ALGIERS REFINERY

REHABILITATION AND ADAPTATION PROJECT

COMPLEX LOOP DESCRIPTION
COMMON MS BLOCK (Unit 505)

Document Class : CLASS 1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-505 CN 0000 0002 B 1/6

COMPLEX LOOP DESCRIPTION

COMMON MS BLOCK (Unit 505)

Pages modified under this revision: First Issue

G PATHAK A YADAV
N AGRAWAL
2012.03.22 18:01:09 2012.03.22 2012.03.26 12:16:03
+05'30' 18:01:33 +05'30'
+05'30'

B 22-MAR-2012 ISSUED FOR DESIGN G.PATHAK A.YADAV N.AGRAWAL

A 18-JAN-2012 ISSUED FOR REVIEW G. PATHAK A.YADAV N. AGRAWAL
Rev Date STATUS WRITTEN BY CHECKED BY APPROVED BY
DD/MMM/YY (name & visa) (name & visa) (name & visa)

DOCUMENT REVISIONS

Sections changed in last revision are identified by a vertical line in the margin
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT
COMPLEX LOOP DESCRIPTION
COMMON MS BLOCK (Unit 505)

Document Class : CLASS 1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-505 CN 0000 0002 B 2/6

CONTENTS

1. UNIT OBJECTIVE ............................................................................................................................................................. 3

2. CONTROL PHILOSOPHY................................................................................................................................................ 3
2.1 GENERAL CONTROL DESCRIPTION ..................................................................................................................... 3
3. DESCRIPTION OF COMPLEX LOOPS......................................................................................................................... 3
3.1 STEAM GENERATION CIRCULATING WATER PUMPS CONTROL (505-UC-0001) ........................................ 3
3.2 PURE STEAM CONDENSATE TRANSFER PUMPS CONTROL (505-UC-0005) .................................................. 4
3.3 SUSPECT CONDENSATE TRANSFER PUMPS CONTROL (505-UC-0006) ......................................................... 4
3.4 CB DRUM PUMP CONTROL (505-UC-0003) ........................................................................................................... 4
3.5 FLARE KNOCKOUT DRUM PUMPS CONTROL (505-UC-0004) .......................................................................... 5
3.6 PURE CONDENSATE DRUM (505-D-002) PRESSURE CONTROL....................................................................... 5
3.7 FLASH STEAM CONDENSER (505-EA-001)HIGH VIBRATION TRIP (505-UC-0002 A/B) ................................ 6
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT
COMPLEX LOOP DESCRIPTION
COMMON MS BLOCK (Unit 505)

Document Class : CLASS 1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-505 CN 0000 0002 B 3/6

1. UNIT OBJECTIVE
The objective of the Common MS Block is to develop the Process area battery limit, Steam
generation system, utilities network, as well as the flare and closed drain distribution linked to
Naphtha Hydrotreating Unit (NHT-U500),Light Naphtha Isomerization Unit (ISOM-U510) &
Continuous Catalytic Regeneration Unit (CCR-U520) units.
Common MS Block is divided into different sections:
 Process area Battery limit.
 Steam generation system
 Flare system as well as Flare knock out drum
 Close blow down system as well as CB Drum.
 Utilities:
- Cooling water distribution network
- Steam and condensate distribution as well as Pure condensate & Suspect condensate
recovery system and Steam drum blow down system.
-Air distribution (Plant Air and Instrument air)
-Miscellaneous distribution (Service water, Potable water, Fuel gas, Fuel oil, Flushing oil
and Nitrogen)

2. CONTROL PHILOSOPHY

2.1 GENERAL CONTROL DESCRIPTION

Control operations of Common MS Block are handled by the DCS system. This system is an interface
between the operator and the plant. The DCS can be used by operator to manually control valve
opening but it can also function as a controller to ensure that process parameters (such as pressure,
temperature or flow) are maintained automatically at their desired value. These control loops have
been indicated on the P&ID’s. Most control loops are quite basic: an instrument transmitter gives off a
signal to the DCS where it is used in as controller block. The controller then gives an output signal to
another controller block or to a control valve. Some control loops are more complex with multiple
controllers description of these complex loops. This document does not constitute a through
description of DCS and related controller blocks functioning.

3. DESCRIPTION OF COMPLEX LOOPS

3.1 STEAM GENERATION CIRCULATING WATER PUMPS CONTROL (505-UC-0001)

Process P&ID:
- 9952T-505-PID-0021-1106

3.1.1 OBJECTIVE
The objective of this control loop is to maintain the flow of steam generation circulating water
through 520-F-001/002/003/004 heaters.
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT
COMPLEX LOOP DESCRIPTION
COMMON MS BLOCK (Unit 505)

Document Class : CLASS 1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-505 CN 0000 0002 B 4/6

3.1.2 FUNCTION DESCRIPTION

The flow control of steam generation circulating water to 520-F-001/002/003/004 heaters
is done by 505-UC-0001.
If 505-FZI-0003 detects a low flow, Stand by motor of steam generation circulating water pump
selected in AUTO mode (505-P-005 A or B) is started.

3.2 PURE STEAM CONDENSATE TRANSFER PUMPS CONTROL (505-UC-0005)

Process P&ID:
- 9952T-505-PID-0031-2132

3.2.1 OBJECTIVE
The objective of this control loop is to protect dry run of Pure steam condensate transfer pump
(505-P-001 A/ B) in case of low level in the Pure condensate drum 505-D-002.

3.2.2 FUNCTION DESCRIPTION

The dry run protection of Pure steam condensate transfer pump (505-P-001 A/ B) is done by 505-
UC-0005.
If 505-LI-0008 detects a low low liquid level, running motor of Pure steam condensate transfer
pump selected in AUTO mode (505-P-001 A or B) is stopped.

3.3 SUSPECT CONDENSATE TRANSFER PUMPS CONTROL (505-UC-0006)

Process P&ID:
- 9952T-505-PID-0031-2134

3.3.1 OBJECTIVE
The objective of this control loop is to protect dry run of Suspect condensate transfer pump
selected (505-P-002 A/ B) in case of low level in the Suspect condensate drum 505-D-004.

3.3.2 FUNCTION DESCRIPTION

The dry run protection of Suspect condensate transfer pump selected (505-P-002 A/B) is done by
UC-0006.
If 505-LI-0013 detects a low low liquid level, running motor of Suspect condensate transfer pump
selected in AUTO mode (505-P-002 A or B) is stopped.

3.4 CB DRUM PUMP CONTROL (505-UC-0003)

Process P&ID:
- 9952T-505-PID-0031-2147

3.4.1 OBJECTIVE
The objective of this control loop is to control the level in the CB drum 505-D-009.
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT
COMPLEX LOOP DESCRIPTION
COMMON MS BLOCK (Unit 505)

Document Class : CLASS 1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-505 CN 0000 0002 B 5/6

3.4.2 FUNCTION DESCRIPTION

The level control of the CB drum 505-D-009 is done by 505-UC-0003.
If 505-LI-0018 A detects a high liquid level, motor of CB Drum pump (505-P-004 A) is started. By
low liquid level detection, pump is stopped.
In case 505-LI-0018A fails to start /stop 505-P-004, detection of high high (or low low) level by 505-
LI-0019 will be an additional safeguard to start (or stop) CB Drum Pump 505-P-004.

3.5 FLARE KNOCKOUT DRUM PUMPS CONTROL (505-UC-0004)

Process P&ID:
- 9952T-505-PID-0031-2186

3.5.1 OBJECTIVE
The objective of this control loop is to control the level in the Flare knockout drum 505-D-012.

3.5.2 FUNCTION DESCRIPTION

The level control of the Flare knockout drum 505-D-012 is done by 505-UC-0004.
If 505-LI-0026 A detects a high liquid level, motor of Flare knockout drum pump selected in AUTO
mode (505-P-008 A or B) is started.
If LI-0026 B detects a low liquid level, motor of Flare knockout drum pump selected in AUTO mode
(505-P-008 A or B) is stopped.

3.6 PURE CONDENSATE DRUM (505-D-002) PRESSURE CONTROL

Process P&ID:
- 9952T-505-PID-0031-2132

3.6.1 OBJECTIVE
The objective of this control loop is to control the pressure of the Pure condensate drum (505-D-
002).

3.6.2 FUNCTION DESCRIPTION

The pressure of Pure condensate drum (505-D-002) is monitored by PIC-0020 that acts in split
range on the valves 505- PV-0020 A & 505-PV-0020B.
If pressure of the Pure condensate drum (505-D-002) increases above the set point, the control
vale 505-PV-0020 B starts to open in order to send excess gas to atmosphere while the control
valve 505-PV-0020 A remains closed.
If pressure of the Pure condensate drum (505-D-002) decreases below the set point, the control
vale 505-PV-0020 A starts to open in order to allow nitrogen to enter inside the vessel while the
control valve 505-PV-0020 B remains closed.
 ALGIERS REFINERY
REHABILITATION AND ADAPTATION PROJECT
COMPLEX LOOP DESCRIPTION
COMMON MS BLOCK (Unit 505)

Document Class : CLASS 1 Project N° - Unit Doc Type Material Code Serial Number Rev. Page

9952T-505 CN 0000 0002 B 6/6

Valve
opening

100 %
OPEN
505-PV-0020A 505-PV-0020B

0%
CLOSED

4 12 20 (mA)

3.7 FLASH STEAM CONDENSER (505-EA-001)HIGH VIBRATION TRIP (505-UC-0002 A/B)

3.7.1 Objective
The objective of this loop is to stop the Fan Motor in case of High Vibration. One Vibration Switch is
provided for each Fan driver of Flash Steam Condenser.

Process P&ID:

9952T-505-PID-0031-7101

3.7.2 Functional description

Flash Steam Condenser (505-EA-001) Fan vibration control is done by 505-UC-0002A/B.

In case of high vibration of Fan, 505-UC-0002 A/B will stop the Fan motor 505-EAM-001 A/B
respectively.