Honeywell Process Solutions – Functional Design Specification

4.2. PRODUCT TANK INTERLOCKS

All the tanks are connected with 1 Nos. radar gauge, these signals (4-20 mA) are directly
hardwired to process PLC, also H & L hardwired alarm are interface with PLC from Radar
Gauge. For HH & LL alarm float type level switches are provided on each product tank.
Level Alarms viz. L, LL, H& HH shall be configured for all tanks.

4.3. MOVINTERFACE
Tank inlet & jetty MOVs will be interfaced with the process PLC through serial
communication and required data (feedback and command signals) will be fetched from
MOV.
Below signal are considered for MOV operation:
Below digital serial interface signal are considered for MOV operation
• Open/Close status
• Remote/Local status
• Open/Close commands
All the tank outlet MOV shall be hardwired to TAS PLC, following are the hardwired signals
considered for MOV control.
• MOV Local /Remote Status.
• MOV Open status
• MOV Close status
• MOV open command
• MOV close command

4.4. SAFETY INTERLOCKS FOR PROCESS PLC

Note: All the below given interlocks will be actuated based on the Tanks Mode.

Actuated
Sr. No Interlock No. Description Action
By

On Occurrence of I‐1:
a) ESD Close command (by PLC) to tank Inlet
MOV.
Tank Level – b) ESD Close command (by PLC) to corresponding
1 I‐1 LevelSwitch HHAlarm running product pump through its normal
closure port
c) Close command (by PLC) to MOV through its
normal closure port after the pump stop
feedback is updated in the TAS system

Sr. No Interlock No. Actuated Description Action

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 Honeywell Process Solutions – Functional Design Specification

By

On Occurrence of I‐2:
Radar type
Tank Level ‐ H a) Alarm will be displayed on operator station to
2 I‐2 Level
Transmitter take nessary action at operator level.

On Occurrence of I‐3:
a) Close command (by PLC)to all the TLF Pumps.
Actuated by b) Close command (by PLC) to all the Tank Inlet /
any ofthe Outlet MOVs through their normal port.
Plant ESD c) Open command (by PLC)to Entry &Exit Barrier
3 I‐3 ESD signals or gate through its normal port.
Soft ESD from d) Close command (by PLC) to all the jetty MOV’s.
theOIC e) Close command (by PLC)to the batch
graphics controllers (inTFL gantry) through their normal
ports to abort the loading operations at TLF
gantries.
f) Command from PLC to blow hooters.

4.5. TANK MODE OPERATION

There are 4 modes of operations:
1. TLF Dispatch Mode Operation (TLF-DISP)
2. PLT/Jetty Receipt Mode Operation (PLT/JETTY-REC)
3. Day End Dormant mode Operation (DAY END DORMANT)
4. Maintenance mode of operation (MAINTENANCE)

4.5.1. Tank Lorry Filling Dispatch Mode (TLF‐DISP)

Tank will be allowed in TLF dispatch mode only when the following interlocks are
healthy:
• ESD is not activated.
• Tank is not selected for any other operation.
• Tank inlet MOV should be in closed condition.
• Tank outlet MOV shall be in remote auto mode.
• Any other tank is not selected for this operation in the same product group.
Sequence of operation:
1. From the HMI, Operator will select the operation “TLF-DISP” for the dormant tanks
available of that product and press “START” button.
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 Honeywell Process Solutions – Functional Design Specification

2. PLC issues open command to tank outlet MOV, and will wait for the open feedback of
the MOV.
3. After receiving open feedback from the tank outlet MOV, TLF pump with Priority 1 will
start in remote auto mode depending upon the pump demands received from the
batch controller at the gantry.
4. Logic continuously monitor for L and LL level of the tank. Once L level reaches, alarm
will be displayed in the alarm window. When tank level goes to LL, TLF dispatch pump
will get stopped automatically.
Caution: NO simultaneously operation of two tanks for TLF Dispatch & Receipt will not be
carried out in remote mode.
Note:
• The Pumps selected in Local mode shall not appear for selection.
• Tank Inlet and Out MOV shall always remain in Remote Auto mode. However if tank
inlet MOV and outlet MOV is operated in Remote Manual mode by the user, system
shall allow opening of inlet MOV only when outlet MOV is closed and vice versa.
TLF Pump Priority Selection Philosophy:
Pumps will be operated in two modes i.e. Remote and Local. Selector switch for Remote
/Local selection will be available on MCC control panel. This will be used to select the
pump in remote/local mode. If Remote/Local Switch is in Local position then all the
interlocks will be bypassed and pump will be operated from the field with the use of local
push button station. Only ESD command will be activated during this mode, however
pump status will be displayed in the TAS system. If Remote/Local Switch is in Remote
position then pump will be operated from the Control Room in Two -modes either in
Manual mode or Auto mode. Soft button will be provided on HMI to select Auto/Manual
mode of pump.
While designing pump logic it is considered that flow rate on a single loading point is to be
maintained at optimum level which depends on quantity of Pumps available at terminal
and pump capacity.
Pump priority will be set based on least run hours/manual selection from OIC’s. In case
the selected pump (selected as 1st Priority pump on least run hours/manual selection)
failed to start or selected in remote manual/local mode or tripped, then the 2nd priority
(selected as 2nd least run Hour on least run hours/manual selection) pump will be
selected for the operation and it starts automatically.
Following are TLF Pump Interlock to start the pump:
1. ESD should be healthy.
2. Respective product tank should be in TLF Dispatch Mode.
3. Tank Level should not be LL for the tank selected for TLF dispatch.
4. Respective Tank outlet MOV should be open
5. Remote/Local switch Position of Pump should be in remote.
6. Pressure Transmitter status on pump suction should be healthy.
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7. Respective Tank inlet MOV should be closed.

8. Pressure transmitter status on pump discharge should not be high.
9. MOV on the pump discharge side shall have a feature of delayed start & shall start
opening after 60-90 seconds (site configurable) from pump start time to ensure low
starting torque during start-up. In case, MOV does not open fully after 60-90 (site
configurable) seconds (say), Pump shall be tripped automatically.
10. During TLF operation, if pump gets tripped, discharge MOV shall get closed
automatically.
TLF pump shall be configured to trip under:
• Low suction pressure
• High discharge pressure
• LL level of dispatching tank
• Tank Truck Overrun

Remote auto mode of operation:

Mode of operation in MCC is selected as Remote of the respective pumps. Pump need to be
selected for Auto Mode from the available pump pop-up on the graphics. System will check
all the TLF pump interlocks mentioned above and if the interlocks are found healthy pump
will be started automatically when there is pump demand from the BCU. When there is no
pump demand the pump will stop after a configurable time delay of 60 Sec.
All the TLF pumps will have pump sequence logic. When batch controller starts a batch, it
will generate a pump demand signal. These pump demand signals are hardwired to the
Process PLC.
Remote manual mode of operation:
Mode of operation in MCC is selected as Remote of the respective pumps. In this mode,
the Operator will operate pump manually from HMI. All above Pump interlocks will be
checked in
Alarms to be configured in HMI (site configurable):
• Low pump Suction Pressure.
• High pump Discharge Pressure.
• Low pressure at TLF header.
• High pressure at TLF header.
• Closure of tank outlet MOV during TLF operation.
• Pump (s) tripping during loading operation.
.

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4.5.2. Pipeline/Jetty Receipt Mode Operation (PLT/JETTY‐REC)

From the HMI, user will select the operation i.e. “PLT/JETTY-REC” for a particular product
from the tank menu Operation Screen
Sequence of operation:
1. Step 1: System will prompt for entering batch size (KLs) i.e. quantity to be taken in
the tank. If the batch size entered is more than the ullage available for the tank
selected, a message will be prompted by the system that “entered batch size is not
available.” Operator has to reduce the batch size and then, the dormant tanks with
available batch size will be enabled for operation.
2. Step 2: Operator has an option to click AUTO button from the HMI screen to put all
inlet MOV’s & outlet MOV’s in Remote –Auto Mode. If in case any of the respective MOV
is in Local mode, Auto Tab in the screen is hidden. Operator then has to put the MOV
in Remote Mode from the field.
3. Step 3: System shall prompt all the dormant tanks available of that product for
selection by operator for dispatch and receipt after checking healthiness of following
interlocks:
The tank will be selected for PLT receipt after checking healthiness of the
following interlocks:
1. ESD is not activated.
2. Tank HH & H alarm is not activated from Level Switch OR Radar type level Tx.
3. Tank Inlet MOV shall be in remote auto mode.
4. Jetty MOV shall be in remote auto mode.
5. Tank Outlet MOV should be in closed condition.
6. Any other tank is not selected for this operation in the same product group.
Once above all the interlock are ready, Start command is given from the HMI Screen. PLC
gives the open command to the inlet MOV of the tank selected and corresponding receipt
manifold MOV. Logic will wait for the open feedbacks of Inlet MOV and receipt manifold
MOV.
Once inlet MOV and corresponding jetty MOV open feedbacks are received, system will
display the “tank mode i.e. PLT/JETTY RECPT” near to the Tank in HMI. Logic continuously
monitor for H & HH level of tank during receipt. Once H level reaches, alarm will be
displayed and operator needs to take appropriate action. When the level reaches to H, PLC
will give close command to the inlet MOV and corresponding receipt manifold MOV.
After completion of the filled batch quantity system shall flash message of completion of
batch quantity. Control room officer shall initiate closure operation of receiving tank.
Alarms to be configured in HMI:
• After completion of the filled batch quantity, flash message shall get generated in the
control room.
• Closure of tank Inlet MOV during receipt operation.
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 Honeywell Process Solutions – Functional Design Specification

• Closure of receipt jetty MOV during receipt operation.

4.5.3. Day End Dormant Mode

This is one of the tank mode. In this mode both inlet and outlet MOV of respective tank
will be in closed condition.
Note: During this mode of operation tank is supposed to maintain the product level and
ensure the tank integrity. Incase if ±20MM (configurable from TAS) product level variation
gets observed by TFMS/ TAS system, TAS must give tank product leakage alarm.
4.5.4. Maintenance Mode
In this mode an operator can put the respective product in maintenance mode with proper
level of access. A tank can be put into maintenance mode only from the dormant mode.

4.6. FIRE ENGINE AND JOCKEY PUMP OPERATION

Fire Engine & Jockey Pump operation shall be controlled by third party PLC supplied by
others. Monitoring shall be done on HAIL HMI by taking the data from third party PLC on
serial link.

4.7. GANTRY ESD PHILOSOPHY

MISPL supplied Manual call points will be installed at the locations in the terminal as per
below table. The Field MCP will be in energized condition (NC) when healthy. Whenever
any of the field MCP is pressed in case of emergency, the contact will be de-energized
(NO) which is interfaced with the PLC (DI).

MCP NO. LOCATION

MCP01_G1B1 MANUAL CALL POINT-01 AT GANTRY I BAY 1
MCP02_G1B2 MANUAL CALL POINT-02 AT GANTRY I BAY 2
MCP03_G1B3 MANUAL CALL POINT-03 AT GANTRY I BAY 3
MCP04_G1B4 MANUAL CALL POINT-04 AT GANTRY I BAY 4
MCP05_G1B5 MANUAL CALL POINT-05 AT GANTRY I BAY 5
MCP06_G1B6 MANUAL CALL POINT-06 AT GANTRY I BAY 6
MCP07_G1B7 MANUAL CALL POINT-07 AT GANTRY I BAY 7
MCP08_G1B8 MANUAL CALL POINT-08 AT GANTRY I BAY 8
MCP09_G1B9 MANUAL CALL POINT-09 AT GANTRY I BAY 9
MCP10_G1B10 MANUAL CALL POINT-10 AT GANTRY I BAY 10
MCP11_G1B11 MANUAL CALL POINT-11 AT GANTRY I BAY 11
MCP12_G1B12 MANUAL CALL POINT-12 AT GANTRY I BAY 12
1. This field status is processed in PLC and a soft system status is generated in the logic.
2. There is a provision of RESET given on the HMI for ESD.

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3. As soon as the field ESD is pressed the field and the system status will de-energized
and will trip the entire Gantry.
4. When the ESD is restored to healthy condition, the field status will become healthy but
the system remains in de-energized state and the gantry is trip.
5. ESD will trip all the tank outlet MOV’s& Pumps, tanks will go in Day End Dormant
mode, and all gantry operations will stop.
6. Hooter will start
7. After this the operator with managerial access has to press the RESET button from
HMI. This will make the system status healthy after the field status is healthy.
8. After reset, the entire gantry will resumed to its initial state.
9. There is also provision of ESD from HMI with managerial access.

4.8. HYDROCARBON DETECTOR LOGIC

There are two types of Hydrocarbon detectors provided at Installations
• Point type Hydrocarbon Detector
• Open path type Hydrocarbon Detector
The analog value from the HCD will be interfaced with the Safety PLC. Output from the
sensor is 4 to 20 mA. However 4 mA corresponds to 0 %, LEL and 20mA corresponds to
100% LEL. This analog value will be scaled in the logic and two alarms will be generated
at 20% LEL (H) and 40% LEL (HH) which will be monitored on the HMI screen. HCD’s to
be displayed on the dynamic graphics of the related facilities having percentage Hydro
carbon concentration display and LEL alarms.

4.9. THIRD PARTY SERIAL INTERFACE WITH TAS PLC

Following systems shall be interfaced with HAIL PLC on serial link (RS485):

• Master Control Station (MCS) for MOV

• Interface of pipe line control Room
• Interface of SCADA/RTU
• Diesel Generator
• Weigh Bridge
• VFD Interface
• Interface of OWS
• Cathodic Protection System
• Fire Alarm System
• UPS

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4.10. PRESSURE TRANSMITTER – TLF HEADER

Pressure Transmitters are mounted at Header lines of the product. These signals are
connected to PLC system for monitoring and control purpose.

4.11. HOOTER LOGIC

Hooter will be activated in case of:
• Field ESD
• ESD from HMI
• HH alarm (40%) from hydrocarbon detectors
• Local hooter where HCD alarm is generated in the field should be activated.
Following are the Min. location of hooters in the terminal:
HOOTER NO. LOCATION
HOOTER_01_G HOOTER ACTIVATION DO 01 AT GANTRY
HOOTER_02_CR HOOTER ACTIVATION DO 02 AT CONTROL ROOM
HOOTER_03_PMP HS HOOTER ACTIVATION DO 03 AT PUMP HOUSE
HOOTER_04_TF HOOTER ACTIVATION DO 04 AT AG TANK FARM
HOOTER_05_TF HOOTER ACTIVATION DO 05 AT AG TANK FARM
HOOTER_06_TF HOOTER ACTIVATION DO 06 AT AG TANK FARM

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Project: CONSTRUCTION OF LIQUID STORAGE Doc Name: Functional Design Specification‐System

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