Control Narrative Logic

for the new

"CRUDE OIL MAIN PUMP"
item D8-PAX60122B
DS-8 CRUDE EXPORT SYSTEM DESCRIPTION
The Crude Export System at DS-8 is comprised of four (4) Booster Pumps and four (4) Crude Oil
Main Pumps.
The Booster Pumps and Main Pumps operate in series. The Crude Oil Main Pumps are connected
in parallel.
The pumps have been divided into two groups, an East Station and a West Station:
The pumps arrangement is presented diagrammatically below:

All four (4) of the Booster Pumps and three (3) of the Crude Oil Main Pumps are existing units.
The existing units are controlled by an existing relay based logic control system. The 4th Crude Oil
Main Pump, D8-PAX601022B, is new and will be controlled by a new PLC based system. This
PLC based system will be housed in a new Main Control Panel, OIP601022, and associated unit

rev. 03 08-01-2014

control panel ACP601022B. A control cabinet has been provided to allow future conversion of the
control system for D8-PAX601022A should that be desired.
The Control Narratives described herein relate strictly to 4th Crude Oil Main Pump, D8PAX601022B.

DS8 CRUDE EXPORT SYSTEM OPERATION

A number of potential operating scenarios have been included in the design:
1. Booster Pumps Only
2. East Station and/or West Station Independent Operation
3. Combined Mode
Booster Pumps Only
In this arrangement no Crude Oil Main Pumps are in operation. From 1 to 4 Booster Pumps may
operate to ship the crude.
Station Basis
In this arrangement the Booster Pump(s) from the respective Station feed only their respective
Crude Oil Main Pump(s). The manual Isolation Valve is Closed in this case. The number of
Booster Pumps must equal the number of Crude Oil Main Pumps in operation at each station,
either 1 or 2 pump sets at each Station.
Common Basis
In this arrangement all operating Booster Pump(s) feed a common suction header for the Crude
Oil Main Pump(s). The manual Isolation Valve is Open in this case. The number of Booster
Pumps must equal the number of Crude Oil Main Pumps in operation, from 1 to 4 pump sets.

rev. 03 08-01-2014

DESCRIPTION OF OPERATION "CRUDE OIL MAIN" PAX60122B

Pls refer to:

- 084488_P&ID piping & instrument diagram.

- 084488_LCP local control panel lay-out & wiring diagram.
- 084488_MCP_1 main control panel lay-out.
- 084488_MCP-2 main control panel wiring diagram.
- 084488_LOG logic diagram.
- 084488_HMI HMI Operating Procedure (EMB A4-C139-752).
LCP = Local Control Panel tag IQD8-LCP601022B
MCP = Main Control Panel tag ACP601022B
HMI = Human Main Interface (Touch-screen display) on the MCP tag OIP601022

A) - NORMAL START-UP
1. Pre-Set the Pump for Start-Up
Place OFF/LOCAL/AUTO key Selector Switch "HS-601022B-10" on LCP to AUTO
position. Note that if in the "OFF" position the pump cannot be started. Indication of this
switch position is provided at the MCP on HMI "XL-601022B-24" LOCAL and
"XL-601022B-25" AUTO.
Note that when main pump D8-PAX601022B is operating it will be not stopped if
OFF/LOCAL/AUTO selector switch "HS-601022B-10" is switched from LOCAL to
AUTO position, and vice versa. The pump will stop if the Selector switch is positioned to
"OFF".
2. Select The Operating Mode
Select "Booster Pumps - Station Basis or Common Basis via software selector switch
"HS-601022A/B-22" on HMI (common page for all main pumps D8-PAX601022A, D8PAX601022B & D8-PAX6012A, D8-PAX6012B).
Station Basis:

It is assumed that the manual Isolation Valve is closed and that the
Booster Pump(s) are providing flow only to their respective Crude Oil
Main Pump(s). In order for D8-PAX601022B to receive a Start
permissive signal, there must be one more dedicated Booster Pump
operating than Crude Oil Main Pump operating. If D8-PAX601022A is
not operating then either D8-PAX601021A or D8-PAX601021B must
be running. If D8-PAX601022A is operating then both D8PAX601021A and D8-PAX601021B must be running to permit the 4th
Crude Oil Main Pump to start.

Common Basis: It is assumed that the Isolation Valve is open and that the Booster
Pump(s) are providing flow to the suction header to the Crude Oil
Main Pump(s). In order for D8-PAX601022B to receive a Start
permissive signal, there must be one more dedicated Booster Pump
operating than Crude Oil Main Pumps operating.

rev. 03 08-01-2014

The selection of Station Basis or Common Basis is indicated at the HMI, "XL601022A/B-22" or "XL-601022A/B-23", and the LCP, "XL-601022B-15" or "XL601022B-16", respectively.
3. Set the time of timer "TIM-601022B-07" which controls the delay time for stop the main
pump, after dedicated booster pump is stopped.
4. Place LOCAL/OFF/REMOTE selector switch located on suction motor-driven valve
"MOV-601022B-01" in REMOTE position.
With the switch on "REMOTE" the opening and the closure of the valve is automatic
according to the logic described below.
5. Select LOCAL/OFF/REMOTE selector switch located on discharge motor-driven
valve "MOV-601022B-02" in REMOTE position.
With the switch on "REMOTE" the opening and the closure of the valve is automatic
according to the logic described below.
Note that with the switch in "LOCAL" for either "MOV-601022B-01" "MOV601022B-02" it's possible to initiate the opening or the closure of the valve using push
buttons on the electric actuator; this function will only be utilized in the case of a
Manual Start-up.
If OFF/LOCAL/AUTO key Selector Switch "HS-601022B-10" is in AUTO then
both MOVs must be set to AUTO in order for the normal start sequence to proceed.
REMOTE

6. Reset all shut-down conditions using Reset push-button "PB-601022B-15" on LCP.

Should bearing temperatures, seal failure or motor failure conditions exceed the
shutdown limits the start sequence will be inhibited.
7. The start-up sequence (motor-pump) is then initiated by pressing the Start push button
"PB-601022B-12" on LCP. Note that a Start push button "PB-601022B-02" has been
provided on the MCP to facilitate remote starting but this pushbutton has been disabled.
The start sequence will proceed automatically as follows:
7-1

The software timer "TIM-601022B-01" (PLC) which controls the time for start-up
sequence is activated. At the end of the time, if the Main Pump is not in operation
and the discharge valve is not open, the start-up sequence is interrupted.

7-2 The control system will check that the discharge valve "MOV-601022B-02" is in
Closed position via "ZSL-601022B-02"; if the valve is not closed, then the control
system will close it via a signal to the MOV.
Simultaneously with close command, the control system will insert software timer
"TIM-601022B-02" (PLC). At the end of the time, if the discharge valve is not close,
the start-up sequence is interrupted.

rev. 03 08-01-2014

7-3 The control system will check that the suction valve "MOV-601022B-01" is Open
via "ZSH-601022B-01". If it is not opened, the control system will open it via a
signal to the MOV.
Simultaneously with open command, the control system will insert software timer
"TIM-601022B-03" (PLC). At the end of the time, if the discharge valve is not close,
the start-up sequence is interrupted.
SUCTION
7-4 After confirmation is received that the suction valve is Open via "ZSH-601022B01" , with the suction pressure > = 4,5 kg/cm2 via "PIT-601022B-01" (suction
pressure non-low) and that the discharge valve is "Close" via "ZSL-601022B-02",
the control system will send a signal to the electric motor of the pump to start.
7-5 Simultaneously with electric motor start command, the control system will insert
software timer "TIM-601022B-04" (PLC) to override the interlock signal from pump
bearings housing vibration "XAHH-601022B-01" & "XAHH-601022B-02" and from
discharge pressure high "PAH-601022B-02".
7-6 When the motor starts a Motor Running signal will be provided from the Motor
Control Center (MCC) which is located elsewhere. This signal will provide Status at
the MCP and LCP, "XL-601022B-01" or "XL-601022B-11", respectively.
7-7 When the discharge pressure rises above 28,5 kg/cm2 via "PIT-601022B-02", the
control system will open the discharge motor-driven valve "MOV-601022B-02".
Simultaneously with open command, the control system will insert software timer
"TIM-601022B-05" (PLC). At the end of the time, if the discharge valve is not open,
the start-up sequence is interrupted.
7-8 Once the discharge valve is Open via "ZSH-601022B-02" and TIM-601022B-04"
(PLC) has timed out, if there are no vibration or discharge pressure alarms the system
will generate a "PUMP CONTINUE RUNNING" signal.
7-9 All timers are internal to the PLC and are adjustable via software tools. Preliminary
settings anticipated for the durations are indicated below:
TIMER (PLC)

DURATION

TIM-601022B-01

140 sec

TIM-601022B-02

70 sec

TIM-601022B-03

70 sec

TIM-601022B-04

60 sec

TIM-601022B-05

70 sec

TIM-601022B-06

24 hour

TIM-601022B-07

5 sec

TIM-601022B-08

300 sec

PLEASE REVIEW THIS LINE. FROM

084488_LDG REV.2, THE PIT-02
DOES NOT HAVE ANY INPUT TO
THE MOV-2 OPEN COMMAND.
EXISTING CONTROL IS FOR MOV-2
TO CONTINUE TO OPEN AFTER
PUMP START COMMAND PROVIDED
AND WILL HAVE A SHUTDOWN IF
NOT FULLY OPENED AFTER LAPSE
OF TIM-05.

rev. 03 08-01-2014

7-10 The "Sequence Reset" pushbutton "PB-601022B-14", is used to close suction &
discharge valves (initial position for start-up) with the following conditions:
- Main Pump not running.
- OFF/LOCAL/AUTO key Selector Switch "HS-601022B-10" on LCP to OFF.
- LOCAL/OFF/REMOTE selector switches located on suction & discharge motordriven valves in "REMOTE" position.
PLEASE CHECK THIS SETTING. FROM
084488_LDG, REV. 2, SHOULDN'T THIS
BE "AUTO"?

B) - MANUAL PUMP START-UP

1. Pre-Set the Pump for Start-Up
Place OFF/LOCAL/AUTO key Selector Switch "HS-601022B-10" on LCP to LOCAL
position.
2. Select The Operating Mode
Select "Booster Pumps - Station Basis or Common Basis via software selector switch
"HS-601022A/B-22" on HMI. See discussion under the Normal Start-up section.
REMOTE

3. Place LOCAL/AUTO selector switch located on suction motor-driven valve "MOV601022B-01" in LOCAL position and open the valve using the pushbuttons on the MOV.
REMOTE

4. Select LOCAL/AUTO selector switch located on discharge motor-driven valve "MOV601022B-02" in LOCAL position. Close the valve to suit, using the pushbuttons on the
MOV.
5. Reset all shut-down conditions using Reset push-button "PB-601022B-15" on LCP. Should
bearing temperatures, seal failure or motor failure conditions exceed the shutdown limits
the start sequence will be inhibited.
6. Set the time of timer "TIM-601022B-08" which controls the time for override position of
discharge valve, for pump start-up sequence.
7. Press the Discharge Valve Override push button "PB-601022B-19" on LCP for insertion
timer "TIM-601022B-08".
Note: If the timer is activated, it's possible to start the pump with the discharge
valve closed or open.

8. With suction valve open, suction pressure not low and discharge valve close or open, the
start-up sequence (motor-pump) is then initiated by pressing the Start push button "PB601022B-12" on LCP.
After that, all automatic control protective devices will be active.
Note that the control system will not override the motor protective circuit.

rev. 03 08-01-2014

9. With main pump running, if the discharge valve is close, open the valve using the
pushbuttons on the "MOV-601022B-02"

C) - MANUAL PUMP SHUTDOWN

1. The pump "PAX-601022B" may be manually stopped from the LCP, via "PB-601022B13", or from the MCP, via "PB-601022B-03".
The provision to manually stop "PB-601022B-30" the pump from a future/other remote
location has also been provided.
With these commands, we have:
- Stop main motor.
- Suction valve "MOV" closing command & Discharge valve "MOV"
closing command.
Note: After stop, is possible to re-start again the pump.
2. The pump "PAX-601022B" may be manually shut-down using "Emergency Stop
Pushbutton" in the LCP, via Emergency "PB-601022B-11", or from the MCP, via "PB601022B-01".
With these command, we have:
- Stop main motor
- Suction valve & discharge valve "MOV" opening & closing inhibition.
Note: After stop, start-up of the pump, is possible only after Shut-Down Reset
via "PB-601022B-15", and Sequence Reset via "PB-601022B-14" from LCP.

D) - AUTOMATIC (INTERLOCK) PUMP SHUTDOWN

The pump "PAX-601022B" will automatically shut-down via the control system under the
following conditions:
D1) - DISCHARGE VALVE POSITION - "MOV-601022B-02"

VALVE

After the start sequence has successfully completed if the discharge vale is not open
"ZSH-601022B-02".
D2) - SUCTION VALVE POSITION - "MOV-601022B-01"

SUCTION VALVE

After the start sequence has successfully completed if the discharge vale is not open
"ZSH-601022B-01".
D3) - PUMP CASING TEMPERATURE
When the pump casing temperature "TIT-601022B-02".
D4) - SUCTION LINE LOW PRESSURE
If the suction pressure is LOW (< 4,5 kg/cm2) via "PIT-601022B-01".
rev. 03 08-01-2014

D5) - DISCHARGE LINE LOW PRESSURE

After the start sequence has successfully completed if the discharge pressure is LOW
(< 24 kg/cm2) via "PIT-601022B-02".
D6) - DISCHARGE LINE HIGH PRESSURE
After the start-up sequence has successfully completed if the discharge pressure is still
HIGH (> 30 kg/cm2) via "PIT-601022B-02".
D7) - PLAN 65 SEAL LEAKAGE DETECTOR (N.D.E. and D.E.)
After the start-up sequence has successfully completed if either level switch "LSH601022B-01" or "LSH-601022B-02" trips after an adjustable time "TIM-601022B-06"
delay of 0 to 24 hours . The Restriction Orifice, RO-601022B-01/ 02, is sized to allow
a maximum of xx ml/minute to drain from the system without building level and
activating the LSH.
D8) - PUMP BEARING TEMPERATURE
When the pump bearing temperature is too high (> 95 C) "TIT-601022B-01" or
"TIT-601022B-03".
D9) - MOTOR BEARING TEMPERATURE
When the motor bearing temperature is too high (> 100 C) "TE-601022B-12" or
"TE-601022B-13".
D10) - MOTOR WINDING TEMPERATURE
When the motor winding temperature is too high (> 155 C) "TE-601022B-14
A/B/C/D/E/F".
D11) - PUMP BEARING HOUSING VIBRATION
After the start-up sequence has successfully completed if the vibration is still HIGH
(> 8,5 mm/s RMS) via "XT-601022B-01" or "XT-601022B-02".
D12) MOTOR FAILURE
Should the electric motor experience a problem it is protected by settings in its own
Motor Control Center (MCC) which is located elsewhere. Should the motor
shutdown or lock itself out to preclude subsequent start attempts, a signal will be
provided at the MCP and LCP, "XL-601022B-03" or "XL-601022B-13",
respectively.

rev. 03 08-01-2014

General Notes Applicable To All Shut-Downs

When the Crude Oil Main Pump PAX-601022B stops (due to a control interlock or manual
pushbutton) indication is provided at the LCP and MCP, "XL-601022B-14" and "XL601022B-04", respectively.
REMOTE

When the Crude Oil Main Pump PAX-601022B stops (due to a control interlock or manual
pushbutton) or the start-up sequence is interrupted, the closure of the suction valve "MOV601022B-01" and the closure of discharge valve "MOV-601022B-02" automatically occurs
if the LOCAL/AUTO selector switches located on suction/discharge motor-driven valve
"MOV-601022B-01/02" is in AUTO position.
All manual Stop pushbuttons are functional regardless of the position of HS-601022B10" on LCP, whether it is in Local or AUTO position.

ON BOTH LCP AND ON THE MOV'S

Note that when any working Crude Oil Main Pump stops there is no provision to
automatically start another Crude Oil Main Pump.
Should an operating Booster Pump stop there is no provision to automatically start another
Booster Pump or to directly shutdown an operating Crude Oil Main Pump. Individual Crude
Oil Main Pumps may shutdown in response to Low Suction Pressure (PIT-601022B-01in the
case of the 4th Pump). It is suggested that the PIT on the suction of each of the Crude Oil
Main Pumps have staggered settings to allow for sequential shutdown of Crude Oil Main
Pumps should a Booster Pump(s) be lost during operation.
Note:
For main crude oil pumps "PAX-601022A" & "PAX-601022B" sequential shutdown, is
determined by the setting of timer "TIM-601022A-07" or "TIM-601022B-07"

E) ALARMS & SHUTDOWNS INDICATION

PLS. CHECK. IN 084488_LDG,

REV. 2. TIM-07 CURRENTLY IS
USED FOR OK TO START
SIGNAL FOR BOOSTER
PUMPS.

All of the following will generate both audible and visual alarms in the Main Control Room
and at the pump package:
Shut-Down Indications
- LOW suction pressure "PAL-601022B-01" on HMI and "PAL-601022B-03" on LCP.
(see interlock ref. D4).
- LOW discharge pressure "PAL-601022B-02" on HMI and "PAL-601022B-04" on LCP.
(see interlock ref. D5).
- HIGH discharge pressure "PAH-601022B-02" on HMI and "PAH-601022B-04" on LCP.
(see interlock ref. D6).
- HIGH-HIGH temperature pump casing "TAHH-601022B-02" on HMI.
(see interlock ref. D3)
- HIGH-HIGH temperature D.E. pump bearing "TAHH-601022B-01" on HMI.
(see interlock ref. D8)
- HIGH-HIGH temperature N.D.E. pump bearing "TAHH-601022B-03" on HMI.
(see interlock ref. D8)

rev. 03 08-01-2014

- HIGH-HIGH temperature D.E. motor bearing "TAHH-601022B-12" on HMI.

(see interlock ref. D9)
- HIGH-HIGH temperature N.D.E. motor bearing "TAHH-601022B-13" on HMI.
(see interlock ref. D9).
- HIGH-HIGH temperature motor winding "TAHH-601022B-14 A/B/C/D/E/F" on HMI.
(see interlock ref. D10), and common signal "TAH-601022B-18" on LCP.
- HIGH-HIGH vibration D.E. pump bearing housing "XAHH-601022B-01" on HMI.
(see interlock ref. D11).
- HIGH-HIGH vibration N.D.E. pump bearing housing "XAHH-601022B-02" on HMI.
(see interlock ref. D11).
- Seal Leakage D.E. "LAH-601022B-01" on HMI and "LAH-601022B-03" on LCP.
(see interlock ref. D7)
- Seal Leakage N.D.E. "LAH-601022B-02" on HMI and "LAH-601022B-04" on LCP.
(see interlock ref. D7)
- MOV not OK position "VAX-601022B-26" on HMI.
- Any of the above signals as well as the activation of any manual pump shutdown
pushbuttons will cause the Main Pump Shutdown indicator to be illuminated, "XL-601022B04" on HMI and "XL-601022B-14" on LCP.
Alarm Indications
- HIGH temperature pump casing (> 65 C) "TAH-601022B-02" on HMI and
"TAH-601022B-05" on LCP.
- HIGH temperature D.E. pump bearing (> 87 C) "TAH-601022B-01" on HMI and
"TAH-601022B-04" on LCP.
- HIGH temperature N.D.E. pump bearing (> 87 C) "TAH-601022B-03" on HMI and
"TAH-601022B-06" on LCP.
- HIGH vibration D.E. pump bearing housing (> 5,4 mm/s RMS) "XAH-601022B-01" on HMI
and "XAH-601022B-03" on LCP.
(during the motor start-up alarm bypassed).
- HIGH vibration N.D.E. pump bearing housing (> 5,4 mm/s RMS) "XAH-601022B-02" on
HMI and "TAH-601022B-04" on LCP.
(during the motor start-up alarm bypassed).
- HIGH temperature D.E. motor bearing (> 90 C) "TAH-601022B-12" on HMI and
"TAH-601022B-16 on LCP.
- HIGH temperature N.D.E. motor bearing (> 90 C) "TAH-601022B-13" on HMI and
"TAH-601022B-17 on LCP.
- HIGH temperature motor winding (> 145 C) "TAH-601022B-14 A/B/C/D/E/F" on HMI.
rev. 03 08-01-2014

- Common 24VDC Power Supply Failure "IAL-601022B-21" on HMI and Common 24VDC
Power Supply Failure "XL-601022B-17" on LCP.
- MCP cabinet High Temperature "TAH-601022B-20" on HMI.

F) CONTROLS AND SIGNALS

The following controls & signals are available on the HMI (touch-screen) and/or LCP.
- MOV suction valve "MOV-601022B-01" position signals.
Closed "ZLL-601022-01" on HMI, "ZLL-601022B-03" on LCP.
Opened "ZLH-601022B-01" on HMI, "ZLH-6012B-03" on LCP.
- MOV discharge valve "MOV-601022B-02" position signals.
Closed "ZLL-601022-02" on HMI, "ZLL-601022B-04" on LCP.
Opened "ZLH-601022B-02" on HMI, "ZLH-6012B-04" on LCP.
- Booster pumps running signals.
Booster pump "D8-PAX601021A" running "XL-601021A-01" on HMI.
Booster pump "D8-PAX601021B" running "XL-601021B-01" on HMI.
Booster pump "D8-PAX601011A" running "XL-601011A-01" on HMI.
Booster pump "D8-PAX601011B" running "XL-601011B-01" on HMI.
- Main pumps running signals.
Main pump "D8-PAX601022A" running "XL-601022A-01" on HMI.
Main pump "D8-PAX601012A" running "XL-601012A-01" on HMI.
Main pump "D8-PAX601012B" running "XL-601012B-01" on HMI.
- Motor failure signal from MCC "XL-6010122B-31" on MCP and "XL-601022B-13" on
LCP.
-03
- Motor trouble signal from MCC "XL-6010122B-03" on LCP. AND "XL-601022B-32" ON MCP.
-31

- Alarm & Trip acknowledge push button "PB-601022B-18" on LCP and "PB-601022B-20"
on HMI. (for acknowledge horns "ALH-601022B-02" & "ALH-601022B-01).
- Alarm & Trip signal reset push button "PB-601022B-17" on LCP and "PB-601022B-21" on
HMI. (for reset annunciator ISA sequence).
- Lamp Test push button "PB-601022B-16" on LCP and "PB-601022B-04" on HMI.

rev. 03 08-01-2014

G) VARIABLE INDICATION (ANALOG SIGNALS)

The following signals are displayed on the HMI (touch-screen).
- Pump Suction pressure range

010 kg/cm2 - "PI-601022B-01"

- Pump discharge pressure range

040 kg/cm2 - "PI-601022B-02"

- Pump D.E. bearing temperature range

0150 C - "TI-601022B-01"

- Pump casing temperature range

0150 C - "TI-601022B-02"

- Pump N.D.E. bearing temperature range

0150 C - "TI-601022B-03"

- Pump D.E. bearing housing vibration range

010 mm/s RMS - "XI-601022B-01"

- Pump N.D.E. bearing housing vibration range

010 mm/s RMS - "XI-601022B-02"

- Motor D.E. bearing temperature range

0150 C - "TI-601022B-12"

- Motor N.D.E. bearing temperature range

0150 C - "TI-601022B-13"

- Motor winding temperature range

0200 C - "TI-601022B-14 A/B/C/D/E/F"

rev. 03 08-01-2014