min, only flush a maximum of two (2)

pump sets.

Flow rate < 9000 L/min, only the current pump is flushed.

Note: On pump stations HTP and MTB, when the mainline pumps are bypassed (XV N1K

open, station flow detected (FT 121 > 9000 L/min) and no mainline pump running),

automatic flushing of the mainline pumps will not take place.

A check is undertaken to ensure that the Pump Set Device Group is ready and not online and

not in Mixed Mode of Control (as compared with HP Routing MoC). If these conditions are not

met, the sequence will not be initiated. Otherwise, it is placed online provided that the

flowrate through the manifold is higher than the combined minimum flowrate required by all

the pumps. The duty controller will assume a ‘Flush Active’ condition during flushing. Refer to

the Station Duty and Speed Control Device Group (section 6.15 for details).

If the station manifold flowrate is below the combined minimum flow required by the pumps,

the control system determines the maximum number of pump sets that can be flushed

simultaneously. The maximum number of pumps will be placed online and run until the

interface has passed through these pumps. The Station Duty and Speed Controller latches a

‘Not Flushed’ condition which prevents it from starting the pump set.

Any sub-sequence failure during the Flush Sequence will result in the sequence continuing to

completion, although with the individual faulty pump set flush sequence being aborted,

complete with all associated alarming and event logging procedures. Placing the HP Routing

Device Group in manual mode while the sequence is running will result in the sequence

aborting.

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7.2.15.5: Mainline Pump P01-P03 Flush Sequence


6.39.5.1 Station Line-Up Sequence Availability


The following conditions will render the Station Line-Up Sequence “Not Available”.

Table 6.39-1: Station Line-Up Sequence Availability

Condition Logic

Lube Oil Not Rdy or Mixed MoC

All Lube Oil Sequences are Not

Available or the Group is Not in Automatic or Mixed Mode of Control.

No Pump Rdy or Mixed MoC

(P0x Not Available AND XV PxE Not

Available) OR Pump Group Not in Automatic OR in Mixed Mode of

Control.

HP Online Seq Not Ready Sequence is Not Available or Group

Not in Automatic.

Segment Online Seq Not Ready Sequence is Not Available or Group Not in Automatic.

Vent Fans DuC Not Rdy or Mixed

MoC

Group is Not Available or Not in

Automatic or Mixed Mode of Control.

6.39.5.2 Station Online Sequence Availability


The following conditions will render the Station Online Sequence “Not Available”.

Table 6.39-2: Station Online Sequence Availability

Condition Logic

DuC Not Avail or Mixed MoC DuC Not Available or Mixed Mode of

Control.

Station Not Lined-Up Refer to Section 6.39.4.2.

6.39.6 Station Offline Sequence Availability


The following conditions will render the Station Offline Sequence “Not Available”.

Table 6.39-3: Station Offline Sequence Availability

Condition Logic

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Condition Logic

Segment Offline Not Ready Sequence is Not Available or Group

Not in Automatic.

6.39.7 Station Isolation Sequence Availability


The following conditions will render the Station Isolation Sequence “Not Available”.

Table 6.39-4: Station Isolation Sequence Availability

Condition Logic

HP Offline Seq Not Ready Sequence is Not Available or Group

Not in Automatic.

Lube Oil Manual or Mixed MoC Group is Not in Automatic or Mixed Mode of Control.

6.39.8 Station Flush Sequence Availability


The Station Flush will be available if at least one sub-sequence is ready and in the same

Mode of Control as the General Device Group. Sequences that are not Ready or not in the

correct Mode of Control, will not be run. The following conditions will render the Station Flush

Sequence “Not Available”.

Table 6.39-5: Station Flush Sequence Availability

Condition Logic

Launcher Not Rdy or Mixed MoC Group is Not Available or Not in


Receiver Not Rdy or Mixed MoC Group is Not Available or Not in


Strainer S01 and S02 Not Ready Strainer software not Available.

Pump Flush Seq Not Avail Group is Not Available or Not in


6.39.9 Pump Set P01-P03 Flush Sequence Availability


The Pump Set Flush will be available if at least one pump flush sub-sequence is ready and in

the same Mode of Control as the General Device Group. Sequences that are not Ready or not

in the correct Mode of Control, will not be run. The following conditions will render the Pump

Set P01-P03 Flush Sequence “Not Available”.

Table 6.39-6: P01-P03 Flush Sequence Availability

Condition Logic

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Condition Logic

P01 Not Rdy or Mixed MoC Group is Not Available or Not in


P02 Not Rdy or Mixed MoC Group is Not Available or Not in Automatic or Mixed Mode of Control.

P03 Not Rdy or Mixed MoC Group is Not Available or Not in Automatic or Mixed Mode of Control.

6.39.10 Group Status


None defined.


None defined.


None defined.


6.39.11.1 Hard Wired Interlocks

None defined.


None defined.

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7 APPENDICES

7.1 Appendix A: Flow Compensation

7.1.1 Description

All flows used for control and metering will be compensated. Flow compensation is done in

the PLC using the specified pressure and temperature transmitters. These instruments may

be wired into other PLCs and if so, the values will be obtained via comms.

Flow and volumetric compensation is to be done in accordance with the following criteria:

As a standard, where a flow meter provides dual flow outputs (i.e. pulsed and

Analogue), the pulsed output (volumetric flow) will be used for metering.

As a standard, where no metering is performed, the flow tag (FT) will utilise the 4-20

mA Analogue signal, and KT the pulsed (digital) signal, regardless of whether KT is

used or not.

Software - Uncompensated flow tag is to be FT xxxx_G

Software - Compensated flow tag is to be FT xxxx_S (after compensation)

Software - Compensation is to be done using only PT and TT, with a default density

per product being determined as below

Alarm - On a wirebreak or over-range of a PT or TT, an additional alarm on the

compensated FT is created with priority 10 - "Flow Compensation Calculation Error"

The faceplate developed for Flow Compensation should show uncompensated and

compensated flow values, and in a second tab pressure, temperature and density values

(password protected – Technician level).

The faceplate developed for Volumetric Compensation is to have similar functionality to

custody metering, i.e. PT and TT field values and 3x DT options:

Field values

Keypad values

Product based on route

Compensation is to be done in accordance with API MPMS Chapter 11 1980.

Density values (configurable) are to be used in the following order of preference:

Where a density reading is available, this actual value should be used in the

compensation algorithm. Where the product is known, the following values will

be used in the compensation algorithm:

Diesel: 0.858

ULP: 0.7243

Jet Fuel: 0.796

Other Multi-products: 0.7912

Where a sonic velocity reading is available, the values above are to be used.

Where density or sonic readings are unavailable, and the product is unknown,

the ‘Other Multi-products’ density value above should be used in the

compensation algorithm

Where FT signals need to be transferred/repeated across PLC/Control Systems, this

should be deterministic, i.e. either using Profibus comms or hardwired.

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7.1.1.1 Alarm and Event Strategies

On a wire break or over-range of a pressure or temperature transmitter, an additional alarm

on the compensated flow transmitter is created with priority 10:

Flow Compensation Calculation Error

7.1.1.2 Failure Modes

As per the Analogue Typical with the following addition:

Flow Compensation Failure


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7.2 Appendix B: Sequence Flowcharts & Tables

The Sequence Flowcharts and Tables listed below are Typical Examples, and will need to be

modified on a per Station basis.

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7.2.1 Receiver Device Group

7.2.1.1 Receiver Online Sequence

START

True

Open

XV R1A

XV R1E

1 -S

XV R1A Open

XV R1E Open

XV R1K Closed

END

Open Receiver Inlet &

Outlet Valve

Close Receiver

Bypass Valve

Close

XV R1K

2 -S



aborting, complete with all

associated alarming and

event logging.

Figure 7.2-1 – Receiver R01 Online Sequence

7.2.1.2 Receiver Offline Sequence

START

True

Open

XV R1K

1 -s

XV R1K Open

XV R1A Closed

XV R1E Closed

END

Open Receiver

Bypass Valve

Close Receiver Inlet &

Outlet Valve

Close

XV R1A

XV R1E

2 -s





event logging.

Figure 7.2-2: Receiver R01 Offline Sequence

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7.2.2 Launcher Device Group

7.2.2.1 Launcher Online Sequence

START

True

Open

XV L1A

XV L1E

1 -S

XV L1A Open

XV L1E Open

XV L1K Closed

END

Open Launcher Inlet &

Outlet Valve

Close Launcher

Bypass Valve

Close

XV L1K

2 -S





event logging.

Figure 7.2-3: Launcher L01 Online Sequence

7.2.2.2 Launcher Offline Sequence

START

True

Open

XV L1K

1 -s

XV L1K Open

XV L1A Closed

XV L1E Closed

END

Open Launcher

Bypass Valve

Close Launcher Inlet &

Outlet Valve

Close

XV L1A

XV L1E

2 -s





event logging.

Figure 7.2-4: Launcher L01 Offline Sequence

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7.2.3 MV Booster Pump Device Group

7.2.3.1 MV Booster Pump Online Sequence

END

Close Booster

Pump B01

Discharge

Valve

Close

XV B1E

4 -s

XV B1E close AND

No other Booster Pump Maximum demand inhibit AND

Booster Pump B01 staging enabled

Open Booster Pump

B01 Discharge Valve

Open

XV B1E

7 -s

XV B1E open

Start Booster

Pump B01

Start Pump B01

5 -s

Booster Pump B01 running

Wait 5 secWait

5 Sec

6 -s

Timer Expired

5s

MMS Trip Reset

2

MMS Healthy

Perform MMS Trip Reset

- s

START

Abort Sequence1 -s

No Valid FlowpathValid Flowpath

Abort Sequence3 -s

MMS Rack Fault

5s





B01 Offline = Abort, Idle or Complete

Figure 7.2-5: Booster Pump Set B01 Online sequence

7.2.3.2 MV Booster Pump Offline Sequence

START

StopPump B01

1 -s

Booster Pump B01 stopped OR not Avail

XV B1E close

OR not Avail

END

Stop B01

Close B1EClose

XV B1E

2 -s

B01 Online = Abort, Idle or CompleteB01 Online = Abort, Idle or Complete





logging.

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Figure 7.2-6: Booster Pump Set B01 Offline sequence

7.2.4 MV Mainline Pump Set Device Group - DOL

7.2.4.1 MV Mainline Pump Online Sequence

END

Close Pump P01 Discharge

Valve, Open Bypass Valve

Close XV P1E

Open XV P1K

2 -s

XV P1E close AND XV P1K open AND

No other Mainline Pump Maximum demand inhibit

Open Pump B01

Discharge Valve

Open

XV P1E

5 -s

XV P1E open

Start Mainline

Pump P01

Start Pump P01

3 -s

Mainline Pump P01 running

Wait 5 secWait

5 Sec

4 -s

Timer Expired

5s

START

Abort Sequence1 -s






P01 Offline & Flush = Abort, Idle or Complete

Figure 7.2-7: MV Mainline Pump Set P01 Online Sequence

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7.2.4.2 MV Mainline Pump Offline Sequence

START

StopPump P01

1 -s

Pump P01 stopped OR not Avail

XV B1E close

OR not Avail

END

Stop P01

Close P1EClose

XV P1E

3 -s

P01 Online & Flush = Abort, Idle or CompleteP01 Online & Flush = Abort, Idle or Complete





logging.

Open XVP1K

2 -s

Pump P01 Bypass valve open OR not Avail

Open P1K

Figure 7.2-8: MV Mainline Pump Set P01 Set Offline Sequence

7.2.4.3 MV Mainline Pump Flush Sequence

START

Open XV P1E

1 -s

Pump P01 Discharge valve open

END

Open XVP1E

P01 Online & Offline = Abort, Idle or CompleteP01 Online & Offline = Abort, Idle or Complete





Close XVP1K

2 -s

Pump P01 Bypass valve closed

Close P1K

Figure 7.2-9: MV Mainline Pump Set P01 Flush Sequence

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7.2.5 MV Mainline Pump Set Device Group – VSD (24” MPP)

7.2.5.1 MV Mainline Pump Line-Up Sequence

START

XV P1E Closed AND

Pump Breaker Closed

END

Close P1E

Close P01 Breaker

Close XV P1E

Close P01

Breaker

1 - s

TrueTrue





Figure 7.2-10: MV Mainline Pump Set P01 Line-Up Sequence


MMS Trip Reset

MMS Healthy

XV P1E Open AND

Pump Breaker Closed

END


Close P1E

Close P01 Breaker

Open XV P1E

Close P01

Breaker

4 - s

P01 Running

Start P01

Start P01

5 - s





START

Abort Sequence1 -s


Abort Sequence3 -s

MMS Rack Fault

2 - s5s

Lineup/Offline/Flush

= Abort, Idle or

Complete

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START

END

Stop P01Stop P01

2 - s

P01 stopped OR not Avail

Close P1EClose XV P1E

3 - s

XV P1E Closed

OR not Avail

Lineup/Online/Flush =

Abort, Idle or Complete





logging.

Initiate Lube Oil System

Online SequenceStart Lube Oil

True

1 - s5s

Figure 7.2-12: MV Mainline Pump Set P01 Offline Sequence

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7.2.5.4 MV Mainline Pump Flush Sequence





END

P01 Stopped

Stop P01Stop P019

Close

XV P1E

10

XV P1E Closed

Close P1E

-s

-s

Initiate Lube Oil System

Online SequenceStart Lube Oil

8

True

MMS Trip Reset

3

MMS Healthy

XV P1E Open AND

Pump Breaker Closed


Close P1E

Close P01 Breaker

Open XV P1E

Close P01

Breaker

5 - s

P01 Running

Start P01

Start P01

6 - s

START

Abort Sequence2 -s


Abort Sequence4 -s

MMS Rack Fault

P01 Flushed State AND

No Interface Present

Wait for Flushed

StateFlushed

7 -s

- s5s

- s5s

Lineup/Online/Offline = Abort, Idle or Complete

True

Reset Flush

StateReset Flush

1 -s

Figure 7.2-13: MV Mainline Pump Set P01 Flush Sequence

TRANSNET PIPELINES





7.2.6 MV Mainline Pump Set Device Group – VSD (Crude)

7.2.6.1 MV Mainline Pump Line-Up Sequence

START

XV P1E Closed AND

Pump Breaker Closed

END

Close P1E

Close P01 Breaker

Close XV P1E

Close P01

Breaker

1 - s

TrueTrue





Figure 7.2-14: MV Mainline Pump Set P01 Line-Up Sequence


END

Close Pump P01 Discharge

Valve, Open Bypass Valve

Close XV P1E

Open XV P1K

2 -s

XV P1E close AND XV P1K open AND

No other Mainline Pump Maximum demand inhibit

Open Pump B01

Discharge Valve

Open

XV P1E

5 -s

XV P1E open

Start Mainline

Pump P01

Start Pump P01

3 -s

Mainline Pump P01 running

Wait 5 secWait

5 Sec

4 -s

Timer Expired

5s

START

Abort Sequence1 -s






P01 Offline & Flush = Abort, Idle or Complete


TRANSNET PIPELINES






START

StopPump P01

1 -s

Pump P01 stopped OR not Avail

XV B1E close

OR not Avail

END

Stop P01

Close P1EClose

XV P1E

3 -s

P01 Online & Flush = Abort, Idle or CompleteP01 Online & Flush = Abort, Idle or Complete





logging.

Open XVP1K

2 -s

Pump P01 Bypass valve open OR not Avail

Open P1K

Figure 7.2-16: MV Mainline Pump Set P01 Set Offline Sequence

TRANSNET PIPELINES





7.2.7 Lube Oil Device Group (24” MPP Stations)

7.2.7.1 Lube Oil Online Sequence

END

Lube Oil 1

Available

X21 Running

OR not Avail

Start X21

Lube Oil 1

Not Available

Start

X21

2 - s

Lube Oil 1

AvailableLube Oil 1

1 0s

Lube Oil 2

Available

X22 Running

OR not Avail

Start X22

Lube Oil 2

Not Available

Start

X22

4 - s

Lube Oil 2

AvailableLube Oil 2

3 0s

Lube Oil 3

Available

X23 Running

OR not Avail

Start X23

Lube Oil 3

Not Available

Start

X23

6 - s

Lube Oil 3

AvailableLube Oil 3

5 0s

START

Offline = Abort, Idle or

Complete





logging.

Figure 7.2-17: Lube Oil Online Sequence

7.2.7.2 Lube Oil Offline Sequence

START

END

Stop X21

Stop X22

Stop X23

1

X21 Stopped OR not Avail AND

X22 Stopped OR not Avail AND

X23 Stopped OR not Avail

Stop X21, X22, X23

- s

Wait

60 sec Timer Expired

2 - s

Stop

P01, P02, P03

Fan Duty Standby

P01, P02, P03 Fan Duty

Standby Stopped

3 - s

Stop P01, P02, P03 Fan

Duty Standby

Start Delay Timer

Online = Abort, Idle or

Complete

60s





logging.

Figure 7.2-18: Lube Oil Offline Sequence

TRANSNET PIPELINES





TRANSNET PIPELINES





7.2.8 HP Routing Device Group

7.2.8.1 HP Routing Isolation Online Sequence

START

Open

XV I1E

1

XV I1E Opened

END

Open I1E

-s

TNI Offline = Abort,

Idle or Complete





Figure 7.2-19: HP Routing Isolation Online Sequence (TNI)

7.2.8.2 HP Routing Isolation Offline Sequence

START

Close XV I1E

Close XV D1F

Close XV D2F

Close XV D3F

Close XV D4F

Close XV D8F

10

XV I1E Closed OR not Avail AND

XV D1F Closed OR not Avail AND




XV D8F Closed OR not Avail

END

Close I1E,

D1F, D2F,D3F,D4F, D8F

0s

TNI Online = Abort,

Idle or Complete





logging.

Close XV D1E

Close XV D2E

Close XV D3E

Close XV D4E

Close XV D8E

11

XV D1E Closed OR not Avail AND




XV D8E Closed

Close D1E, D2E, D3E, D4E,

D8E

0s

Stop Duty controllerStop Duty control

1

Duty controller stopped

-s

Start P01 Offline

sequenceStart P01 Offline

2

P01 Offline OR not Avail

-s

Interlock P01Interlock P01

3

True

-s

P01 Automatic P01 Not Automatic

WaitWait

4 10s

Start P01 Offline


4


-s


5

True

-s


WaitWait

6 10s

Start P03 Offline


7


-s


8

True

-s


WaitWait

9 10s

Figure 7.2-20: HP Routing Isolation Offline Sequence (TNI)

TRANSNET PIPELINES





7.2.9 Sump & Intermix Transfer Device Group

7.2.9.1 Intermix Transfer Online Sequence

START

True

Open XV T1A

1 -S

XV T1A Open

X01 Running

END

Open T01 Route

Start X01Start X01

2 -S

All faults during the

process result in the

sequence aborting,

complete with all


event logging.

Figure 7.2-21: Intermix Transfer Online Sequence

7.2.9.2 Intermix Transfer Offline Sequence

START

Stop X01

1 -S

X01 Stopped OR

Not Available

XV T1A Closed OR

Not Available

END

Stop X01

Close RouteClose XV T1A

2 -S



sequence continuing,

complete with all


event logging.

True

TRANSNET PIPELINES





Figure 7.2-22: Intermix Transfer Offline Sequence

7.2.10 Sump Injection Device Group (Venturi)

7.2.10.1 Sump Injection Online Sequence

START

True

Open XV G1A

Open XV G1E

1 -S

XV G1A, XVG1E

Open

XV G1B Open

END

Open G1A

Open G1E

Open G1BOpen XV G1B

2 -S



sequence aborting,

complete with all


event logging.

Figure 7.2-23: Sump Injection Online Sequence

7.2.10.2 Sump Injection Offline Sequence

START

True

Close XV G1B

1 -S

XV G1B Closed OR

Not Available

XV G1A, XV G1E

Closed OR Not

Available

END

Close G1B

Close G1A,

Close G1E

Close XV G1A

Close XV G1E

2 -S



sequence continuing,

complete with all


event logging.

TRANSNET PIPELINES





Figure 7.2-24: Sump Injection Offline Sequence

7.2.11 Inhibitor/DRA Injection Device Group

7.2.11.1 Inhibitor/DRA Online Sequence

END

Start Inhibitor Pump X01Start X01

1

-s

Inhibitor Pump X01 Running

Stop Inhibitor

Pump X01

Stop Pump X01

2 -s

X01 Stopped

START

Abort Sequence3 -s

X01 Not AvailableGroup in MANUAL MOO

FT121 < 500 l/min OR Offline Request issued OR LT171 Low Level Trip ORHP Route Closed





Manifold Flow FT121 > 500 l/min

Figure 7.2-25: Inhibitor/DRA Online Sequence

TRANSNET PIPELINES





7.2.12 LP Routing – Product Device Group

7.2.12.1 LP Routing Intake Manifold Layout (Example)

XVH3A

CLIENT 2

CLIENT 1XVM1E ZVM1AFT811

XVM2E ZVM2AFT812 XVCC2

XVCM2

XVH1A XVCC1

XVCM1

XVH5A

CVH0J XVH0A XVY1KHP

MANIFOLD

PROVER

Figure 7.2-26: LP Routing Intake Manifold Layout (Example)

TRANSNET PIPELINES





7.2.12.2 LP Routing – PRDx Intake Route Tables

INTAKE MAN_1 Common Source

ROUTING VALVES Strainer

XV CV XV XV XV ZV ZV XV ZV XV ZV XV XV XV XV Flow

H0A H0J H1A H3A H5A S1A S1E M1E M1A M2E M2A CC1 CC2 CM1 CM2 Path

Client 1 to Line x x x x x x x x

x x x x x x x x

Client 2 to Line x x x x x x x x

x x x x x x x x

INTAKE MAN_1 Common

ROUTE AVAILABILITY Strainer Consignee Valves



Client 1 to Line a a a a/c a/c o/w b o/w b a o/w b a/c a a/c Yes

a a a a/c a/c o/w b o/w b a/c a o/w b a a/c Yes

Client 2 to Line a a a a/c a/c o/w b o/w b a o/w b a/c a/c a Yes

a a a a/c a/c o/w b o/w b a/c a o/w b a/c a Yes

INTAKE MAN_1 Common

OPEN ROUTE INDICATION Strainer Consignee Valves



Client 1 to Line o/w b o/w b o/w b c o/w b o/w b Yes

o/w b o/w b o/w b c o/w b o/w b Yes

Client 2 to Line o/w b o/w b o/w b c o/w b o/w b Yes

o/w b o/w b o/w b c o/w b o/w b Yes

INTAKE MAN_1 Common

ONLINE INDICATION Strainer Consignee Valves



Client 1 to Line o/w b o/w b o/w b o/w b o/w b o/w b o/w b Yes

o/w b o/w b o/w b o/w b o/w b o/w b o/w b Yes

Client 2 to Line o/w b o/w b o/w b o/w b o/w b o/w b o/w b Yes

o/w b o/w b o/w b o/w b o/w b o/w b o/w b Yes

Prover

Route

Source Prover

Destination Prover

Consignors

Route

Source Prover

Route

Meter 1 Meter 2

Meter 1 Meter 2

Meter 1 Meter 2

Meter 1 Meter 2

Route

Source

Table 7.2-1: LP Routing - PRDx Intake Route Tables

Legend:

a = available a/c = available or closed o = open c = closed c/wb = closed or wirebreak o/wb = open or wirebreak h = high l = low (* denotes an OR condition)

TRANSNET PIPELINES





7.2.12.3 LP Routing – PRDx Open Route Sequence (Intake Manifold)

START

Close XVM1E

Close XVCC1

Close XVCC1A

2 -s

END

XVH1A Closed

M2E, CC!, CC2, CM1, CM2

Closed OR N/A AND

CC1A, CC2A, CM1A, CM2A

Closed





logging.

Close XVM2E

Close XVCC1

Close XVCC1A

Close XVCC2

Close XVCC2A

Close XVCM1

Close XV CM1A

Close XV CM2

Close XVCM2A

1 -s

Close valves

associated with second

meter run (dual meter

manifolds) and all

consignor valves

M1E, CC1 Closed OR N/A AND

CC1A Closed

XVH1A Not Closed

Close selected product

meter outlet and

consignor valve

Open XVCC1

Open XVCC1A

Open XVH0A

3 -s

CC!, H0A Open OR NA AND

CC1A Open

Open selected product

consignor, common

header valves

Figure 7.2-27: LP Routing – PRDx Open Route Sequence (Intake)

TRANSNET PIPELINES





7.2.12.4 LP Routing – PRDx Start Intake Sequence (Intake Manifold)

START

Close XVM2E

Close XVCC2

Close XVCC2A

Close XVCM1

Close XVCM1A

Close XVCM2

Close XVCM2A

INT Close XVH3A

INT Close XVH5A

3 -s

M2E, CC2, CM1, CM2, H3A, H5A

Closed OR Not Avail AND

CC2A, CM1A, CM2A Closed

END

Open XVM1E

2 -s





logging.

M1E Open

H1A Open

True

Open XVH1A

1





-s

Open selected Product

Header valve

Open selected Product

Meter Outlet valve

Close Previous

Route valves,

including cross

product header

valves

Figure 7.2-28: LP Routing – PRDx Start Intake Sequence

TRANSNET PIPELINES





7.2.12.5 LP Routing – PRDx Stop Intake Sequence (Intake Station)

START

Close XVM1E

Close XVM2E

Close XVCC1

Close XVCC1A

Close XVCC2

Close XVCC2A

Close XVCM1

Close XVCCMA

Close XVCM2

Close XVCM2A

3 -s

END

XVH3A Closed AND

XVH5A Closed

H0A Closed OR N/A





logging.

Close XVH0A

1 -s

Close common header

valve

M1E, M2E, CC1, CC2,

CM1, CM2 Closed OR N/A

AND

CC1A, CC2A, CM1A, CM2A

Closed

XVH3A Not Closed OR

XVH5A Not Closed

Close same product

dual meter manifold

valves

Close XVH1A

2 -s


header valve

H1A Closed OR N/A

Figure 7.2-29: LP Routing – PRDx Stop Intake Sequence

TRANSNET PIPELINES





7.2.12.6 LP Routing Delivery Manifold Layout (Example)

XVH3B

CLIENT 2

CLIENT 1

XVCM1

XVCC1

XVT2A

XVM1AZVM1E FT811

XVM2AZVM2E FT812XVDM2

XVDC2

XVT2C

ZVS1E ZVS1A XVH1B

A01

XVDM1

XVDC1

XVT2BT2T2

XVH5B

CVH0J XVH0A

XVH1C CVA1J

XVH5A

XVH3A

XVH1AHP

MANIFOLD

XVT2EZVA1A

S01

X01XVG1E CVG1J

T1T1XVT1EZVX1A

T2T2

BLEND

ACC TANK

TRANSFER

Figure 7.2-30: LP Routing Delivery Manifold Layout (Example)

TRANSNET PIPELINES





7.2.12.7 LP Routing – PRDx Delivery Route Tables

DELIVERY MAN_1 Common

ROUTING VALVES Strainer Meter 1 Meter 2 Rack 1 Rack 2 Blend

XV CV XV XV XV XV XV XV XV ZV XV A CV ZV ZV XV ZV XV ZV XV XV XV XV XV XV XV XV XV XV Flow

H0A H0J H1A H1B H3A H3B H5A H5B T1E A1A H1C 01 A1J S1A S1E M1A M1E M2A M2E DC1 DM1 T2B DC2 DM2 T2C CC1 CM1 T2A G1E Path

Line to CC1 x x x x x x x x x x

x x x x x x x x x x

Line to CM1 x x x x x x x x x x

x x x x x x x x x x

Line to Tank T2 x x x x x x x x x x

x x x x x x x x x x

Tank T2 to CC1 x x x x x x x x x x

x x x x x x x x x x

Tank T2 to CM1 x x x x x x x x x x

x x x x x x x x x x

Tank T2 to T2 x x x x x x x x x x

x x x x x x x x x x

DELIVERY MAN_1 Common

ROUTE AVAILABILITY Strainer Meter 1 Meter 2 Rack 1 Rack 2 Consignee Valves Blend

XV CV XV XV XV XV XV XV XV ZV XV A CV ZV ZV XV ZV XV ZV XV XV XV XV XV XV XV XV XV XV Flow Tank

H0A H0J H1A H1B H3A H3B H5A H5B T1E A1A H1C 01 A1J S1A S1E M1A M1E M2A M2E DC1 DM1 T2B DC2 DM2 T2C CC1 CM1 T2A G1E Path Level

Line to CC1 a a a a a/c a/c a/c a/c a/c o/w b o/w b a o/w b a/c a a/c a/c a/c a a/c Yes

a a a a a/c a/c a/c a/c a/c o/w b o/w b a/c a o/w b a/c a a/c a/c a a/c Yes

Line to CM1 a a a a a/c a/c a/c a/c a/c o/w b o/w b a o/w b a/c a/c a a/c a/c a a/c Yes

a a a a a/c a/c a/c a/c a/c o/w b o/w b a/c a o/w b a/c a/c a a/c a a/c Yes

Line to Tank T2 a a a a a/c a/c a/c a/c a/c o/w b o/w b a o/w b a/c a/c a/c a a/c a a/c Yes Not AH

a a a a a/c a/c a/c a/c a/c o/w b o/w b a/c a o/w b a/c a/c a/c a a a/c Yes Not AH

Tank T2 to CC1 c c c c c c a o/w b a a a o/w b o/w b a o/w b a/c a a/c a/c a/c a a/c Yes

c c c c c c a o/w b a a a o/w b o/w b a/c a o/w b a/c a a/c a/c a a/c Yes

Tank T2 to CM1 c c c c c c a o/w b a a a o/w b o/w b a o/w b a/c a/c a a/c a/c a a/c Yes

c c c c c c a o/w b a a a o/w b o/w b a/c a o/w b a/c a/c a a/c a a/c Yes

Tank T2 to T2 c c c c c c a o/w b a a a o/w b o/w b a o/w b a/c a/c a/c a a/c a a/c Yes Not AH

c c c c c c a o/w b a a a o/w b o/w b a/c a o/w b a/c a/c a/c a a a/c Yes Not AH

DELIVERY MAN_1 Common Destination

OPEN ROUTE INDICATION Strainer Meter 1 Meter 2 Rack 1 Rack 2 Consignee Valves Blend



Line to CC1 o/w b o/w b o/w b c o/w b o/w b c c c c Yes

o/w b o/w b o/w b c o/w b c o/w b c c c Yes

Line to CM1 o/w b o/w b o/w b c o/w b o/w b c c c c Yes


Line to Tank T2 o/w b o/w b o/w b c o/w b o/w b c c c c Yes


Tank T2 to CC1 o/w b o/w b c o/w b o/w b c o/w b o/w b c c c c c Yes

o/w b o/w b c o/w b o/w b c o/w b c o/w b c c c c Yes

Tank T2 to CM1 o/w b o/w b c o/w b o/w b c o/w b o/w b c c c c c Yes


Tank T2 to T2 o/w b o/w b c o/w b o/w b c o/w b o/w b c c c c c Yes


DELIVERY MAN_1 Common Destination

ONLINE INDICATION Strainer Meter 1 Meter 2 Rack 1 Rack 2 Consignee Valves Blend



Line to CC1 o/w b o/w b o/w b c/w b o/w b o/w b o/w b o/w b o/w b o/w b Yes

o/w b o/w b o/w b c/w b o/w b o/w b o/w b o/w b o/w b o/w b Yes

Line to CM1 o/w b o/w b o/w b c/w b o/w b o/w b o/w b o/w b o/w b o/w b Yes


Line to Tank T2 o/w b o/w b o/w b c/w b o/w b o/w b o/w b o/w b o/w b o/w b Yes


Tank T2 to CC1 c/w b o/w b o/w b o/w b r o/w b o/w b o/w b o/w b o/w b o/w b Yes

c/w b o/w b o/w b o/w b r o/w b o/w b o/w b o/w b o/w b o/w b Yes

Tank T2 to CM1 c/w b o/w b o/w b o/w b r o/w b o/w b o/w b o/w b o/w b o/w b Yes


Tank T2 to T2 c/w b o/w b o/w b o/w b r o/w b o/w b o/w b o/w b o/w b o/w b Yes


Route

Prover

Route

Prover

Route

Route

Source

Source

TanksSource

Prover

Prover

Destination

Consignee Valves

Destination

Source

Table 7.2-2: LP Routing - PRDx Delivery Route Tables

Legend:

a = available a/c = available or closed o = open c = closed

TRANSNET PIPELINES





c/wb = closed or wirebreak o/wb = open or wirebreak h = high l = low (* denotes an OR condition)

TRANSNET PIPELINES





7.2.12.8 LP Routing – PRDx Open Route Sequence (Delivery Manifold)

START

XVH1B Closed AND

XVH3B Closed AND

XVH5B Closed

Close XVH0A

1 -s

H1A/B Closed OR N/A AND



G1E Closed OR N/A

Close XVH1A/B

INT Close XVH3A/B

INT Close XVH5A/B

INT Close XVG1E

H0A Closed OR N/A

2 -s

Close H0A

Close Source valves,

Set other product

header valves to Auto

and Closed

XVH1B Not Closed OR

XVH3B Not Closed OR

XVH5B Not Closed

Close XVM1A

Close XVDM1

Close XVT2B

Close XVCC1

Close XVCC1A

4 -s

END

XVH1B Closed

M2E, DM2, DC2, T2C, CC!, CM1,

T2A Closed OR N/A AND

CC1A/B, CM1A/B, T2AA/B Closed





logging.

Close XVM2A

Close XVDM2

Close XVDC2

Close XVT2C

Close XVCC1

Close XVCC1A/B

Close XVCM1

Close XVCM1A/B

Close XVT2A

Close XVT2AA/B

3 -s

Close valves

associated with second

meter run (dual meter

manifolds) and all

consignor valves

M1A, DM1, T2B, CC1 Closed OR N/A

AND

CC1A Closed

XVH1B Not Closed


meter outlet,

distribution and

consignor valves

Open XVDC1

Open XVCC1A

Open XVH0A

5 -s

DC!, H0A Open OR NA AND

CC1A Open


consignor, common

header valves

Figure 7.2-31: LP Routing – PRDx Open Route Sequence (Delivery)

TRANSNET PIPELINES





7.2.12.9 LP Routing – PRDx Start Delivery Sequence (Delivery Manifold)

START

Close XVM2A

Close XVDM1

Close XVT2B

Close XVDM2

Close XVDC2

Close XVT2C

Close XVCC1B

Close XVCM1

Close XVCM1A/B

Close XVT2A

Close XVT2AA/B

INT Close XVH3A

INT Close XVH3B

INT Close XVH5A

INT Close XVH5B

4 -s

M2A, DM1, T2B, DM2, DC2,

T2C, CM1, T2A, H3A, H3B,

H5A, H5B Closed OR Not Avail

AND

CC1B, CM1A/B, T2AA/B Closed

END

Open XVH1B

2 -s

H0A, H1A Open





logging.

Open XVH0A

Open XVH1A

H1B Open

M1A AND

H1A Closed

True

Open XVM1A

Close XVH1A

1





3 -s

-s


Meter Inlet valve and

close product header

ball valve

Open Product Header

EPV valve

Open Product Header

ball valve and

Common Header valve

(H0A Set to Auto and

Open)

Close Previous

Route valves,

including cross

product header

valves

Figure 7.2-32: LP Routing – PRDx Start Delivery Sequence

TRANSNET PIPELINES





7.2.12.10 LP Routing – PRDx Stop Delivery Sequence (Delivery Manifold)

START

Close XVM1A

Close XVM2A

Close XVDC1

Close XVDM1

Close XVT2B

Close XVDC2

Close XVDM2

Close XVT2C

Close XVCM1

Close XVCC1

Close XVT2A

Close XVG1E

Close XVCC1A/B

Close XVCM1A/B

Close XVT2AA/B

4 -s

M1A, M2A, DC1, DM1, T2B, DC2,

DM2, T2C, CM1, CC1, T2A, G1E

Closed OR Not Avail AND

CC1A/B, CM1A/B, T2AA/B Closed

END

Close CVH0J

1 20s

H0A Closed or Not Avail





logging.

XVH3A Closed AND

XVH5A Closed

Close XVH0A

Minimum Step Time

exceeded

2 -s

Close XVH1A

Close XVH1B

3 -s

XVH3A Not Closed OR

XVH5A Not Closed

H1A, H1B Closed or Not

Avail

Close Common

Header valve (Set to

Auto and Open)

Close same

product Dual Meter

Manifold valves

Close CVH0J (Set to

Auto and Open)

Close selected Product

Header valve

Figure 7.2-33: LP Routing – PRDx Stop Delivery Sequence

TRANSNET PIPELINES





7.2.13 Prover Device Group

7.2.13.1 Prover Availability Table

XV

Y1A

XV

Y1E

XV

Y1K

XV

Y1V

XV

Y2V

XV

F1A

XV

F1B

LSH

861

LSL

862

LSH

863

LSL

864

Content XV

F1R

X01 XV

F1E

LT

861

Prover Online a a a c c c c PRDx

Prover Offline a a a

PRDx Fill c c a a a a l* l* PRDx/Empty a a a Not empty

PRDx Drain c c a a a a h* h* PRDx a a a Not full

Y01

PRDx

Manifold Prover Transfer

Full

Table 7.2-3: Prover Y01 Availability

Legend:

a = available a/c = available or closed o = open c = closed c/wb = closed or wirebreak o/wb = open or wirebreak h = high l = low (* denotes an OR condition)

7.2.13.2 Prover Online Sequence

START

Open XV Y1A

Open XV Y1E

1 - s

XV Y1A Open AND

XV Y1E Open

XV Y1K Closed

END

Open Y1A, Y1E

Close XV Y1K

2 - s

Close Y1K

ULSD 1 Offline =






Figure 7.2-34: Prover Y01 Online Sequence

TRANSNET PIPELINES





7.2.13.3 Prover Offline Sequence

START

Open XV Y1K

1 - s

XV Y1K Open

XV Y1A closed AND

XV Y1E closed

END

Open Y1K

Close Y1A, Y1EClose XV Y1A

Close XV Y1E

2 - s

ULSD 1 Online =






Figure 7.2-35: Prover Y01 Offline Sequence

TRANSNET PIPELINES





7.2.13.4 Prover Fill Sequence

START

Open XV Y1V

Open XV Y2V

Open XV F1A

Open XV F1B

Open XV F1E

Reverse XV F1R

1 -s

Open Y1V, Y2V, F1A, F1B,

F1E

Close F1RXV Y1V open AND

XV Y2V open AND

XV F1A open AND

XV F1B open AND

XV F1E open AND

XV F1R reverse

Start X02

2 -s

Start transfer pump

X02 running

3 -s

LT861 low trip OR

FS861 not active

Wait till tank empty or pump

no flow

Close XV F1A

Close XV F1B

5 -s

Close F1A, F1B

XV F1A closed OR not Avail AND

XV F1B closed OR not Avail

Stop X02

Close XV F1E

Close XV F2E

Forward XV F1R

6 -s

Stop X02

Close F1E, F2E

Open F1R

X02 stopped OR not Avail AND

XV F1E Closed OR not Avail AND

XV F2E Closed OR not Avail AND

XV F1R forward OR not Avail

END

Close XV Y1V

Close XV Y2V

4 -s

XV Y1V closed OR not Avail AND

XV Y2V closed OR not Avail

Close Y1V, Y2V

Opening

Closing

Drain = Abort, Idle or

Complete

Drain = Abort, Idle or

Complete





logging.





Figure 7.2-36: Prover Y01 Fill Sequence

TRANSNET PIPELINES





7.2.13.5 Prover Drain Sequence

Figure 7.2-37: Prover Y01 Drain Sequence

START

Open XV Y1V

Open XV Y2V

Open XV F1A

Open XV F1B

Open XV F1E

Forward XV F1R

2 -s

Open Y1V, Y2V, F1A, F1B,

F1E, F1R

XV Y1V open AND

XV Y2V open AND

XV F1A open AND

XV F1B open AND

XV F1E open AND

XV F1R forward

Start X02

3 -s

Start X02

X02 running

4 -s Wait till all prover switches

indicate empty or pump no

flow

6 -s

Wait 20 sec before checking

levels again

LSH861 not low OR

LSL862 not low OR

LSH863 not low OR

LSL864 not low

LSH861 low AND

LSL862 low AND

LSH863 low AND

LSL864 low

Opening

Fill = Abort, Idle or

Complete

Fill = Abort, Idle or

Complete

20s





LSH861 low AND

LSL862 low AND

LSH863 low AND

LSL864 low

FS861 not active

Count FS Trips

5 -s

Count FS Trips

Not More then 3 Trips More then 3 Trips

ABORT

Close XV F1A

Close XV F1B

7 -s

Close F1A, F1B

XV F1A closed OR not Avail AND

XV F1B closed OR not Avail

Stop X02

Close XV Y1V

Close XV Y2V

Close XV F1E

Reverse XV F1R

8 -s

Stop X02

Close Y1V, Y2V, F1E, F1R

X02 stopped OR not AvailXV Y1V closed OR not Avail AND

XV Y2V closed OR not Avail AND

XV F1E closed OR not Avail AND

XV F1R reverse OR not Avail

END

Closing





logging.

TRANSNET PIPELINES





7.2.14 Intermix Blend Device Group

7.2.14.1 Intermix Blend Online Sequence

START

Source 8508

(Tank T05)

Close XVT4E

Open XVT5E

Close XVT6E

Close XVT7E

2 -s

T5E Open AND

T4E, T6E, T7E Closed

Open XVG1R

Open XVT4A/T4B

Close XVG1E

Close XVG3E

Close XVG5E

Close XVT6B

Close XVT7B

Close XVX1E

5 -s

G1R, T4A, T4B Open

AND G1E, G3E, G5E,

T6B, T7B, X1E Closed

Start X05

Interlock Open

CVG0J

6 -s

Interlock Closed

CVG0J

8 -s

Recirc Volume Reached

Close XVG1R

Close XVT4A/T4B

-s

END

Recirc Volume

Reached

7 -s

X05 Running AND CVG0J Open





logging.





Source 8408

(Tank T04)

Open XVT4E

Close XVT5E

Close XVT6E

Close XVT7E

T4E Open AND


Source 8608

(Tank T06)

Close XVT4E

Close XVT5E

Open XVT6E

Close XVT7E

T6E Open AND


Source 8708

(Tank T07)

Close XVT4E

Close XVT5E

Close XVT6E

Open XVT7E

T7E Open AND


1 -s 3 -s 4 -s

CVG0J Closed

Destination 32

(MAN2)

Open XVG3E

-s

G3E Open

Destination 31

(MAN1)

Open XVG1E

G1E Open

Destination 33

(MAN3)

Open XVG5E

G5E Open

-s -s

G1R, T4A, T4B Closed

Remove CVG0J

Interlock

-s

CVG0J Interlock

removed

Recirc

Open Blend

From Tank

Open Route to

Recirc Tank

(T0$)

Start Blend

Pump, Open

Blend Control

valve (Set to

Auto and Open)

Recirc Volume

Reached?

Close Blend

Control valve

(Set to Auto and

Close)

Open Blend Inlet

valve

Close Recirc

valves

Set Blend

Control valve to

control

9 10 11

12

13

Figure 7.2-38: Intermix Blend Online Sequence (WAO)

TRANSNET PIPELINES





7.2.14.2 Intermix Blend Offline Sequence

START

True

Stop X05

1 -s

X05 Stopped or Not

Avail

Close XVG1E

Close XVG3E

Close XVG5E

2 -s

G1E, G3E, G5E Closed

or Not Avail

T4E, T5E, T6E, T7E, G1R

Closed or Not Avail

Close XVT4E

Close XVT5E

Close XVT6E

Close XVT7E

Close XVG1R

3 -s

END





logging.

Stop Blend

Pump

Close all Blend

valves

Close Tank

Outlet valves

Figure 7.2-39: Intermix Blend Offline Sequence (WAO)

TRANSNET PIPELINES





7.2.15 Station Sequences

7.2.15.1 Station Line-Up Sequence

True

Start

Segmentation

Online Sequence

2 -s

Segmentation Open Sequence

Completed OR Aborted OR Idle

Start Segmentation

Online Sequence

Start HP Online

Sequence

3 -s

HP Online Sequence Completed

OR Aborted OR Idle

P0x Not Ready

OR Mixed MoC

Start Lube Oil

Online Sequence

4 -s

Lube Oil Online Sequence


Start Lube Oil

Online Sequence

Start Main

Pumphouse

Ventilation Duty

Controller

5 -s

Main Pumphouse Ventilation Duty

Controller Running

Start Main Pumphouse

Ventilation Control

Note: Any failure shall


continuing, complete with

all associated alarming and

event logging.

Start P0x

Line-up

Sequences

Start P0x Line-up

Sequences

1 60s

P0x Line-up Sequence


P0x Ready AND

Not Mixed MoC

Start HP Online

Sequence

END

START

Figure 7.2-40: Station Line-Up Sequence (TNI)

7.2.15.2 Station Online Sequence

Note: Step 1 does not apply

to TNI, only MBT and HTP

START

END

Open Mainline Pumps

Bypass ValveOpen XV N1K

1 -s

True

XV N1K Opened

Start Station Duty ControllerStart Station Duty

Controller

2 10s

Station Duty Controller

ActiveNote: Any failure shall




event logging.

Figure 7.2-41: Station Online Sequence (TNI)

7.2.15.3 Station Offline Sequence

START

END

Start Segmentation Offline Sequence

Start

Segmentation

Offline Sequence

1 -s

True

Segmentation Close

Sequence Completed OR

Aborted OR Idle





event logging.

Figure 7.2-42: Station Offline Sequence (TNI)

TRANSNET PIPELINES





7.2.15.4 Station Isolation Sequence

Start HP Offline

Sequence

START

END

Open Pump BreakersOpen Pump

Breakers

2 -s

1 -s

HP Offline Sequence

Completed OR Aborted OR

Idle

Start Lube Oil

Offline Sequence

4 3s

Timer expired

Lube Oil Offline Sequence

Completed OR Aborted OR

Idle

Stop Main

Pumphouse

Ventilation Control

5 -s

Ventilation Duty Controller

Stopped

Start HP Offline Sequence

Start Lube Oil Offline

Sequence

Stop Main Pumphouse

Ventilation Duty ControllerWaiting Time

3 30s

Wait for Lube Oil

Stopping Timer

True

Pump Breakers Open

OR Fault





event logging.

Figure 7.2-43: Station Isolation Sequence (TNI)

[Type here]

Page 323 of 326 Originator: Vasu Govender Original date: 20/03/2016 Always refer to the electronic copy for the latest version.

7.2.15.5 Station Flush Sequence

START

END

1

Launcher Flush Sequence

Completed OR Aborted OR IdleStrainer Flushed or Not Ready

True



continuing, although the

individual flush sequence

aborts, complete with all


event logging.

Receiver Flush Sequence


Start Receiver

Flush SequenceFlush Receiver

5 -s

Receiver Ready AND

Not Mixed MoC

Receiver Not Ready

OR Mixed MoC

Start Launcher

Flush SequenceFlush Launcher

Launcher Ready AND

Not Mixed MoC

Launcher Not Ready

OR Mixed MoC

6 -s

Start Strainer

Flush Sequence

Enable Strainer

Software

7 -s

Pump Flush Sequence


Start Pump Flush

SequenceFlush Pumps

At Least One Pump

Flush Available and

Not Mixed MoC

No Pump Flush

Available OR Mixed

MoC

8 -s

Strainer Not ReadyStrainer Ready

Figure 7.2-44: Station Flush Sequence (TNI)

[Type here]

Page 324 of 326 Originator: Vasu Govender Original date: 20/03/2016 Always refer to the electronic copy for the latest version.

7.2.15.6 MV Mainline Pump P01-P03 Flush Sequence

END

Flow > 9000 l/m Flow =< 9000 l/m

START

True

Flow =< 12000 l/m

P02 and P03 not online P02 and P03 online

P01 online

P02 Ready and Not Mixed MoC


P02 and P03Not Ready or Mixed MoC

Flush P02

1Start P02

flushing

sequence

- s

Flush P03

2Start P03

flushing

sequence

- s

P02 flush complete or aborted or idle

P03 flush completeor aborted or idle

P01 and P03 not online P01 or P03 online

P02 online




Flush P01

3Start P01

flushing

sequence

- s

Flush P03

4Start P03

flushing

sequence

- s

P01 flush complete or aborted or idle


P01 and P02 not online P01 or P02 online

P03 online




Flush P01

5Start P01

flushing

sequence

- s

Flush P02

6Start P02

flushing

sequence

- s



Flow > 12000 l/m

P01 online ORNot Ready or Mixed MoC

Flush P01

7Start P01

flushing

sequence

- s


P01 not Online AND Ready AND not Mixed MoC


Flush P02

8Start P02

flushing

sequence

- s




Flush P03

9Start P03

flushing

sequence

- s



Figure 7.2-45: MV Mainline Pump P01-P03 Flush Sequence (TNI)

TRANSNET PIPELINES





7.3 Comment Resolution

Item Section Comment / Clarification

Response Date / Rev

Originated

Comment Source

Comment Status

Approval Status

TRANSNET PIPELINES





7.4 DOCUMENT CHANGE HISTORY:

The owner of this document is responsible for the revision and control of the document,

including updating of the table below, which contains the history of the document with

details of each revision.

Date Previous

Rev No.

New

Rev No.

Details of Revision

13/06/2016 00 00 New Template

This table summarises what has been changed in the document so that it is easy to keep track of the effected changes.