Interlock and Logic

Educational Institute for
Equipment & Process Design
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Interlock & Logic Diagram

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Action performed in the IS are called IS-group (Interlock Safety) and actions performed in the
DCS are called I-group (Interlock).
Due to a considerable higher cost of IS than DCS hardware, consideration has been given to
define which actions (groups) are to be performed in the IS system and which actions are to be
performed in the DCS. In order to establish guidelines for the distinction of those actions, the
following rules are applied:
Trips in IS groups are generally based on 2-out-of-3 voting.
IS-groups must protect:
- personnel against safety hazards
- critical plant equipment
- unit trips which will result in a significant production loss when initiated
I-groups must protect:
- auto start and stop of motors
- avoidance of PSV relief
- switching of operating mode

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Pumps
1.Typical pump
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IS-56: Trip of stabilizer column reflux pumps, P 5003 A/B
The causes for IS-56 trip are:
- Manual panel trip

- Low level in stabilizer column OH accumulator D 5001, LSAL-5094
The following actions are carried out automatically:
- Stop stabilizer column reflux pump P 5003 A, stop MP-5003 A

- Stop stabilizer column reflux pump P 5003 B, stop MP-5003 B
Interlock Diagram
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2. BFW pump
IS-70: Trip of BFW pumps, P 7001 A/B/C
The causes for trip are:
- Manual panel trip

- Low level in deaerator D 7001, LSAL-7091
- Stop BFW pump P 7001 A, IS-71

- Stop BFW pump P 7001 B, IS-72
- Stop BFW pump P 7001 C, IS-73
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IS-71: Trip of HP BFW pump, P 7001 A
- Manual panel trip

- Trip of BFW pumps P 7001 A/B/C, IS-70
- Low suction pressure of BFW pump P 7001 A, PSAL-7112
- Stop steam to turbine FP 7001 A, close USV-7130
IS-72: Trip of HP BFW pump, P 7001 B
- Manual panel trip

- Low suction pressure of BFW pump P 7001 B, PSAL-7116
- Stop steam to turbine FP 7001 B, close USV-7135
IS-73: Trip of HP BFW pump, P 7001 C
- Manual panel trip

- Low suction pressure of BFW pump P 7001 C, PSAL-7120
- Stop BFW pump P 7001 C, stop MP-7001C

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Interlock Diagram
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Logic Diagram
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3. Steam condensate pump

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Saturated steam from the outlet of the steam turbine is recovered in the condenser and
maintained by means of a split range controller (LIC-3540) that operates the condensate
discharge valve (LCV-3540A) and the condensate recycle valve (LCV-3540B) to maintain
the liquid level constant in order to avoid eventual air to backflow inside the condenser
causing high pressure.
Two level thresholds on the condenser level transmitters (LSH-3540 and LSL-3540) start and
stop the standby condensate pump if necessary, while another threshold of minimum level
(LSLL-3540) stops both the pumps.
Instrumentation for protection in case of high high exhaust pressure (PSHH-3547) is provided
on condenser steam inlet.

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4. Lube oil pump

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Lube oil system
Lube oil is used to create lift by forming a film of oil between the shaft and bearing and to cool
the bearings to keep them at an optimum temperature as power is dissipated in the bearings,
causing them to heat up.
The oil is drawn from a lube oil reservoir (TK3002), equipped with an electric heater (E3015)
to give the oil the right viscosity for start-up, and sent to the system by two pumps (P3013A
and P3013B), one main and the other stand-by.
If main lube oil pump is running, stand-by pump is automatically started from the logic in case
of the following alarms:
PSL-3506 Low lube oil pressure at the delivery of the pumps;
PSL-3520 Low lube oil pressure at the end of lube oil header - this signal is also an inhibit to
start the compressor;
PSL-3528 Low control oil pressure - this signal is also an inhibit to start the compressor.
At the end of the lube oil header is provided also a shutdown signal of the compressor in case of
low low lube oil pressure (PSLL-3520).
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Polishing pump
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Two Intermediate pumps (P7201A/B), one in running and one on standby. P7201A is operated
at normal condition. When the pump (P7201A) is failure or the pump pressure drops to 1 bar,
the standby pump P7201B is running. When P7201A is continuously running for 48 hours,
switch to P7201B. In the same way, when P7201B is continuously running for 48 hours, switch
to P7201A. When the pressure value of PT7209 is greater than or equal to 5 bars, shut off the
standby pump.
When the liquid level of intermediate water tank rises to the set value (2m, adjustable), open the
intermediate pump (P7201A/B).
When the liquid level of intermediate water tank rises to the high level (11m, adjustable), alarm
at the high liquid level.
When the liquid level of intermediate water tank drops to the low liquid level (0.5m,
adjustable), alarm at the low liquid level.
When the liquid level of intermediate water tank continuously drops to the low- low liquid
level (0.4m, adjustable), automatically shut off the intermediate water pump (P7201A/B).
The LT7206 value is used for checking, when the difference value between LT7206 and LT7201
is greater than or equal to 0.2m (adjustable) and delay for 5 seconds, the system will be alarm
and operators will be disposing it.
Adopt protective measures as overloaded, short of phase, short circuit, electric leakage, etc. for
the pump.
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Logic Diagram
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Compressor
1.Nitrogen Compressor
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Logic Diagram
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Trip of primary reformer, H 2001
Trip of primary reformer H2001 is caused by the following:
- Manual panel trip
- Trip of the interlock sequence IS-12 of the flue gas blower (F 2001). If the flue gas blower
shuts down, flue gas will accumulate in the furnace and create excessive over pressure.
- Trip of the interlock sequence IS-10 of the combustion air blower (F 2002). If the combustion
air blower shuts down, the burners may extinguish and natural gas leaks to the re-former
furnace leading to explosion risk. Stop of combustion air blower may also create excessive
vacuum in the furnace.
- Too high temperature of HHP steam from E 2021 1, (TSAH-2355) may overheat the
downstream turbines or damage E 2021 1.
- Too high temperature of HHP steam from E 2021 2, (TSAH-2356) may overheat the
downstream turbines or damage E 2021 2.
- Too high level in the natural gas KO drum, D 1001 (LSAH-1004). Liquid from D 1001 is of
unknown composition and is as such a potential hazard to the prereformer catalyst; furthermore,
liquid must be avoided in fuel piping.
- Too low natural gas flow to reformer (FSAL-6070). If the natural gas flow decreases, the heat
absorbed by the endothermic reforming reaction will drop correspondingly. As a result, the tubes
in the primary reformer and the primary reformer outlet system could overheat.
- Too high level in feed gas scrubber separator, D 6001, (LSAH-6051). Liquid may not be
evaporated in the prereformer feed preheat coil due to the high wall temperatures. Any liquid
entering the prereformer will cause damage to the catalyst.
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- Low total flow of steam to feed gas, FSAL-2062
too low steam/carbon ratio (FFSAL-2064). If the steam/carbon ratio is too low, carbon may form
on the pre-reformer/reformer’ catalyst.
- Too low combustion air pressure (PSAL-2163). If the combustion air pressure is too low, the
burners may extinguish and natural gas leaks to the reformer furnace leading to explosion risk.
- Too low draught in furnace of H 2001 (PSAH-2224). If the pressure in the furnace in-creases
above ambient pressure, hot flue gas (up to approximately 1200ºC) will leak out in numerous
places. This presents a potential danger to personnel and/or damage to the steel casing of the
reformer.
- Too high draught in the furnace of H 2001 (PSAL-2224). Too high vacuum may damage the
furnace casing and refractory.
- Too high temperature of flue gas inlet H 2001 waste heat section (TSAH-2221) may damage
coils.
- Too high temperature of reformed gas exit H 2001 (TSAH-2305). If the reformer outlet
temperature is too high, the reformer tubes and outlet collector may be damaged due to
overheating.
- To high temperature in the chamber between the waste heat boiler and steam super heater
may damage the steam super heater, E 2021 1/ E 2021 2, (TSAH-2335/TSAH- 2336).
- Too low level in the HHP steam drum, D 2001, (LSAL-2372). If the level in the steam drum is
too low the boilers could run dry and thus be exposed to excessive temperatures.
- Too high fuel gas pressure to H 2001 (PSAH-2554), if the pressure in the fuel header gets too
high, the furnace and the reforming tubes may overheat.
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- Too low fuel gas pressure to H 2001 (PSAL-2556), if the pressure in the fuel header gets too
low the burners may extinguish. Unburned natural gas may create an explosive mixture inside
the furnace.
- Too low flow of start-up nitrogen to E 2002 (FSAL-2582), if the nitrogen flow is too low during
heating the reforming tubes may overheat.
- Trip of secondary reformer, IS-2
- Trip of methanol synthesis, IS-3
- Stop emergency methanol to reformer, IS-6
- Trip of combustion air blower F 2002, IS-10
- Trip of flue gas blower F 2001, IS-12
- Trip of purge gas to H 2001 burners, IS-14
- High pressure in reformer furnace box, I-15
- Oxygen ready to start, I-20
- Stop water to saturator T 6001, I-32
- Trip of synthesis gas compressor/recirculator C 3001/C 3002, IS-40

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Interlock Diagram
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Logic Diagram
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IS-10: Trip of combustion air blower
- Manual panel trip

- Trip of primary reformer H 2001, IS-1
- Trip of turbine FT-2002, IS-11 AND trip of motor MF 2002 for combustion air blower
- Trip signal from combustion air blower, F 2002

- Trip of turbine for combustion air blower FT 2002, IS-11
- Trip of vent gas to reformer, I-61
- Stop motor MF 2002 for combustion air blower
It is possible to inactivate the IS-1 trip in order to perform the burner tightness test and furnace
purge.
8.11 IS-12: Trip of flue gas blower, F 2001
- Manual panel trip

- Trip of turbine FT-2001, IS-13 AND trip of motor MF 2001 for flue gas fan
- Trip signal from flue gas fan, F 2001

- Trip of turbine FT 2001 for flue gas fan, IS-13
- Stop motor MF 2001 for flue gas fan
It is possible to inactivate the IS-1 trip in order to perform the burner tightness test and furnace
purge.
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Interlock Diagram
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8.13 IS-14: Trip of purge gas to H 2001 burners
- Manual panel trip

- Low pressure of fuel gas to H 2001, PSAL-2554
- Enable double block and bleed of purge gas to reformer, close USV-2544
- Enable double block and bleed of purge gas to reformer, open USV-2545
- Enable double block and bleed of purge gas to reformer, close FV-2536 - solenoid FUSY-2536
is de-energized
- Stop purge gas from synthesis, close FV-2536 - controller FIC-2536 is switched to manual
mode with 0% output
Interlock Diagram
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8.14 I-15: High pressure in reformer furnace box
The causes for I-15 trip are:
- Manual panel trip

- High pressure in reformer furnace box, PAHH-2224
- Deleted
- Start reformer hazard flashers, XAL-2284
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IS-5: Trip of draining of D 1001
- Manual panel trip

- Low level in natural gas K.O. drum D 1001, LSAL-1004
- Stop draining from D 1001, close USV-1001
Interlock Diagram
Logic Diagram

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Educational Institute for

Equipment & Process Design

Interlock & Logic Diagram

Equipment & Process Design

DCS are called I-group (Interlock).

following rules are applied:

Trips in IS groups are generally based on 2-out-of-3 voting.

IS-groups must protect:

- personnel against safety hazards

- critical plant equipment

I-groups must protect:

- auto start and stop of motors

- avoidance of PSV relief

- switching of operating mode

Equipment & Process Design

Equipment & Process Design

IS-56: Trip of stabilizer column reflux pumps, P 5003 A/B

The causes for IS-56 trip are:

- Manual panel trip

The following actions are carried out automatically:

- Stop stabilizer column reflux pump P 5003 A, stop MP-5003 A

Equipment & Process Design

IS-70: Trip of BFW pumps, P 7001 A/B/C

The causes for trip are:

- Manual panel trip

The following actions are carried out automatically:

- Stop BFW pump P 7001 A, IS-71

Equipment & Process Design

IS-71: Trip of HP BFW pump, P 7001 A

The causes for trip are:

- Manual panel trip

The following actions are carried out automatically:

- Stop steam to turbine FP 7001 A, close USV-7130

IS-72: Trip of HP BFW pump, P 7001 B

The causes for trip are:

- Manual panel trip

The following actions are carried out automatically:

- Stop steam to turbine FP 7001 B, close USV-7135

IS-73: Trip of HP BFW pump, P 7001 C

The causes for trip are:

- Manual panel trip

The following actions are carried out automatically:

- Stop BFW pump P 7001 C, stop MP-7001C

Equipment & Process Design

Equipment & Process Design

Equipment & Process Design

Equipment & Process Design

3. Steam condensate pump

Equipment & Process Design

causing high pressure.

(LSLL-3540) stops both the pumps.

on condenser steam inlet.

Equipment & Process Design

Equipment & Process Design

Equipment & Process Design

Equipment & Process Design

4. Lube oil pump

Equipment & Process Design

Lube oil system

causing them to heat up.