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Reg. No : Y16EI20005


Name : SIGMA SOLUTIONS (I) Pvt. Ltd.

Address : #501 Nagasuri Plaza, Mythrivanam,

Ameerpet, Hyderabad-500 038
Phone No. : 040-66489969, 65351900
Web Address : www.sigmasolutions.co.in

Training Date : 27-02-2017 to 27-05-2017


This is to certify that Mr. PANTHADA KAMESWARA RAO student of ELECTRONICS &
INSTRUMENTATION TECHNOLOGY, University College of Sciences, Acharya Nagarjuna Univercity Guntur
have undergone his Project as part of his curriculum in our organization. The title of his project is “RFID
BASED AUTOMATION OF LIBRARY FOR BOOK TRACKING” is carried out under our guidance and he has
complied with all the rules & instructions.

The results of the Project Training have been found to be satisfactory.

Mr. M. Narsingh Rao

Sr. Manager
Sigma Solutions (I) Pvt. Ltd.
Hyderabad-500 038

I hereby declare that his Project report submitted to the Department of Electronics &
Instrumentation Technology, University College of Sciences, Acharya Nagarjuna University Guntur in
partial fulfillment of requirements for the award of the M.Sc. (Master of Science) of Electronics &
Instrumentation Technology is a bonafide work done by me. I further declare that this report submitted is
entirely original and was not submitted to any other institution.



It’s the only chance for me to thank all those people who helped me for doing this project in this

First of all I would like to thank Mr.M.NAGI REDDY, Mr.Y.SRI NAGESH, HOD (C&I) and our guide
Mr.K.GOPINATH, DEPUTY MANAGER (C&I) for their valuable suggestions and encouragement extended to
us for doing this project and making it a successful one. I would like to thank to INVENSYS TEAM for their
full support throughout the project. From the HR department we would like to thank Mr.B.MALLIKARJUNA
RAO (MANAGER TECH TRAINING) for his kind co-operation.

Control and Instrumentation in any Process Industry can be compared to the nervous system of the
human body. The way the nervous system is controlling the operation of various limbs of the body, in the
same way Control and Instrumentation is controlling and operating the various motors, pumps, dampers,
valves etc., and helps to achieve the targets.

Control and Instrumentation is a branch of engineering which deals with various measurement,
indication, transmission and control in different technical fields. The latest developments made in the area
of instrumentation are so wide that it has become humanly impossible to master the overall system
individually. Even in Instrumentation there are further sub groups now. The term Instrumentation means
“A device or combination of devices used directly or indirectly to measure and display a variable”.

The current project deals with the “INSTRUMENTATIO IN GAS DEHYDRATION UNIT”. It is to remove
water vapour from the gas stream.



 Slug catcher
 Gas Dehydration Unit
 MEG Pre-treatment
 Gas Turbine GENERATOR (GTG)
 Custody Transfer Measurement System

 Distributed Control System (DCS)
 Emergency Shutdown System (ESD)
 Fire and Gas System (FGS)
 Field Instruments
 Types of Protocols


 Objective
 Equipments
 Operating Parameters
 Control Philosophy
 Shutdown Philosophy
 Details of Field Instruments

The Gas discoveries in KG-D6 Block are located in water depths of 400-1800 m and beyond 35 Km
from the coast line. Reliance Industries Limited (RIL) developed the Off-shore gas field known as block KG-
DWN-98/3 (KG-D6 block), which is located in the Krishna Godavari basin, Bay of Bengal of the east coast of
India. The gas field area expands over approximately 7500 Km2 and is located between 40 Km to 60 Km
South-East from Kakinada. The block lies in water depths 400 m in the North-West to over 2700 m in the

The KG-D6 development consists of 18 sub-sea wells connected to 6 sub-sea manifolds. Productions
form the manifolds are routed to the deep water pipeline end manifold (DWPLEM) via 6 in-field pipelines.
Two 24” pipelines route the production flow from the deep water PLEM to the CRP (Control and Riser
Platform), three 24” trunk lines carry the production from the CRP to the OT (Onshore Terminal).


Process facilities at OT :

 Facility to separate and collect liquid slugs (Rich MEG + Hydrocarbon condensate, if any) from the
gas coming from sub-sea pipelines.
 Phase separation of rich MEG (comprising of condensate and produced water + lean MEG injected
at the sub-sea facilities) from hydrocarbon condensate, if any.
 Dehydrate the gas to meet the sales gas specifications.
 Compression and Fiscal metering of the sales gas.
 Regeneration of MEG (the hydrate inhibition chemical) to the required purity and pump to inject
lean MEG at the sub-sea facilities.
 Provision for installation of condensate handling unit.
 Removal and disposal of the salts removed from reclaimed MEG.
 Produce water treatment and disposal of treated effluent water.

Inlet pipelines:

The gas from CRP enters to OT through three 24” inlet pipelines. Each pipeline have blow down
valves (BDV) to HP flare in case of emergency. All the fluid is delivered to pressure reducing station (PRS)
via a common 36” distribution header. Each inlet pipeline has its own pig launcher/receiver, it is used for
removal of dust and rust formed in the piline.

Pressure Reducing Station (PRS):

In PRS the gas entering from the CRP which is at a pressure of 110 bar is reduced to 80 bar. The PRS
is provided in upstream of gas supply to each slug catcher. Each PRS consists of 4 parallel streams, in each
stream there are 3 SDV’s & 1 PCV.

High Integrity Pressure Protective System (HIPPS):

HIPPS is an independent emergency shutdown system used to protect the down stream process
equipment of onshore terminal against high pressure. It consists of inlet pressure of inlet manifold with
three pressure transmitters for sensing the inlet pressure of PRS, logic solver (TRICONEX TMR PLC) with
SOE, HIPPS valves and outlet manifold with three pressure transmitters for sensing the outlet pressure of
The inlet gas HIPPS system consists of two pressure trips:
1. Inlet to the PRS
2. Inlet to the slug catcher

The pressure trips are initiated when 2 out of 3 installed pressure transmitters reach the HIGH TRIP point.
The upstream transmitters are of a part of a HIPPS system to protect the slug catchers and downstream
plant from the possibility of overpressure due to high well fluid arrival pressure, while the downstream
transmitters are part of an inlet gas HIPPS system to protect from the possibility of over pressure due to
pressure control valve failure.
HIPPS shutdown reset and opening of the HIPPS valves to be performed from locally mounted pushbuttons
and from the DCS operator workstation via communication interface.

Slug Catcher:

The well fluid from pipelines is routed to slug catchers to separate gas and MEG. In slug catcher the
condensate and gas are divided depending on the contents density. Each slug catcher consists of 8
pipelines. Each slug catcher is provided with actuated BDV in case of an emergency (Major gas leak or Fire).
Liquid separated in the slug catcher is diverted to MEG pretreatment unit. Gas streams are collected via
36” gas riser on each pipeline and sent to production separator.

Inlet Gas Heater:

The gas stream exiting from the slug catcher is heated if the temperature of the gas is less than 15
deg C and routed to production separators. The heating is done primarily to improve the TEG contractor
performance and avoids potential hydrate formations and minimize sweating of the piping which could
lead to external corrosion. Each heater is provided with actuated BDV in case of an emergency. It also has
manual de-pressuring line to HP & LP flare used prior to maintenance. Heating Medium used to heat the
gas is hot oil (Therminol 66).

Production Separator Distribution manifolds:

Gas flows from either inlet gas heater or its bypass line to common 48” header for distribution to
production separator, the manifold pressure is controlled by PCV’s at PRS using spilt range controller, it is
also provided with actuated BDV in case of an emergency (Major gas leak or Fire), it also has manual de-
pressuring line to HP & LP flare used prior to maintenance. One PCV is set at 88 barg used during start-up
to HP flare.

Gas Dehydration Unit (GDU):

Each gas dehydration unit has 4 parallel trains, each train consists of the following process units:

 Production separator:
It is a two phase vertical separator to knock out the traces of liquid slugs carried over from slug
catcher, two wire demisters are provided in each separator.

 Gas filter coalesce:

It is also has two phase horizontal separators in which each coalesce consists of 81 filter elements,
which separates liquids from gas. Liquids separated are sent to Rich MEG pretreatment unit.

 TEG dehydration unit:

The TEG (Tri Ethylene Glycol) dehydration system comprises of TEG contractor, Gas/TEG exchanger and
TEG regeneration unit. As the water saturation level of the gas increases with the gas temperature of 40
deg C is considered for sizing the dehydration unit. Flow through each dehydration train is controlled by
FCV on dry gas downstream of TEG/Gas exchanger.

MEG Reclamation Unit:

The liquid collected in the slug catcher is routed to rich MEG pretreatment train. The rich MEG
pretreatment train consists of a rich MEG flash drum, which functions primarily as a three phase separator
to separate dissolved gases from the liquid phase and any hydrocarbon condensate from rich MEG phase, a
recycle heating loop and a settling tank.

Lean MEG storage and Injection:

Lean MEG is supplied from the OT vis three 6” pipelines to the well head for injection the max. lean
MEG to avoid the hydrate formation in the pipelines.

GTG (Gas Turbine Generator):

GTG’s are used as source of power in the plant. These generators run on either diesel or on part of
gas from subsea. GTG has its own control system for metering of gas, temperature regulation and other
process requirements. Heat recovery from the turbine exhaust is considered and selected as heat source
for optimization of heating oil circuitry. The hot oil is used as a potential source for heating requirements in
various process applications in the plant.

CTM (Custody Transfer Measurement):

The CTM skid is an integrated piping system supported on a structural base. It accommodates all
primary measurements instruments including the ultrasonic flow meters, pressure transmitters,
temperature transmitters and the MOV’s, flow profiler, piping and structural design, fabrication and
testing is in line with project specifications and applicable codes and standards keeping in view the
functional requirement.

The analyzers perform analysis of gas components, and to provide input to flow computers for
energy computation. Sample probes (installed on the metering skid) and sample handling system is
provided ensuring representative samples.

The metering cabinets are located in the control room in safe area. The panel houses the flow
computer, station computer, GC controllers, PLC, HMI and Ethernet switches with interface to DCS. All flow
and energy calculations are done by the flow computers which collect data of various signals from skids
and analyzer house. The station computers compile the station values and generate reports.

Gas metering skid:

Gas metering station has 24” header from which it is split into 2 streams. Each stream comprises of
one 12” USM, one pressure transmitter, one temperature transmitter, one inlet MOV, and one outlet MOV
in a 2 x 100% configuration. Any of the streams can help the metering station to be put in verification
mode (making the gas flow in series through both the stream ultrasonic flow meters for comparing the
performance of the one stream USM with the check USM). Generally, the cross over line MOV is kept
closed all times, except while in verification mode.

The CCR (Central Control Room) located in OT is the main control centre for the entire OT, CRP
facilities, sub-sea production, Onshore sales gas compression and gas measurement, MA condensate
stabilization, handling storage and export facilities and future compression platform, the CCR is
continuously manned. The design of instrumentation and control system is to provide all essential data to
the operators at the CCR through the operator stations, during normal as well as upset conditions of the
sub sea, CRP & OT.

The instrumentation, control and safety systems are broadly divided into 3 parts, namely:

 CRP and Sub-sea control and Safety systems

 OT control and Safe systems
 EWPL (pipeline compression & fiscal measurement)

Each location is capable of functioning independent of the other, at the same time integrated
together such that all locations can be centrally monitored from the CCR operator stations in the OT and
carry out essential controls of sub-sea and future compression platform from OT.
The CRP is interfaced with the OT DCS located at the CCR. The MCS is interfaced with the DCS by
means of a proprietary ETHERNET based communication system via sub-sea Fiber Optic cables for remote
monitoring and essential control of sub-sea equipment from the OT DCS.
Critical control of any mechanical package is via hardwired interface between plant DCS and ESD
and the package. The safeguarding of the OT is implemented by an integrated plant wide ESD system and a
FGS system located in the CER. All such ESD related shutdowns on F&G detection are achieved in the ESD
through dedicated hardwired outputs from the FGS to ESD system.
The plant wide safeguarding system (ESD FGS) is designed as failsafe. Normally all the systems are
in energized conditions and de-energized in the abnormal conditions, except for the FGS extinguishing
systems such as the FM 200 for the control building. CO2 for the turbine enclosures and deluge valves shall
be normally de-energized and energized to release the extinguishing/Deluge. Such systems which are
normally de-energized shall be in line monitored for short circuit and open circuit. The shutdown valves
shall close by bleeding air from actuators. The OT PA/GA system receives hardwired signals from the OT
FGS to generate different alarm tones.

The PA/GA system has the facility to generate 4 different alarm tones:

 For evacuation of the OT facilities (Abandonment alarm) activated manually, in case of the F&G
detection escalates and the situation cannot be brought under control.
 FIRE alarm tone in all areas activated by confirmed fire in any area.
 GAS alarm tone in all areas activated by confirmed high gas in any area.
 ALL CLEAR alarm tone for return to normal.

These alarm tones has different frequency and pattern to be easily distinguished. An alarm is
provided for the fire water pump starting and linked to the FW pump LCP and also hardwired to the
operator console in CCR, such that whenever the FW pump starts, it gives an alarm, which is capable of
being silenced by the operator.

In order to have a smooth & proper functioning of all the different areas, 9 consoles have been
provided in the control room & a provision to add 6 more consoles for the future developments like
compression platform, other fields in D6 or nearby areas.

Each normal console has two operating stations, each station having 3 screens for
monitoring/controlling the activities through DCS. In addition to these screens , each console has FGS &
CCTV screens common between both the operating stations. Each console has its own bypass/shutdown
switch panel for the assigned portion/facility.

Instrumentation in On-shore Terminal (OT):

1. Distributed Control System (DCS)

2. Emergency Shutdown System (ESD)
3. Fire and Gas System (FGS)
4. Package units
5. Field Instruments


The DCS is a microprocessor based control system consisting mainly of I/O modules, control
processors, operator consoles, printers and communication interfaces. The DCS equipment like system
controllers including I/O cards is located in the CER, FAR-1, FAR-2, FAR-3 and FAR-4. The operator consoles
and printer are located in the CCR. The DCS continuously controls and monitors all process and utilities of
OT except few packages, which are fully monitored nut partly controlled by DCS. These packages are
provided with their own control and monitoring system e.g. turbine generator packages, sale gas metering
skid etc. The package control systems are interfaced to the DCS via redundant serial links in order to the
operator with a single window to the whole plant during normal operating contition and also enable the
operator to affect a selected number of supervisory control functions from the DCS.

 The DCS has the following operational features:

 Alarm management system
 History and trend facilities
 Interface to companywide enterprise management system.
 Fiber Optic link to Offshore control system

The DCS communicates with the ESD in order to obtain data from the ESD system. The maintenance
overrides and operational and start-up overrides of the ESD are implemented from the DCS operator

The operator station for DCS is on Ethernet based TCP/IP network and interfaces with the DCS
deterministic network. The TCP/IP network is an open network for interfacing with telecommunication
system as well as other business domain systems.

The DCS system is designed with an ease of expandability both at the field I/O level and at the system level
for additional controllers and operator and engineering stations.


The ESD is highly reliable and available PLC based safety system. It is TMR (triple modular
redundant) including triplicate redundancy CPU, memory, inter-ESD and remote rack communication. The
ESD system id functionally independent of the DCS but communicates with DCS for transfer for all analog
valves, trip alarms and diagnostic alarms and other ESD related data to the DCS operator station. The ESD
alarm are displayed on the DCS graphics and can be captured in DCS alarm summaries via the DCS alarm
management system and capable of being printed when required .all alarms are capable of being
acknowledged by the operator from the DCS operator station.


The FGS detects any fire and gas breakout in the OT, monitor all fire and gas alarms of the plant and
takes effective actions to prevent fire and gas breakout.

The principal objectives of the fire and gas system (FGS) are:

 The protection of Personnel

 The protection of Environment
 The protection of Equipment, Plant & Structures
The FGS is a TMR based safety system and has triplicate redundancy in CPU, Memory Inter ESD and
remote rack communication and I/O cards and dual redundancy in power supplies and DCS
communications. The FGS is functionally independent of the DCS and the ESD system. The FGS alarms are
displayed on the DCS graphics and are captured in the DCS alarm management system and capable of
being printed when required. All alarms are capable of being acknowledged from the DCS operator station.

For the effectiveness of operation the Fire and Gas System in the plant is divided into two parts:

1. Building FGS
2. Process FGS


Types of Flow Transmitters:

1. Variable area flow meters

2. Differential pressure flow meter
3. Magnetic flow meter
4. Turbine flow meter
5. Mass flow meter
6. Vortex flow meter

Types of Level Transmitters:

1. Displacer type
2. Radar type
3. Guided wave Rader type

Types of Temperature Transmitters:

1. Resistance Temperature Detector (RTD)

2. Thermocouple

Pressure Transmitters:
All the pressure measurements are taken with differential pressure operating principle. Depending on the
requirements the differential pressure can be considered in between two points if same line or can be
taken with reference to atmosphere.
Capacitance type pressure transmitters are used to transmit the obtained pressure from the sensor for
indication and the same can be transmitted to the control centre. Local pressure indication is provided
with weather proof seal for reference.


1. Control valves
2. Shutdown valves
3. Solenoid valves
4. Self regulating valves
5. Blow down valves

Types of Protocol:

1. Foundation Field Bus (FFB):

 The FOUNDATION field bus can be flexibly used in process automation application. The
specification supports bus-powered field devices as well as allows application in hazardous areas.
 Field bus technology replaces the expensive, conventional 4 to 20 mA wiring in the field and
enables bidirectional data transmission. The entire communication between the devices and the
automation system as well as the process control station takes place over the bus system, and all
operating and device data are exclusively transmitted over the field bus.

 The essential objectives in field bus technology are to reduce installation costs, save time and costs
due to simplified planning as well as improve the operating reliability of the system due to
additional performance features. Field bus systems are usually implemented in new plants or
existing plants that must be extended. To convert an existing plant to field bus technology, the
conventional wiring can either be modified into a bus line, or it must be replaced with a shielded
bus cable, if required.
 As far as possible for process control (DCS) requirements, FF instruments are used. Field bus
instruments are utilized for ESD, FGS or HIPPS applications. Furthermore, FF is used for applications
requiring extremely fast response times (such as anti-surge control) or for applications requiring
wide bandwidth (such as machine condition monitoring). In these cases smart transmitters utilizing
HART protocol is considered.

2. HART (Highway Addressable Remote Transducer):

 HART devices communicate their data over the transmission lines of the 4 to 20 mA system. This
enables the field devices to be parameterized and started up in a flexible manner or to read
measured and stored data (re-cords). All these tasks require field devices based on microprocessor
technology. These devices are frequently called smart devices.

 Introduced in 1989, this protocol has proven successful in many industrial applications and enables
bidirectional communication even in hazardous environments.
 The HART protocol makes use of the Frequency Shift Keying (FSK) standard to superimpose digital
communication signals at a low level on top of the 4-20 mA. This enables two-way field
communication to take place and makes it possible for additional information beyond just the
normal process variable to be communicated to/from a smart field instrument. As the digital FSK
signal is phase continuous, there is no interference with the 4-20 mA signal.
 The most important performance features of the HART protocol are:
a) Fore proven in practice, simple design, easy to maintain and operate.
b) Compatible with conventional analog instrumentation.
c) Simultaneous analog and digital communication.
d) Supports multivariable field devices.
e) Sufficient response time of apporx. 500 ms.


The purpose of the Gas Dehydration Unit is to remove water vapour from the gas to outlet water content
(80 Kg/MMSCM), meeting the sales gas dew point specification using a couter current TEG absorption and
TEG Regeneration process.

TEG Contractors
TEG Coldfinger
TEG Reflux condenser
Cold rich/lean TEG Exchanger
Hot rich/lean TEG Exchanger
TEG Activated carbon filter
Rich TEG Particle filter
Lean TEG Particle filter
TEG Still Column
TEG Reboiler (with hot oil Bundle)
TEG Surge Drum
TEG Stripping Column
TEG Vent Condenser
TEG Vent Condenser K.O. drum
TEG Stand Pipe
TEG/Gas exchanger
TEG Circulation pump

Operating parameters:

Equipment Temperature Pressure

TEG contactor 40 deg C 73.5 barg
TEG Surge drum 204 deg C 0.15 barg
TEG Re boiler 204 deg C 0.15 barg
TEG Flash Drum 75 deg C 3.5 barg
TEG Stand Pipe 68 deg C Atm. Pressure
TEG Knock out Drum 55 deg C 0.1 barg

Control Philosophy:

Note: Controlling logics described here are for only one train, similar logics are applicable for other three

TEG Contractor:

Level Control
TEG Contractor level is controlled by a level control valve located in the Rich TEG outlet line. The level
control valve 106-LCV-1060 takes signal from 106-LIC-1060.

Flow Control
The flow passing contactor is controlled by a flow control valve located in the Gas outlet line. A flow
transmitter 106-FT-1001 is located in contactor Gas outlet line. The flow measured by 106-FT-1001 gives
signal to 106-FIC-1001, which controls the flow control valve.
A low Gas outlet line pressure override facility is provided in order to prevent depressurizing of the TEG
contactor on a low scenario. Pressure transmitter106-PT-1002 is located on Gas outlet line.
Block 106-FY-1001 selects the lower signal between 106-PIC-1002 and 106-FIC-1001 for controlling the
flow control valve 106-FCV-1002, which is located Gas outlet line to HP flare is used during startup
(Desined for Maximum flow 5.5MMSCMD at 86 barg).

a) Two alarms for H and L level have been provided on the controller 106-LIC-1060.
b) Incase of contactor HH and LL level, the independent level transmitter 106-LIT-1061 will shutdown
the system.
c) 106-PIT-1072 provides an alarm signal incase of H and L pressure.
d) In order to identify the possibility of foaming and/or excessive gas throughput, the differential
pressure transmitter 106-PDIT-1050 is installed across the structured packing section. 106-PDIT-
1050 will provide H alarm signal.
e) The pressure differential transmitter of Lean TEG filter 106-PDIT-1051 provides H alarm signal.
f) The contactor Lean TEG transmitter inlet temperature transmitter 106-TIT-1055 provides H and L
level alarm.
g) The sales gas dew point analyzer 106-AIT-1050 monitors the water content in the dry gas and
provides H dew point alarm.
Tag Normal Value Alarm Tag Set Value
106-LAH-1060 775mm
106-LIT-1060 650mm
106-LAL-1060 525mm
106-LAHH-1061 975mm
106-LIT-1061 650mm
106-LALL-1061 375mm
106-PAH-1072 96barg
106-PIT-1072 73.5barg
106-PAL-1072 72barg
106-PDIT-1050 0.020-0.025barg 106-PDAH-1050 0.1bar
106-PDIT-1051 0.5barg 106-PDAH-1051 0.8bar
106-TAH-1055 50 deg C
106-TIT-1055 45 deg C
106-TAL-1055 41 deg C
106-AIT-1050 80kg/MMSCM 106-AAH-1050 88kg/MMSCM

Surge Drum:

The surge drum pressure is floating with LP flare header pressure. During normal operation pressure shall
be in the range of 0-100 m barg. A self pressure regulating vavle 106-PRV-1081 is located on the fuel gas
inlet line to Surge Drum set @ 0.25 barg for protecting the vessel against low pressure.
a) The surge drum Level Transmitter 106-LIT-1068 is alerts the operator in case of L and H Level.
Before the low level is reached, the glycol level has to be restored by filling fresh glycol to TEG
Reboiler through the makeup line.
b) The pressure transmitter 106-PIT-1079 is monitor the pressure downstream 106-PRV-1081 and
provide alarms in case of H and L pressure.

Tag Normal value Alarm Tag Set value

106-LIT-1068 1050mm 106-LAH-1068 1300mm
106-LAL-1068 400mm
106-PIT-1079 0.15barg 106-PAH-1079 06barg
106-PAL-1079 0.1barg
Stripping column:

A self regulating pressure control valve 106-PRV-1080 on the stripping gas inlet reduces the pressure of the
LP Fuel Gas to the stripping column down to 1 barg.

The stripping Gas flow to the stripping column is locally monitored by the flow indicator 106-FI-1052
installed on the stripping gas line.

The pressure transmitter 106-PIT-1078 monitors the pressure downstream 106-PRV-1080 and provide
alarms in case of H and L.

Tag Normal value Alarm Tag Set value

106-PIT-1078 1barg 106-PAH-1078 2barg
106-PAL-1078 0.3barg

TEG Still Column/Reflux Condenser/Reboiler:

TEG Reboiler

Temperature Control
The Reboiler temperature is controlled by Temperature controller 106-TIC-1064 acting on the temperature
control valve 106-TCV-1064, which is located on the hot oil outlet lines to reboiler. TEG temperature in the
Reboiler maintained at 204 deg C.

a) The temperature transmitter 106-TIT-1065 shutdowns the system in case of HH or LL temperature.
b) The level in the TEG Reboiler is maintained by weir system discharging into the TEG Surge Drum.
The level transmitter 106-LIT-1066 will monitor the level in the Reboiler and provide H and L level
alarms to the plant operators.
c) An independent level transmitter 106-LIT-1067 shut downs the system in case of HH and LL level.
d) The pressure Transmitter 106-PIT-1076 monitors the pressure in the Reboiler and provide alarms in
case of H and L pressure.

Tag Normal value Alarm Tag Set value

106-TIT-1065 204 deg C 106-TAHH-1065 215 deg C
(ESD) 106-TAHH-1065 185 deg C
106-TIT-1064 204 deg C 106-TAHH-1065 210 deg C
106-TAL-1064 190 deg C
106-LIT-1067 204 mm 106-LAHH-1067 1600 mm
(ESD) 106-LALL-1067 1150 mm
106-LIT-1066 1400 mm 106-LAH-1066 1500 mm
106-LAL-1066 1300 mm
106-PIT-1076 0.25 barg 106-PAH-1076 0.45 barg
106-PAL-1076 0 barg

Still Column & Reflux condenser:

Top temperature
The still column top temperature is controlled by a temperature control valve located on Rich TEG bypass
line to the Reflux Condenser. 106-TT-1063 measures top temperature and gives signal to 106-TIC-1063,
which operates the temperature control valve 106-TCV-1063 to maintain top temperature at 100 deg C.


Tag Normal value Alarm Tag Set value

106-TIT-1063 100 deg C 106-TAH-1063 110 deg C
106-TAL-1063 90 deg C
TEG Flash Drum:

Level Control
a) TEG flash drum level is controlled by 106-LIC-1064 acting on the level control valve 106-LCV-1064,
which is located on rich TEG feed to still column.
b) The liquid level in the Hydrocarbons section of the TEG flash drum is controlled by 106-LIC-1062,
acting on the level control valve 106-LCV-1062 located in closed drain line.

Pressure Control
TEG Flash drum pressure is maintained at 5barg. If pressure goes high the gas is routed to LP Flare Header
through a self regulated pressure valve 106-PRV-1083, which is set at 5 barg. Incase pressure goes below
3.5 bag provision for pressure make up with fuel gas through a self regulating valve 106-PRV-1082, which is
set at 3.5 barg available.

a) The independent level transmitter 106-LIT-1065 in the TEG outlet section provides HH and LL alarm
b) The pressure transmitter 106-Pit-1073 also provides HH and LL alarm signals.
c) The independent level transmitter 106-LIT-1063 in the hydrocarbon section provides HH and LL
alarm signals. In case of LL level only 106-SDV-1052 located on drain line will be shut down.
Tag Normal valve Alarm Tag Set valve
106-PIT-1073 5 barg 106-PAHH-1073 9.5 barg
(ESD) 106-PALL-1073 2.5 barg
106-PIT-1074 5 barg 106-PAH-1064 7.5 barg
106-PAL-1064 3 barg
106-LIT-1065 (Rich 600 mm 106-LAHH-1065 1000 mm
TEG) 106-LALL-1065 300 mm
106-LIT-1064 (Rich 600 mm 106-LAH-1064 750 mm
TEG) 106-LAL-1064 450 mm
106-LIT-1063 (HC) 500 mm 106-LAHH-1063 900 mm
(ESD) 106-LALL-1063 200 mm
106-LIT-1062 (HC) 500 mm 106-LAH-1062 700 mm
106-LAL-1062 300 mm

TEG Flash Drum/Filters/TEG Exchanger:

Rich TEG activated carbon filter, particle filter are equipped with the differential pressure transmitter 106-
PDIT-1052, 106-PDIT-1053 respectively to monitor the fouling conditions.
Tag Normal value Alarm Tag Set value
106-PDIT-1052 0.5 barg 106-PDAH-1052 1 barg
106-PDIT-1053 0.5 barg 106-PDAH-1053 0.8 barg

Lean TEG Circulation Pumps:

a) Stand pipe level transmitter 106-LIT-1069 shutdowns the system on LL level (1000 mm) and gives
an alarm on L Level (2000 mm).
b) High Lean TEG stand pipe outlet temperature transmitter 106-TIT-1071 will shut down the package
on HH Temperature (85 deg C).
c) The max. designed lean TEG flow rate is 19.0 m3/h, however the lean TEG circulation rate can be
adjusted by changing the set point of the flow controller 106-FIC-1050. (Thresholds tor H, L and LL
flow have been provided. When the LL alarm is activated, the DCS will stop the running pump and
start the standby one (pumps change-over). If after 30 seconds the flow is not restored, the DCS
will stop also the second pump and send a signal to ESD for TEG Regeneration Shut Down).
d) Pressure transmitters 106-PIT-1075 and 106-PIT-1077 installed on the pump discharge lines will
provide HH and LL alarms.

Tag Normal value Alarm Tag Set value

106-LIT-1069 N.A. 106-LAL-1069 2000 mm
(ESD) 106-LALL-1069 1000 mm
106-TIT-1071 68 deg C 106-TAHH-1071 85 deg C
106-PIT-1077 73.5 barg 106-PAHH-1077 95 barg
(ESD) 106-PALL-1077 60 barg
106-PIT-1075 73.5a barg 106-PAHH-1075 95 barg
(ESD) 106-PALL-1075 60 barg
106-FIT-1050 18.7 m3/h 106-FAH-1050 20 m3/h
106-FAL-1050 14 m3/h
106-FALL-1050 10 m3/h

Vent Condenser:

Level Control
The condensate water level in the TEG Vent Condenser K.O. Drum measured by 106-LIT-1070, gives signal
to 106-LIC-1070 which in turn acting on the level control valve 106-LCV-1070 to control the level.

a) The temperature transmitter 106-TIT-1070 located at the outlet of the vent condenser, is monitor
the vapor temperature and provide two alarms for H and L temperature in order to alert the
b) Vent condenser fan motors are equipped with a vibration transmitter 106-YST-1002 and 106-YST-
1012 which will shut down the motor in case of HH vibrations.
c) The Level Transmitter 106-LIT-1071, located in vent condenser KOD, will shut down the system in
case of low low level.
Tag Normal value Alarm Tag Set value
106-TIT-1070 55 deg C 106-TAH-1070 70 deg C
106-TAL-1070 20 deg C
106-YSA-1002A (ESD) N.A. 106-YSAHH-1002A 10 mm/s
106-YSA-1002B (ESD) N.A. 106-YSAHH-1002B 10 mm/s
106-LIT-1071 (ESD) 700 mm 106-LAHH-1071 1000 mm
106-LALL-1071 400 mm
106-LIT-1070 700 mm 106-LAH-1070 850 mm
106-LAL-1070 550 mm

Fuel Gas Distribution:

Tag Normal value Alarm Tag Set value
106-PIT-1078 N.A. 106-PAH-1078 2 barg
106-PAL-1078 0.3 barg
106-PIT-1079 N.A. 106-PAH-1079 0.6 barg
106-PAL-1079 0.1 barg
106-FIT-1051 N.A. 106-FAH-1051 250 kg/hr
106-FAL-1051 20 kg/hr

Shut down Philosophy:

The following Interlocks are described in this section.

1. Emergency Shutdown
2. Gas Train 1 Unit Shutdown
3. TEG Regeneration 1 Unit Shutdown
4. TEG Regeneration 1 Local Shutdown
5. Other Interlocks

Note: Interlocks described here are for only one train, similar shutdowns are applicable for other three

ESD Interlocks:


Cause Reset
Emergency plant shutdown(Manual push button) C+F
Instrument air distribution header pressure Low-Low (2 out of C+F
3 voting logics
Loss of power C+F
HP KO Drum level Hi-Hi (2 out of 3 voting logics) C+F
LP KO Drum level Hi-Hi (2 out of 3 voting logics) C+F

1. Contacor1 Lean TEG inlet Shutdown valve 106-SDV-1050 close.
2. Contactor1 Rich TEG outlet Shutdown valve 106-SDV-1051 close.
3. TEG1 circulation pumps trip.
4. Antifoam and pH dosing pumps trip.
5. Vent Condenser fans trip.
6. TEG KOD liquid outlet shutdown valve 106-SDV-1054 close
7. TEG Reboiler Hot oil feed shutdown valve 106-SDV-1053 close.
8. Flash Drum Hydrocarbon outlet shutdown valve 106-SDV-1052 close.
9. TEG Unit Fuel Gas shutdown valve 106-SDV-1055 close
10. Gas dehydration outlet shutdown valve 106-SDV-1005 close.

DCS Actions
1. Contactor 1 liquid outlet control valve 106-LCV-1060 close
2. Flash drum hydrocarbon outlet control valve 106-LCV-1062 close
3. TEG Reboiler Hot oil control valve 106-TCV-1064 close
4. TEG KOD liquid outlet control valve 106-LCV-1070 close
5. Gas Dehydration 1 outlet control valve 106-FCV-1001 close.

Gas Train 1 USD:


Cause Reset
Confirmed fire for gas train 1 C+F
Manual blow down hand switch for gas train-1 (C/Room) C+F
Manual USD hand switch for gas train-1 (Local, C/Room) C+F
Production separator 1 pressure low-low C+F

1. Close Gas Dehydration 1 outlet shutdown valve 106-SDV-1005
2. Trip Gas Dehydration Package
3. Gas Dehydration 1 outlet control valve 106-FCV-1001

TEG Regeneration 1 USD:


Cause Reset
TEG Contactor level Hi Hi C+F
TEG Contactor low low level C+F
TEG Flash Drum HI Hi pressure C+F
TEG Flash Drum low low pressure C+F
TEG Flash Drum HCsection Hi Hi level C+F
TEG Flash Drum TEG section Hi Hi level C+F
TEG Flash Drum TEG section low low level C+F
TEG Reboiler 1 Hi Hi Level C+F
TEG Reboiler 1 Low Low Level C+F
TEG Reboiler 1 Hi Hi Temperature C+F
TEG Standpipe Hi Hi Temparature C+F
TEG Standpipe Lo Lo Level C+F
TEG1 Recirculation pump A Hi Hi Pressure C+F
TEG1 Recirculation pump A Lo Lo Pressure C+F
TEG1 Recirculation pump B Hi Hi Pressure C+F
TEG1 Recirculation pump B Lo Lo Pressure C+F
TEG1 KO Drum Lo Lo Level C+F
Trip TEG Regeneration Unit 1 C+F

1. Trip TEG1 Circulation pumps
2. Trip Anti foam and pH dosing pump
3. Trip vent condenser fans
4. TEG Reboiler Hot oil feed shutdown valve 106-SDV-1053
5. Close Flash Drum 1 HC outlet shutdown valve 106-SDV-1052
6. Close TEG unit 1 Fuel Gas shutdown valve 106-SDV-1055
7. Close Contactor 1 Rich TEG outlet shutdown valve 106-SDV-1051
8. Close Contactor 1 lean TEG inlet shutdown valve 106-SDV-1050
9. Close TEG to TEG regeneration 1 shutdown valve 106-SDV-1001

DCS Actions (Expert for Interlock No 2121-1)

1. Close contactor 1 liquid outlet control valve 106-LCV-1060

2. Close Flash Drum 1 HC outlet control valve 106-LCV-1062
3. Close TEG Reboiler 1 Hot oil control valve 106-TCV-1064
4. Close TEG KOD 1 liquid outlet control valve 106-LCV-1070

TEG Regeneration 1 LSD

Cause 1

Cause Reset
TEG Flash Drum 1 HC out section LL Level C+F


1. Close flash drum 1 HC outlet shutdown valve 106-SDV-1052

2. Close Flash drum 1 HC outlet control valve 106-LCV-1062
Cause 2

Cause Reset
Lean Glycol line LL Flow C+F


1. Change over TEG 1 circulation pumps

Other Interlocks


Cause Reset
TEG vent condenser 1 Fan A/B HH vibration C+F


1. Trip Vent Condenser Fan A/B

Details of field instruments:

Differential Flow Transmitter:

Differential Flowmeters operate on the principle
that a restriction (or obstruction) in the line (or pipe)
of a flowing fluid, introduced by the orifice plate or
venture tube or elbow, produces a differential
pressure across the restriction element which is
proportional to the flow rate.

Make : Rosemount
Model : 3095 series
Supply : 11-55 vdc

Ultrasonic Flow Transmitter:

These devises measure flow by measuring the
time taken for ultrasonic wave to transverse
a pipe section, both with and against the flow
of liquid within the pipe.

Make : Daniel
Model : 3400
Voltage: 10.4 to 36 vdc, 15 W max.
Temp : -40 deg C to 65 deg C

Radar Level Transmitter:

The Radar Level Transmitter is a smart,
two-wire continuous level transmitter
that is based on the time difference
between the transmitted and
reflected pulse.

Make : Rosemount
Model : 5400 series

Level Guage:
Magnetically controlled level indicator is
used of the local indication of level. The
magnetic transfer of the fluid level
from the tank to the indicator is
continuous and vibration-resistant,
even in the case of fast changing levels.

Make : Officine Orobiche

Model : 2016.1.2.G.XX
Range : 1190 mm
Guided wave Radar Level Transmitter:
Guided wave Radar Transmitter is a smart,
two-wire continuous level transmitter that
is based on Time Domain Reflectometery
(TDR) principle.

Make : Rosemount
Model : 5300 series

Temperature Transmitter:
With the increase of temperature, the
electrical resistance of certain
metals increases in direct proportion
to the rise of temperature. Platinum,
copper and nickel are generally used
in resistance thermometers.

Sensing element : RTD (pt 100)

Make : Rosemount
Model : 3144P
Supply : 12.0 to 42.4 vdc
Output : 4 to 20 mA
Range : -200 deg C to 850 deg C
Differential Pressure Transmitter (PDIT):
This sensor measures the difference between two or
more pressures introduced as inputs to the sensing unit,
for e.g., measuring the pressure drop across an orifice.

Make : Rosemount
Supply : 24VDC
Output : 4 to 20 mA

Motor Operated Valve (MOV):

MOV’s are primarily used for isolation
on of process and it’s sub-systems in
Onshore Terminal. The MOV actuators
are ROTORK type IQ and connected
in 2-wire current loops with PAKSCAN
master monitoring stations.

Type : IQ20
Speed : 36 rpm
Temp. : -20 deg C to 70 deg C
Supply : 415-3-50
Nominal motor current : 2.61 Amp

Shut Down Valve (SDV):

Emergency shutdown valves are activated
when certain specified conditions are
violated in the process.

Make : BIFFI
Type : Tyco Flow Control

Solenoid Valve:
The solenoid operated valve is an
“on-off” device that works on the
Principle of Electromagnetism.

A solenoid valve is a combination of two functional units:

 A solenoid operator essentially consisting of a coil, core, core tube, shading coil and sprig.
 A valve body containing orifices in which a disc, diaphragm or piston etc is positioned
according to the type of technology used. The valve is opened or closed by movement of the
magnetic core which is drawn into a solenoid when the coil is energized.

Pressure Reducing Valve (PRV):

These are used to limit the pressure in part
of the circuit to a value lower than that
required in the rest of the circuit.
The pressure reducing valve is a normally
open valve which throttles or closes to
maintain constant pressure in the regulated

Make : Masoneilan
Item : MART 231006
Range : 3.5 bar to 4 bar
Temp. : 30 deg C

Pressure Set Valve (PSV):

Make : Cornaredo
Type : SMU/LIg
Inlet : 1” ASME 150 RF
Outlet : 2” ASME 150 RF
Set Pr. : 10 barg
Temp. : 90 deg C

Control Valve:

The principle of operation is based upon forces

between a pneumatic force from the diaphragm
against a mechanical force produced by the actuator
The control valve worked with pneumatic signal
3 to 15 psi. The motion starts at 3 psi and the end
of the stroke takes place at 15 psi.

Make : Masoneilan

Dew point Analyzer:

The dew point analyzer measures the dew point

in the sample by using aluminum oxide sensor.
The continuous measurement of dew point is
required in the air drier outlet to assess the
performance of Air Dryer Unit.

Model : 241 CE II
Input : 120VAC, 50/60Hz
Output : 4 to 20 mA