A Desal SOP

Effective

Oct 2002

Q.E.W.C

Issued Date Revision Issued ByMay 2003

Production/Operation

Page 1 of 320

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RAF-A DESALINATION STANDARD OPERATION PROCEDURESPART-D1 DISTILLERS

Page 2 of 320

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TO VIEW ANY SOP CLICK ON ITS PAGE NUMBER. TITLE: DISTILLERS Serial no. 1 2 3 4

SOP No. D1-001 D1-002 D1-003 D1-004

DESCRIPTION INTER TRIP TEST SEQUENCE SEA WATER RECEIVING STARTING OF BRINE BLOWDOWN PUMP STARTING OF BRINE RECIRCULATION PUMP COOLING SEAWATER SUPPLY TO EJECTOR CONDENSERS WARMING UP OF EJECTOR STEAM LINE

Page No. 23 24 26 27

5

DI-005

29

6

D1-006

30

7

D1-007

VACUUM RAISING BY HOGGING EJECTOR.

31

8

D1-008

EJECTOR SWITCHING

32

9

D1-009

WARMINGUP OF BRINE HEATER STEAM LINE STEAM ADMISSION & STARTING OF CONDENSATE PUMP

33

10

D1-010

34

Page 3 of 320

Effective

Oct 2002

Q.E.W.C11 12 13 14 D1-011 D1-012 D1-013 D1-014


Production/Operation 36 37 38 39

STARTING ANTISCALE & ANTIFOAM DOSING STARTING OF DISTILLATE EXTRACTION PUMP STARTING OF SECOND BRINE RECIRCULATION PUMP LOADING UP & STABILISATION

15

DI-015

STARTING OF HIGH PURITY DISTILLATE PUMP

40

16

D1-016

STARTING OF SEAWATER RECIRCULATION PUMP DISTILLER SHUTDOWN PROCEDURE PREPARATIONS LOAD REDUCTION

41

17

D1-017

42

18

D1-018

43

19

D1-019

DUMPING OF DISTILLATE & CUTTING OF STEAMCOLD CIRCULATION & SEALING OF PLANT VACUUM STOPPING COLD CIRCULATION & STARTING DRAINING STOPPING SEAWATER FLOW TO HJS

44

20

D1-020

45

21

D1-021

46

22

D1-022

47

23

D1-023

EMERGENCY SITUATIONS

48

Page 4 of 320

Effective

Oct 2002

Q.E.W.C24 25 26 27 D1-024 D1-025 D1-026 D1-027


Production/Operation 49 51 52 54

SEAWATER SUPPLY FAILURE STEAM SUPPLY FAILURE INSTRUMENT AIR SUPPLY FAILURE TWO BRINE RECIRCULATION PUMPS TRIP

28

DI-028

TWO BRINE BLOWDOWN PUMPS TRIP TWO CONDENSATE OR DISTILLATE PUMPS FAILURE UNIT POWER SUPPLY FAILURE

55

29

D1-029

56

30

D1-030

57

31

D1-031

BLACKOUT

58

32

D1-032

OPERATIONAL CHECKS

59

33

D1-033

OPERATION OF EJECTORS AT PHASE I & III

60

34

D1-034

OPERATION OF EJECTORS AT PHASE II

65

35

D1-035

OPERATION OF EJECTORS AT PHASE IV

70

36

D1-036

OPERATION OF EJECTORS AT PHASE V

75

Page 5 of 320

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Q.E.W.C37 38 39 D1-037 D1-038 D1-039



OPERATION OF CO2 RECOVERY SYSTEM IN PHASE I, II, & III STARTUP OPERATION OF CO2 RECOVERY SYSTEM IN PHASE I, II, & III SHUTDOWN OPERATION OF TAPROGGE SYSTEM PROCEDURE FOR FLUSHING WITH DISTILLATE WATER HEAT REJECTION SECTION FILLING METHOD FOR PHASE I, II, III, IV & V

80 81 82

40

DI-040

90

41

D1-041

91

42

D1-042

STARTING FLUSHING CIRCULATION FLUSHING OF HEAT RECOVERY & HEAT INPUT SECTIONS FILLING METHOD FOR PHASE V AND CIRCULATION FOR FLUSHING TUBE LEAK DETECTION HEAT REJECT SECTION TUBE LEAK DETECTION HEAT RECOVERY SECTION HYDROSTATIC TEST FOR TUBE LEAKS TUBE LEAK DETECTION IN PHASE II- HEAT REJECT SECTION TUBE LEAK DETECTION HEAT RECOVERY SECTION TUBE LEAK DETECTION HEAT REJECT SECTION PHASE IV

93

43

D1-043

94

44

D1-044

95

45

D1-045

97

46

D1-046

101

47

D1-047

102

48

D1-048

104

49

D1-049

105

Page 6 of 320

Effective

Oct 2002

Q.E.W.C50 51 52 D1-050 D1-051 D1-052


Production/Operation 107 108 109

TUBE LEAK DETECTION IN PHASE IV HEAT RECOVERY SECTION TUBE LEAK DETECTION IN PHASE V HEAT RECOVERY SECTION TUBE LEAK DETECTION IN PHASE V HEAT REJECT SECTION TUBE LEAK DETECTION IN BRINE HEATE IN ALL PHASES ACID CLEANING PROCEDURE - FILLING WITH SEAWATER ACID CLEANING PROCEDURE PREPARATION ACID CLEANING PROCEDURE STARTING CIRCULATION ACID CLEANING PROCEDURE WARMING UP

53

DI-053

111

54

D1-054

113

55

D1-055

114

56

D1-056

116

57

D1-057

117

58

D1-058

ACID CLEANING PROCEDURE ACID CHARGING ACID CLEANING PROCEDURE FLUSHING WITH SEA WATER ACID CLEANING PROCEDURE DRAINING

118

59

D1-059

119

60

D1-060

120

61

D1-061

BASIC ISOLATIONS FOR SPECIFIC PERMITS

121

62

D1-062

DISTILLER OVERHAUL PERMITS

134

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RAF-A DESALINATION STANDARD OPERATION PROCEDURESPART-D2 BOILERS & DEAERATORS

Page 8 of 320

Effective

Oct 2002

Q.E.W.C63 64 65 GENERAL D2-001 D2- 002


Production/Operation 138 141 143

WATER QUALITY OF H.P.MAKEUP AND CONDENSATE AND BOILER WATER STARTUP OF DEAERATOR SHUTDOWN OF DEAERATOR

66

D2-003

WHB PRESTARTUP CONDITIONS

144

67

D2-004

WHB STARTUP

145

68

D2-005

WHB SUPPLEMENTARY GAS FIRING

147

69

D2-006

WHB SHUTDOWN PROCEDURES

148

70

D2-007

AUX BOILER PRESTART CHECKS

149

71

D2-008

AUX BOILER STARTUP ON GAS

150

72

D2-009

AUX BOILER PRESTARTUP CHECKS FOR OIL

152

73

D2-010

AUX BOILER STARTUP ON OIL AUX BOILER FUEL CHANGEOVER FROM GAS TO OIL AUX BOILER FUEL CHANGEOVER FROM OIL TO GAS

153

74

D2-011

155

75

D2-012

156

Page 9 of 320

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Oct 2002

Q.E.W.C77 78 D2-013 D2- 014



AUX BOILER SHUTDOWN PROCEDURE AUX BOILER PROCEDURE

157 158

79

D2-015

WHB WATER WEDGING PROCEDURE

159

80

D2-016

WHB DEWATERWEDGING PROCEDURE

160

81

D2-017

AUX BOILER WATER WEDGING PROCEDURE

161

82

D2-018

AUX BOILER DEWATERWEDGING PROCEDURE

162

83

D2-019

PTW & WHB PRESSURE PARTS

163

84

D2-020

PTW & WHB NON PRESSURE PARTS

164

85

D2-021

PTW & WHB FUEL GAS SYSTEM HIGH RISK SANCTION FOR WORK AT THE BOILER MECHANICAL & ELECTRICAL ISOLATIONS

165

86

D2-022

166

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RAF-A DESALINATION STANDARD OPERATION PROCEDURESPART- D3 COMMON SERVICES

Page 11 of 320

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87 88 89

GENERAL D3-001 D3-002

OPERATIONAL PROCEDURE COMPRESSED AIR SYSTEM COMPRESSOR STARTUP PROCEDURE COMPRESSOR SHUTDOWN PROCEDURE

169 170 172

90

D3-003

ISOLATION FOR PTW

173

91

D3-004

AIR DRIER OPERATION

174

92

D3-005

INDUSTRIAL WATER SYSTEM PROCEDURE FOR CHANGEOVER OF BOOSTER PUMP ISOLATION FOR PTW

176

93

D3-006

177

94

D3-007

179

95

D3-008

MAKEUP WATER SYSTEM

181

96

D3-009

BEARING COOLING WATER SYSTEM

185

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RAF-A DESALINATION STANDARD OPERATION PROCEDURESPART- D4 FIRE FIGHTINGPage 13 of 320

Effective

Oct 2002

Q.E.W.C



97 98 99

D4-001 D4-002 D4-003

ELECTRIC FIRE PUMPS A & B DIESEL FIRE PUMPS A & B ELECTRIC FIRE PUMP C

187 189 192

100

D4-004

DIESEL FIRE PUMP C FIRE MAIN PRSSURE SUSTAINING PUMPS A1, A2, B1 & B2 DELUGE SYSTEM TANK FARM

194

101

D4-005

196

102

D4-006

198

103

D4-007

SPRINKLER FIRE ALARM

200

104

D4-008

FIRE HYDRANTS SAMPLE OF H-1, H-17 & H- 27

202

Page 14 of 320

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RAF-A DESALINATION STANDARD OPERATION PROCEDURESPART- D5 BOPPage 15 of 320

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Oct 2002

Q.E.W.C



105 106 107 108

GENERAL D5-001 D5-002 D5-003

SEA WATER PUMPS OPERATIONS PRESTART CHECHS STARTING OF S.W.PUMP AT SWPH A STARTING OF S.W.PUMP AT SWPH B STARTING OF S.W.PUMP AT SWPH C

204 205 206 207

109

D5-004

S W PUMPS RUNNING CHECKS

208

110

D5-005

S W PUMP SHUTDOWN

209

111

D5-006

GT C.W PUMPS A & B

210

112

D5-007

BAND SCREENS A , B , C, D, & E

213

113

D5-008

WASHWATER PUMPS A & B

215

114

D5-009

BAND SCREENS & WASHWATER PUMPS F , G & H

217

115

D5-010

BAND SCREENS 2A & 2B CUMBERLAND ELECTROCHLORINATION STREAMS 1, 2 ,3 & 4 ELECTROCHLORINATION G , H & J

219

116 117

D5-011 D5-012

221 225

Page 16 of 320

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Oct 2002

Q.E.W.C118 D5-013



ELECTROCHLORINATION K & L

227

119

D5-014

SCHEDULED CHANGEOVER OF EQUIPMENTS

230

120

D5-015

STARTUP OF RECARBONATION (DTP)

232

121

D5-016

STARTUP OF CO2 COMPRESSOR SYSTEM

233

122

D5-017

STARTUP CHLORINATION PLANT

234

123

D5-018

LIMESTONE FILTERS

235

124

D5-019

RECARBONATION PLANT SHUTDOWN

236

125

D5-020

ELECTROCHLORINATION PLANT SHUTDOWN

237

126

D5-021

FORWARDING PUMPS STARTUP

238

127

D5-022

FORWARDING PUMPS SHUTDOWN

239

Page 17 of 320

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RAF-A DESALINATION STANDARD OPERATION PROCEDURESPART-D6 ELECTRICAL ISOLATIONS

128

GENERAL GENERAL GUIDE LINES Page 18 of 320

240

Effective

Oct 2002

Q.E.W.C129 130 131 132 133 134


Production/Operation 241 242 243 244 245 247

GENERAL GENERAL GUIDE LINES D6-001 D6-002 D6-003 D6-004 D6-005 ISOLATION OF 6.6KV VCB DEISOLATION OF 6.6KV VCB ISIOLATION OF 6.6KV DEISOLATION OF 6.6KV ISOLATION OF 415V ACB FOR WORK ON PUMP

135

D6-006

ISOLATION OF 415V ACB FOR WORK ON MOTOR ISOLATION OF 415V ACB FOR WORK ON MOTOR STARTER STARTER DEISOLATION OF 415V ACB AFTER WORK ON MOTOR ISOLATION OF 415V ACB AT STATION AUX BOARDS ISOLATION OF 415V ACB AT STATION AUX BOARDS FOR WORK ON MOTOR STARTER DEISOLATION OF 415V ACB AFTER WOPRK ON MOTOR STARTER SUPPLY CHANGING OVER FOR 415V DISTILLER BOARDS SUPPLY CHANGING OVER & RELEASING THE INCOMER AT PHASE I ,II, & III

248

136

D6-007

249

137

D6-008

250

138

D6-009

252

139

D6-010

253

140

D6-011

254

141

D6-012

255

142

D6-013

256

Page 19 of 320

Effective

Oct 2002

Q.E.W.C143 144 145 146 147 D6-014 D6-015 D6-016 D6-017 D6-018


Production/Operation 264 265 273 274 275

NORMALISING THE INCOMING SUPPLY IN 415V DISTILLER BOARD SUPPLY CHANGING OVER & RELEASING THE INCOMER IN PHASSE - IV NORMALISING THE INCOMING SUPPLY IN PHASE IV 415V DISTILLER BOARDS SUPPLY CHANGING OVER IN DISTILLER BOARDS 13 & 14 SUPPLY CHANGING OVER IN STATION AUXILIARY BOARDS 7A, 7B, 8A & 8B NORMALISING THE INCOMING SUPPLY IN 415V STATION AUX BOARDS RELEASING OF 415V DISTILLER BOARDS FOR ANNUAL OVERHAUL RELEASING OF 415V DISTILLER BOARDS AT PHASE I, II, III & IV ELECTRICAL ISOLATION FOR OVERHAUL PERMIT OF DISTILLER -13 ELECTRICAL ISOLATION FOR OVERHAUL PERMIT OF DISTILLER -14 TAKING DISTILLER TRANSFORMER IN SERVICE AFTER COMPLETION OF MAINTENANCE ON TXR, OCB, & ACB INTERTRIP TEST SEQUENCE

148

D6-019

276

149

D6-020

277

150

D6-021

278

151

D6-022

279

152

D6-023

280

153

D6-024

282

154

D6-025

284

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Q.E.W.C



RAF-A DESALINATION STANDARD OPERATION PROCEDURESPART-D7 EMERGENCY CONTINGENCY PROCEDURE

Page 21 of 320

Effective

Oct 2002

Q.E.W.C155 D7-001 BLACK OUT



287

156

D7-002

OIL SLICK CONTINGENCY PLAN

289

Page 22 of 320

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Q.E.W.C



RAF-A DESALINATION STANDARD OPERATION PROCEDURESPART-D1 DISTILLERS

Page 23 of 320

Effective

Oct 2002

Q.E.W.CSOP No



TITLE: DISTILLERS

D1-001

ACTIVITY REFERENCE RESPONSIBILITY COMMUNICATION

DISTILLER START-UP PROCEDUREDSCE/PERMIT ENGINEER/SUPERVISOR/DIST

Location OPERATION Field CCR/DCR

INTERTRIP TEST SEQUENCE

Prior to start-up, the following items are to be checked and confirmed. Piping connections are tightened, all related drain valves are closed and hogging ejector vapour suction valve is opened. Strainers are cleaned where applicable. Pump lubrication is adequate, cooling/flushing/sealing water is in service and pumps suction valves are opened. Instrument air is in service and control valves opening position match to controller output. All control valves are closed and their isolation valves are opened and the bypass valve is closed. All instrument devices are available and functioning. The chemicals are prepared in local day tanks and power supply for the mixer motors are turned ON at their circuit breakers. The 6.6 kV and 415V electrical supplies to the electrical equipment are available and the selectors on their circuit breakers are positioned in control room. Steam and seawater supplies are ready for service.Page 24 of 320

*

* *

*

* *

* *

Effective

Oct 2002

Q.E.W.CSOP No



TITLE: DISTILLERS

D1-002

ACTIVITY REFERENCE RESPONSIBILITY COMMUNICATION OPERATION

DISTILLER START-UP PROCEDURE

CCR/DCR/LOCAL DIST SPERVISORS CCR/DCRLocation Field CCR/DCR

Seawater Receiving Confirm that, all heat reject section water boxes vent isolation valves are opened and all drain isolation valves are closed. Open seawater reject TCV(SW-19FCV-102A/SW-2TCV005/SW-19FCV1002A/TCV104/QL-FV-604) by 15% for Phase I & III, also open seawater reject TCV by 15% for Phase II, IV & V. Gradually, open the S W main isolation valve (SW1/VSW-1/SW-1/SW-1/QL-MV-600) of the seawater inlet up to 25% (at Phase IV & V it is motorized valve, except distiller No. 10). When water boxes venting are completed and seawater to reject pressure indicator goes up to 2.7 barg or higher and becomes stable, gradually open seawater main isolation valve(SW-1/VSW-1/SW-1/SW-1/QL-MV-600)100%, then maintain the reject flow as required by TCV(SW-19FCV102A/SW-2TCV-005/SW-19FCV1002A/TCV104/QL-FV604) and close vent isolation valves of water boxes. Start Fe SO4 dosing at Phase IV. To start shell filling, confirm that hogging ejector vapour suction isolation valve (VA-11/VAE-1/VA-11/VA-11/LQPage 25 of 320 *

*

*

*

*

*

*

Effective

Oct 2002

Q.E.W.C



XV-793) is opened, and seawater make-up FCV(SW22,FCV012/VFW2,FCV-502/SW-22,FCV-012/FCV104/QL-V-619) isolation valves (U/S: SW-21/VFW-1/SW21/SW-2/QL-V-630 & D/S: -/VFW-3/-/QL-V-629) are opened and bypass isolation valve (SW-24/VFW-4/SW24/SW-4/QL-V-631) is closed. Open seawater make-up FCV (SW22,FCV012/VFW2,FCV-502/SW-22,FCV-012/FCV-104/ QL-V-619)as required to adjust the last stage level to the normal working level. At Phase IV, adjust seawater deaerator level by opening seawater make-up FCV(SW22,FCV012/VFW2,FCV-502/SW-22,FCV-012/FCV-104/ QL-V-619), and then adjust the last stage level by opening deaerator LCV(LCV-106). Start Na2 SO3 dosing at Phase IV; the dosing is in seawater make-up outlet line from seawater deaerator.

*

Page 26 of 320

Effective

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Q.E.W.C



TITLE: DISTILLERS SOP No

D1-003



CCR/DCR/LOCAL DIST SUPERVISORS CCR / DCRLocation Field CCR/DCR

Starting of Brine Blowdown Pump Confirm that: - BlowdownLCV(BD-8,LCV-001/VBD-8,LCV352/BD-8,LCV-001/LCV-103/QN-LV-752) isolation valves (U/S: BD-7/VBD-7/BD-7/BD85/QN-V-609& D/S: BD-8/VBD-8/BD-8/-/QN-V610) are opened and bypass isolation valve(BD10/VBD-10/BD-10/B-86/QN-V-611) is closed. - Blowdown pump suction isolation valve(BD-1,BD2/VBD-1,VBD-2/BD-1,BD-2/B-79,B-80/QN-V600,QN-V-605) and casing with suction vent isolation valves are opened. - Sealing/flushing water is in service.Page 27 of 320

* *

*

Effective

Oct 2002

Q.E.W.C


Production/Operation * *

Open Blow down discharge isolation valve(BD-5,BD6/VBD-5,VBD-6/BD-5,BD-6/B-81,B-82/QN-V-603,QNV-608) of blowdown pump upto 20% to fill up discharge line with seawater and open discharge vent isolation valve and then close the pump discharge isolation valve(BD5,BD-6/VBD-5,VBD-6/BD-5,BD-6/B-81,B-82/QN-V603,QN-V-608). When last stage level rises up to 80%, release E.P.B. Emergency Push Button then start the pump. Check the discharge pressure, and then open the discharge isolation valve (BD-5,BD-6/VBD-5,VBD-6/BD-5,BD-6/B81,B-82/QN-V-603,QN-V-608) and close the discharge vent isolation valve. Check the electric current, and make sure that there is no abnormal noise or vibration from the pump. Adjust FCV (seawater make-up) (SW22,FCV012/VFW2,FCV-502/SW-22,FCV-012/FCV-104/ QL-V-619) & LCV (BD-8,LCV-001/VBD-8,LCV352/BD-8,LCV-001/LCV-103/QN-LV-52)to keep last stage level around 90% and seawater make-up flow around 1000 t/hr. Open the discharge isolation valve (BD-5,BD-6/VBD5,VBD-6/BD-5,BD-6/B-81,B-82/QN-V-603,QN-V-608). of the other pump to make it in standby position for emergency auto changeover.TITLE: DISTILLERS SOP No

* * *

D1-004



CCR/DCR/LOCAL DIST SUPERVISORS CCR/DCR

Page 28 of 320

Effective

Oct 2002

Q.E.W.COPERATION


Production/OperationLocation Field CCR/DCR

Starting of One Brine Recirculation Pump & Establishing of Cold Circulation Confirm that: - Brine Pump suction isolation (B-3,B4/VBR1,VBR2/B-3,B4/B-1,B-2/QM-MV-600,QMMV604)valve is opened. - Suction(V-28,29/VVA-16,17/VA-28,29/B-V-4,8/ QQV-601,603), casing(Ph-1~4 N/A//QQV-600,602 ) and discharge (BD-52,53/N/A/BD-52,53/B-V1,2,5,6/QM-V-658,659,660 )vent valves are opened. - Sealing/flushing/cooling water is in service. - Oil level for thrust bearing and motor bearing, where applicable, are normal. - Opening & closing sequence of Brine pump discharge motorised valves (B-7/VBR-5/B-7/B3/QM-MV603 & B-8/VBR-6/B-8/B-4/QM-MV607). - Taprogge ball strainers are in backwash position. - Open emergency blowdown isolation valve (B9/VEB-1/B-9/B-7/--) or discharge motorised valve(B-7/VBR-5/B-7/B-3/QM-MV603 & B8/VBR-6/B-8/B-4/QM-MV-607). and FCV (recirculating brine at Phase I to IV) (B14,FCV-001/VBR-7,FCV-503/B-14FCV-107) up to 30% to fill up the discharge line with seawater, and then close the valves. Open vent isolation valves and close drain isolation valves of water boxes for heat recovery section and brine heater. Get clearance from the generation to start the brine recirculation pump. Open FCV (B-14,FCV-001/VBR-7,FCV-503/B-14FCVPage 29 of 320 * * * * * * * *

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*

*

*

*

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Q.E.W.C


Production/Operation * * * *

107/QM-FV-666)(Isolation Valves U/S:B-13/NA/B13/NA/NA & D/S:B-15/NA/B-15/NA/NA)15%, release E.P.B. then start BRP-B and then open discharge motorised valve 100% for priming the water boxes. At Phase V the priming will be by the discharge motorised valve, and after priming the water boxes, open the motorised valve(B-7/VBR-5/B-7/B-3/QM-MV603 & B8/VBR-6/B-8/B-4/QM-MV-607). 100% and adjust the flow by FCV FCV (B-14,FCV-001/VBR-7,FCV-503/B14FCV-107/QM-FV-666). Check the discharge pressure and electric current, and make sure that there is no abnormal noise and vibration from the pump. Vent the discharge line, and keep the pump running under close observation. Open self-flushing isolation valve and isolate the industrial water at Phase IV. Close the water box vent valves after venting is completed. Adjust recirculating brine flow while maintaining first and last stage level. Start debris separator system at Phase I, III & V. Start Na2SO3 dosing at Phase I & III; the dosing is in the common discharge line of the brine recirculation pumps.

Page 30 of 320

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Q.E.W.C




D1-005



CCR/DCR/LOCAL DIST SUPERVISORS CCR/DCRLocation Field CCR/DCR

Cooling Seawater Supply to Ejector Condensers Open the cooling seawater main isolation valve (SW2/SW-7/SW-2/SW-8/QLV-618). Check seawater to vent condenser C/V (SW-6), its by-pass (SW-5) & Isolation Valves (U/S: SW-3, D/S: S/W-4) at Phase I & III. Confirm that seawater flow is established to each condenser and seawater pressure and the flow are normal.* * *

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Q.E.W.C




D1-006



CCR/DCR/LOCAL DIST SUPERVISOR CCR/DCRLocation Field CCR/DCR

Warming-Up of Ejector Steam Line Confirm that: - Steam trap isolation valves are closed. - Steam drain valves are opened. - Steam isolation valve (S-15/VHS-11/S-15/S10,11/--)(S-16/VHS-12/S-16/S-14,15/--) to each ejector is closed. Drain the accumulated water in vapour lines where applicable. Open steam to ejectors main isolation valve (S-13/S-13/LQ-MV-630) around 10% (at Phase I, III & V). Open the isolation valves (VHS-8/S-7,S-8) of PCVPage 32 of 320

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Effective

Oct 2002

Q.E.W.C


Production/Operation * * *

(VHS-7/PCV-101) (to ejectors) and close the bypass(VHS9/S-9) valve of PCV(VHS-7/PCV-101), and then open PCV(VHS-7/PCV-101) around 10% (at Phase II & IV). Open the equalising isolation valve of the steam unit isolation valve (U/S: S-8 (MOV)/VHS-1A/S-8 (MOV) /S1/LQ-MV-603, S-9/VHS-1B/S-9/S-3/NA. D/S:S12/A(MOV)/S-12/S-2/NA ) step by step, observing steam drainage. When water draining is reduced, open the trap isolation valves, and when steam draining is finished completely, close the drain bypass isolation valves. Open the steam unit isolation valve (S-8&9/S4002/S8&9/S-252/LQ-V-600) and then close the equalising isolation valve of steam unit isol. V/v(S-8&9/S4002/S8&9/S-252/LQ-V-600).


D1-007



CCR/DCR/DIST LOCAL SUPERVISORS CCR/DCRLocation Field CCR/DCR

Page 33 of 320

Effective

Oct 2002

Q.E.W.CVacuum Raising by Hogging Ejector



Confirm that: - All vent valves, drain valves, sampling valves connected to vacuum zone are closed. - Pump casing drain valves are closed. - Service ejectors are isolated. - Line up stage No. 1 & 2 vapour line to vent condenser at Phase I & III. Slightly open the hogging ejector steam isolation valve (S14/VHS-10/S-14/S-12/LQ-XV-777) to warm up the ejector, and when white smoke exhaust begins, slowly open the isolation valve to full open position. Confirm that pressure indicators go down to lower than 450 mbarA for the first 30 min, when the pressure indicator drops to 200 mbarA, switch over the ejector to service ejectors.

Line diagram of ' VACUUM SYSTEM '

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* *


D1-008



CCR/DCR/DIST LOCAL SUPERVISORS CCRDCRLocation Field CCR/DCR

Ejector SwitchingPage 34 of 320

Effective

Oct 2002

Q.E.W.C



Confirm that each ejector exhaust isolation valves(VA14/NA/VA-14/VA-9/NA , VA-18/NA/VA-18/VA-14/NA, VA-22/NA/VA-22/NA/N/A ,VA-22/NA/VA-22/NA/NA) are opened. Close the hogging ejector vapour suction isolation valve (VA-11/VAE-1/VA-11/VA-11/LQ-XV-793) and then the steam isolation valve (S-14/VHS-10/S-14/S-12/LQ-XV777). Slowly open the steam isolation valve of the secondary ejector(S-17/VHS-11/S-17/S-13/LQ-XV-783, OR S18/VHS-12/S-18/S-14/LQ-XV-785) to full open position. Then open the vapour suction isolation valve(VA-16/VAE4/VA-16/VA-12/LQ-XV-798 OR VA-17/VAE-5/VA17/VA-13/LQ-XV-800) of the secondary ejector. Slowly open the steam isolation valve (S-15/VHS-11/S15/S-10/LQ-XV-779 OR S-16/VHS-12/S-16/S-11/LQXV-781)of the primary ejector to full open position. Then open the vapour suction isolation valve(VA-12/VAE2/VA-12/VA-7/LQ-XV-794 OR VA-13/VA-3/VA13/VA8/LQ-XV-796) of the primary ejector (at Phase I & III there are three stages service ejector). For more details refer to Operation of Venting System section. Confirm that pressure drop down approximately 30 mbar per 10 min, until reach 100 mbarA.

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*

*


D1-009

ACTIVITY

DISTILLER START-UP PROCEDUREPage 35 of 320

Effective

Oct 2002

Q.E.W.CREFERENCE RESPONSIBILITY COMMUNICATION OPERATION




Warming-Up of Brine Heater Steam Line Confirm that: - Steam drain valves are opened. - PCV(s) (to brine heater) (S-10,TCV-071/VHS2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) is closed. Slowly open the equalising valve(s) of PCV) (S-10,TCV071/VHS-2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679)up-stream isolation valve (S-8/VHS-1A,VHS-1B/S-8/S1,S3/LQMV603), when drain become hot, open the isolation valves of steam traps. As the steam exhaust from the drain valves becomes stronger, close the steam drain valves, and confirm that steam traps are functioning. Open PCV(S-10,TCV-071/VHS-2,TCV-004A; VHS2,TCV-004B/S-10,TCV-071/PCV-102A,PCV-102B/LQTV-679) up-stream isolation valve(s(S-8/VHS-1A,VHS-1B/S8/S1,S3/LQ-MV603), (motorised valve at Phase I, III & V), and close the equalising valve(s). Open PCV(S-10,TCV-071/VHS-2,TCV-004A; VHS2,TCV-004B/S-10,TCV-071/PCV-102A,PCV-102B/LQTV-679) Steam PCV down stream isolation valve(s) (S12/VHS-3,VHS-4/S-12/S-2,S-4/--) (motorised valve at Phase II & IV), and the steam trap isolation valves (at Phase V there is no down stream isolation valve).Page 36 of 320

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Effective

Oct 2002

Q.E.W.C




D1-010




Steam Admission & Starting of Condensate Pump Line diagram of ' STEAM & CONDENSATE ' Confirm that: - Cooling water header isolation valve (HM-6/VCH19/HM-6/O-HM-287/LT-V-625) to the desuperheater is opened (H.P. make-up at Phase I to IV and condensate at Phase V), and isolation valves (U/S:C-16/VCH-15C-16/C-11LT-V-622 &D/S:C-18/VCH-17/C-18/C-12/LT-V-623)of LP. Steam TCV(C-17*TCV-073/VCH-16*TCV-009/C17/TCV-073/TCV-101/LT-TV-814), LCV(C11*LCV-003/VCH-8*LCV-354/C-11/LCV-003/ LCV-101/LT-LV-822) (brine heater), and CRV(C9/VCH-11/C-9/CRV-103-B/LT-XV-841) (condensate) are opened. - Brine heater vent to atmosphere valve is opened (at Phase V, vent line connected to seawaterPage 37 of 320

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Effective

Oct 2002

Q.E.W.C



deaerator vent header at start up only). - B.H LCV (C-11*LCV-003/VCH-8*LCV-354/C11/LCV-003/ LCV-101/LT-LV-822)(U/S:C10/VCH-7/C-10/C-7/LT-V-610)(D/S:C-12/VCH9/C-12/C-8/LT-V-611)(BY-PASSV/V:C-13/VCH10/C-13/C-9/LT-V-612)& TCV (C-17*TCV073/VCH-16*TCV-009/C-17/TCV-073/TCV101/LT-TV-814)are closed, and Condensate CRV(C-9/VCH-11/C-9/CRV-103-B/LT-XV-841) is in dump position. - Open LP. Steam TCV(C-17*TCV-073/VCH16*TCV-009/C-17/TCV-073/TCV-101/LT-TV814) up to 10% and PCV(S-10,TCV-071/VHS2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) step by step and atomising steam to desuperheater at Phase V only.

* * * * * * * * *

To start the condensate pump, confirm that: - Pump suction valves(C-1/VCH-1/C-1/C-1/LT-V600 &C-2VCH-2/C-2/C-2/LT-V-605), vent valves & Dump V/V(C-8//C-8/NA/LT-V-627) are opened. - Sealing/flushing/cooling water is in service. - Bearing oil level is normal at Phase IV & V.*

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*

Fill up the pump casing. Start the pump, and then open the discharge valve (C5/VCH-5/C-5/C-5/LT-V-603) OR(C-6VCH-6/C-6/C-6LTV-608) very slowly . Check discharge pressure and electric current, and vent the discharge line. Open the discharge valve(C-5/VCH-5/C-5/C-5/LT-V-603) OR(C-6VCH-6/C-6/C-6LT-V-608) of the other pump to make it in standby position for emergency auto changeover. Adjust the level of the brine heater by LCV(C-11*LCVPage 38 of 320

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Effective

Oct 2002

Q.E.W.C



003/VCH-8*LCV-354/C-11/LCV-003/ LCV-101/LT-LV822). Continuous Load Up Increase steam supply to the brine heater step by step, at the same time increase the brine recirculation rate. Confirm that: - Brine temperature rising rate must be less than 20 o C per hour (to prevent the thermal damage to the B. H. tubes). - Brine pressure at the brine heater inlet must be higher than the saturated vapour pressure at its temperature (to prevent flashing in the tube, which will cause scale formation and hammering). When condensate conductivity drops down to 2.5 S/cm, retain(V/V.NO:C-11/VCH-12/C-11/CRV-103-A/LT-XV840) the condensate to the condensate header (V/V. NO:C-22/VCH-12/C-14/C-22/LT-XV-614) and to desuperheating system (V/V. NO:-C-20/VCH14/C-20/C-10/LT-V-620)


D1-011 Page 39 of 320

Effective

Oct 2002

Q.E.W.CACTIVITY REFERENCE RESPONSIBILITY COMMUNICATION OPERATION




LOCAL DIST SUPERVISOR CCR/DCRLocation Field CCR/DCR

Starting Antiscale & Antifoam Dosing Line diagram of ' ANTI SCALE & ANTI FOAM ' Confirm that: - Tanks are filled with chemical and they have proper concentration. - All valves in suction and discharge are opened. - Suction strainers are cleaned. - Accumulator gas pressure is adequate. Open the accumulator isolation valves, and open the accumulator drain valves to vent the pumps casing then close them. Start the chemical dosing pumps. Check the discharge pressure and the electric current. Adjust the pumps stroke dial according to the lab instruction.

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D1-012 Page 40 of 320

Effective

Oct 2002





CCR/DCR/LOCAL DIST SUPERVISORS CCR/DCR/TCCLocation Field CCR/DCR

Starting of Distillate Extraction Pump Line diagram of ' DISTILLATE ' Confirm that: - The pump suction isolation valves(DP-1/VDM1/DP-2/DP-2/QQ-V-600 &DP-2/VDM-2/DP-2/DP2QQ-V-604) and casing vent isolation valve is opened. - Sealing/flushing water is in service. - The pump casing is filled up with water by checking temperature of pump casing. - The isolation valves(U/P:DP-10/VDM-7/DP10/DP-7/QQ-V-780&D/S:DP-12/VDM-9/DP12/DP-8/QQ-V-781) of LCV (DP-11*LCV002/VDM8*LCV-353/DP-11*LCV-002/LCV104/QQ-LV-702)and CRV (DP-8/VDM-12/DP8/CRV-101-B/QQ-XV-719) (distillate) are opened - Distillate LCV(DP-11*LCV-002/VDM8*LCV353/DP-11*LCV-002/LCV-104/QQ-LV702)Distillate Retain C/V(VDM-11/CRV-101A/QQ-XV-718)andC/V By-pass (DP-13/VDM10DP-13/DP-9/QQ-V-782) are closed and Distillate dump CRV(DP-8/VDM-12/DP-8/CRV101-B/QQ-XV-719)Iso. V/v.(DP-7,DP-9/ TAG No. N/A/DP-7/N/A/QQ-V-637) is in dump position. When the distillate level comes up, release the E.P.B., and then start the distillate extraction pump.Page 41 of 320

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Effective

Oct 2002

Q.E.W.C



Close casing vent valve, check the discharge pressure and electric current then o pen discharge isolation valve(DP-5,DP-6/VDM-5,VDM6/DP-5,DP-6/DP-5,DP-6/QQ-V-603,QQ-V-607) and vent discharge line. Open the discharge valve (DP-5,DP-6/VDM-5,VDM6/DP-5,DP-6/DP-5,DP-6/QQ-V-603,QQ-V-607) and casing vent valve of the other pump to make it in standby position for emergency auto changeover. Open LCV(DP-11*LCV-002/VDM8*LCV-353/DP11*LCV-002/LCV-104/QQ-LV-702), and adjust the distillate level to the working level. When distillate conductivity goes down to acceptable limit, retain the distillate to the distillate header.V/V.NOS:(VDM-13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP106)Iso. V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA).


D1-013




Starting of Second Brine Recirculation Pump When the top brine temperature reach 102 oC, start preparation for starting BRP-A.Page 42 of 320 *

Effective

Oct 2002

Q.E.W.C



Confirm that: - Pump suction isolation valve (B-3/VBR-1/B-3/B1/QM-MV-600) is opened. - Suction, (V-28,29/VVA-16,17/VA-28,29/B-V-4,8/QQ-V601,603 ), casing (Ph-1~4 N/A// QQ-V-600,602) and discharge vent valves (BD-52,53/N/A/BD-52,53/B-V1,2,5,6/QM-V-658,660 ) are opened. - Sealing/flushing/cooling water is in service. Oil level for thrust bearing and motor bearing where applicable is normal. Get clearance from the generation to start the brine recirculation pump. Release E.P.B. and then start the pump, close the casing vent valve and open motorised discharge valve(B-7/VBR5/B-7/B-3/QM-MV-603). Check the discharge pressure and electric current, and make sure that there is no abnormal noise and vibration from the pump.-

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*


D1-014




Page 43 of 320

Effective

Oct 2002

Q.E.W.CLoading Up & Stabilisation



Continuously increase the output of PCV(S-10,TCV071/VHS-2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) (steam to brine heater) with the corresponding value of brine flow, until reaching the target values. Once the target condition is achieved, all interlocks to be restored where applicable and controllers to be put on auto mode. After the process is stabilised, start taprogge system. Line up CO2 vent gas to compressor at Phase I, II, III & V.

*

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D1-015



CCR/DCR/LOCAL DIST SUPERVISORS CCR/DCR

Page 44 of 320

Effective

Oct 2002

Q.E.W.COPERATION


Production/OperationLocation Field CCR/DCR

Starting of High Purity Distillate Pump After the process is stabilised, start preparation for starting the H.P. distillate pump. Confirm that: - The pumps suction isolation valves(HD-1/VDH1/HD-1/HD-1/QQ-V-615),(HD-2/VDH-2/HD2/HD-2/QQ-V-618)&(HD-3/VDH-3/HD-3/HD3/QQ-V-610) are opened. - Sealing/flushing water is in service. - Isolation valves(U/S:NA/VDH-10/NA/HD-10/QQV-621)(D/S:NA/VDH-12/NA/NA/QQ-V-622) of CRV (HD-13/VDH-11/HD-13/NA/QQ-FV-734)for H.P. Distillate are opened and CRV(HD-14/VDH14/HD-14/CRV-101-B/QQ-XV-788) is in dump position. Though the selection of the pump to operate depends on the demand of H.P. distillate. It is recommended at start up to run each pump for 10 minutes to replace the water stored in suction piping and pump casing. This operation is effective to reduce the conductivity quickly. Select the flow transmitter according to pump selection at Phase IV. Start the pump and open the discharge valve(HD-7/VDH7/HD-7/HD-4/QQ-V-617)OR(HD-8/VDH-8/HD-8/HD5/QQ-V-620)OR(HD-9/VDH-9/HD-9/HD-6/QQ-V-612). Vent the discharge line completely during suction water replacing. Check the electric current. When H.P. distillate conductivity drops down to less than 2.5 S/cm, you can retain(V/V NO:HD-16/VDH-15/HD-16/CRV102-A/QQ-XV-788) it to the H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQ-V-641)Page 45 of 320

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Effective

Oct 2002

Q.E.W.CSOP No



TITLE: DISTILLERS

D1-016




Starting of Seawater Recycle Pump To control seawater inlet temperature during winter, seawater recycle pump is put in service. Confirm that: - Pump suction valve(SW-38/VSW-3/SW-38/SW5/QL-V-610),discharge valve (SW-15/NA/SW15/SW-7/NA) and casing vent valve(SW-V-1/VVA-9/SW-V-1/SW-V-2/N/A ) are opened. - Sealing/flushing water is in service. - The pump casing is filled up with seawater. - The isolation valve (SW-18/NA/SW18/TagNo.NA/NA)of seawater reject TCVB (SW26*FCV-1002-B/NA/SW-26*FCV-1002B/NA/NA)and down stream isolation valve(SW17/VSW-6/SW-17/SW-7/QL-V-620) of seawater recycle TCV(SW-16*TCV-066/VSW-5*HI010/SW-16/TCV-066/TCV-103/QL-TV-605) are opened at Phase I & III. - Bearing oil level is normal at Phase IV. Get clearance from the generation to start the pump at Phase IV only. If S.W.Recycle flow become less than 2500 m3/hr (phase-iv) pump to be stopped asPage 46 of 320

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Effective

Oct 2002

Q.E.W.C



recommended by manufacturer. Release E.P.B. and start the pump. Check the discharge pressure and electric current, and make sure that there is no abnormal noise and vibration from the pump. Adjust the seawater flow by opening seawater recycle TCV(SW-16*TCV-066/VSW-5*HI-010/SW-16/TCV066/TCV-103/QL-TV-605). Close seawater reject TCVA (SW-19*FCV-1002-A/ SW-19*FCV1002-A) and open TCVB (SW-26*FCV-1002-B/ SW-26*FCV1002-B) at Phase I & III.TITLE: DISTILLERS SOP No

D1-017


DISTILLER SHUTDOWN PROCEDURE


Preparations for Shutdown The normal shutdown should be carried out according to the guidelines provided in this section. Stop the operation of ball tube cleaning system and set it for ball collection and inform lab. Turn CRV (H.P. Distillate) (HD-14/VDH-14/HD-14/CRV101-B/QQ-XV-788) to dump position if it is on retaining position. Stop H.P. distillate pump, and Isolate the header (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQ-V641).Page 47 of 320 * * * *

Effective

Oct 2002

Q.E.W.Ccontrollers to be put on manual mode.



Interlocks to be cancelled where applicable and the


D1-018



CCR/DCR/DIST LOCAL SUPERVISORS CCR/DCRLocation Field CCR/DCR

Load Reduction Reduce brine recirculation flow and steam supply by closing FCV(B-14,FCV-001/VBR-7,FCV-503/B-14FCV107/QM-FV-666) & PCV (S-10,TCV-071/VHS-2,TCV004A; VHS-2,TCV-004B/S-10,TCV-071/PCV102A,PCV-102B/LQ-TV-679) step by step. Brine top temperature reducing rate must be kept less than 20 oC/hr, and brine recirculation flow should be decreased in a way so that first stage brine level be constant.Page 48 of 320 *

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Effective

Oct 2002

Q.E.W.C



When top brine temperature is reduced to 102 oC, shut down BRP-A by following normal procedure. Close CO2 vent gas isolation valve(CO-1001A,B/CO1001C,D,E,F/CO1001G,H/N/A//QG-V-635) to the CO2 recovery system. Turn CRV (condensate) (C-9/VCH-11/C-9/CRV-103B/LT-XV-841 to dump position when conductivity of condensate increases, then close LCV (brine heater) (C11*LCV-003/VCH-8*LCV-354/C-11/LCV-003/ LCV101/LT-LV-822), and line up the cooling water to desuperheater (HM-6/VCH-19/HM-6/O-HM-287/LT-V625) from the H.P. make-up header (from condensate header at Phase V), then isolate condensate header (V/V. NO:-C-22/VCH-12/C-14/C-22/LT-XV-614) .

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D1-019



CCR/DCR/LOCAL SUPERVISORS CCR/DCRLocation Field CCR/DCR

Page 49 of 320

Effective

Oct 2002

Q.E.W.C



Dumping of Distillate & Cutting of Steam When distillate conductivity increases, turn CRV (distillate) CRV(DP-8/VDM-12/DP-8/CRV-101-B/QQXV-719)Iso. V/v.(DP-7,DP-9/ TAG No. N/A/DP7/N/A/QQ-V-637) to dump position and isolate distillate header.V/V.NOS:-(VDM-13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP13/DP-14/NA/NA).. Stop seawater recycle pump if it is running. When brine recirculation temperature become lower than 60 oC, cut steam to brine heater, then close isolation valves (up-stream isolation valve()s(S-8/VHS-1A,VHS-1B/S8/S1,S3/LQ-MV603)down stream(S-12/VHS-3,VHS-4/S12/S-2,S-4/--), of PCV(s)(S-10,TCV-071/VHS-2,TCV004A; VHS-2,TCV-004B/S-10,TCV-071/PCV102A,PCV-102B/LQ-TV-679) and stop the chemical dosing pumps. Close TCV (C-17*TCV-073/VCH-16*TCV-009/C17/TCV-073/TCV-101/LT-TV-814) Cooling water header isolation valve (HM-6/VCH-19/HM-6/O-HM-287/LT-V625) and TCVs isolation valves(U/S:C-16/VCH-15C16/C-11LT-V-622 &D/S:C-18/VCH-17/C-18/C-12/LT-V623) ( Isolate H.P. make-up header in Phase1- 4 and in Phase V isolate condensate header). Stop condensate pump at brine heater shell level around 55%. When distillate flow falls down, close LCV (distillate) (DP-11*LCV-002/VDM8*LCV-353/DP-11*LCV002/LCV-104/QQ-LV-702), then stop distillate extraction pump. Slowly decrease the flow of the seawater make-up.* * * * *

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Page 50 of 320

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Oct 2002

Q.E.W.C




D1-020




Cold Circulation & Sealing of Plant Vacuum Keep the recirculation until top brine temperature and bottom brine temperature become equal to seawater makeup temperature. Seal plant vacuum and then close the steam isolation valves of the ejectors(S-15,17,19,16,18,20/VHS11A,11B/S-15,17,19,16,18,20/S-10,S13,S-11,S-14/LQXV-779,783,781,785). Close steam to ejector PCV(VHS-7/PCV-101) and its isolation valves at Phase II & IV, and close the ejector steam main isolation valve(VHS-8/S-7,S-8). Close steam to ejector main isolation valve at Phase I, III & V. steam to ejectors main isolation valve (S-13/S-13/LQ-MV-630) Close the steam unit valve (S-8&9/S4002/S-8&9/S252/LQ-V-600), confirm that its equalizers valve is completely closed.

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Page 51 of 320

Effective

Oct 2002

Q.E.W.C




D1-021




Stopping of Cold Circulation & Starting of Draining Release plant vacuum by slowly opening the suction valve (VA-11/VAE-1/VA-11/VA-11/LQ-XV-793)of hogging ejector to full open position. Stop debris separator at Phase I, III & V. Stop feeding seawater make-up. Stop Na2 SO3 dosing. Close the discharge motorised valve of BRP-B(B-8/VBR6/B-8/B-4/Q-M-MV-607) and stop the pump. Open the vent valves and the drain valves of the water boxes of HRS and brine heater, avoid overflow. Close LCV (brine blowdown) (BD-8,LCV-001/VBD8,LCV-352/BD-8,LCV-001/LCV-103/QN-LV-52)when shell level is minimum, and stop brine blowdown pump. Open blowdown LCV ((BD-8,LCV-001/VBD-8,LCV352/BD-8,LCV-001/LCV-103/QN-LV-752)and its bypass isolation valve(BD-10/VBD-10/BD-10/B-86/QN-V-611),Page 52 of 320 * * * * * * * * * *

Effective

Oct 2002

Q.E.W.C



also open all drain valves related to brine shell for natural draining. Open emergency blowdown valve (B-9/VEB-1/B-9/B-7/--) for faster draining of water boxes and tube bundles at Phase I to IV. Drain out distillate channel, if it is required.

*


D1-022




Stopping of Seawater Flow to HJS Close the cooling seawater main isolation valve (SW2/SW-7/SW-2/SW-8/QLV-618) to ejector condensers. Close the seawater main isolation valve (motorised valve at Phase IV & V (SW-1/VSW-1/SW-1/SW-1/QL-MV600), and stop Fe SO4 dosing at Phase IV. Open the vent valves and the drain valves of the water boxes of HJS, avoid overflow.* * * *

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Q.E.W.C




D1-023



CCR/DCR/LOCAL DIST SUPERVISORS DSCE/PERMIT ENGINEER/CCR/DCR

EMERGENCY SITUATIONSPlant emergency can be classified in to two categories depending on the status of the brine recirculating pumps during the emergency. The first one is that one of the pumps can be operated, in this case the load should be reduced, then the plant should be put in cold running. The second one is that the pump can not be operated in this case the plant should be shut down completely.

Page 54 of 320

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Q.E.W.C




D1-024



DSCE/PERMIT ENGINEER/CCR/DCR/LOCAL DIST SUPERVISORS CCR/DCRLocation Field CCR/DCR

Seawater Supply Failure When interlock is cancelled or not available, plant will continue to run in case of seawater supply failure. Cut steam to ejectors (S-15,17,19,16,18,20/VHS11A,11B/S-15,17,19,16,18,20/S-10,S13,S-11,S-14/LQXV-779,783,781,785). , open the water boxes vent valves of the heat reject section and stop seawater recycle pump, if it is running. Cut steam to brine heater PCV (S-10,TCV-071/VHSPage 55 of 320 * * * *

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Oct 2002

Q.E.W.C


Production/Operation * * * *

2,TCV-004A; VHS-2,TCV-004B/S-10,TCV-071/PCV102A,PCV-102B/LQ-TV-679) , close ejectors vapour section isolation valves(VA-12,VA13/VAE-2,VAE-3/VA12,VA13/VA-7,VA-8,LQ-XV-794,LQ-XV-796), isolate the main steam supply line (S-8&9/S4002/S-8&9/S252/LQ-V-600), and then depressurise it. Close the seawater main isolation valve (SW-1/VSW1/SW-1/SW-1/QL-MV-600), and close the cooling seawater to ejector condensers isolation valve (SW-2/SW7/SW-2/SW-8/QLV-618). . Close LCV (condensate) (C-11*LCV-003/VCH-8*LCV354/C-11/LCV-003/ LCV-101/LT-LV-822)(U/S:C10/VCH-7/C-10/C-7/LT-V-610) & TCV (cooling water to super heater) (C-17*TCV-073/VCH-16*TCV-009/C17/TCV-073/TCV-101/LT-TV-814). Turn CRV (C9/VCH-11/C-9/CRV-103-B/LT-XV-841) to dump position and stop condensate pump and isolate the headers (V/V. NO:-C-22/VCH-21/C-22/ Tag No N/A /LT-XV-614) . Brine shell level to be maintained by stopping brine blowdown pump and keeping the plant run in closed circulation. Turn CRV (HD-14/VDH-14/HD-14/CRV-101-B/QQ-XV788) to dump position of H.P. distillate. Stop the operation of ball tube cleaning system and set it for ball collection. Reduce the brine recirculation flow then shut down one brine recirculation pump. Turn CRV CRV(DP-8/VDM-12/DP-8/CRV-101-B/QQXV-719)Iso. V/v.(DP-7,DP-9/ TAG No. N/A/DP7/N/A/QQ-V-637) to dump position of distillate when conductivity becomes high. Close LCV (distillate) (DP-11*LCV-002/VDM8*LCV353/DP-11*LCV-002/LCV-104/QQ-LV-702),and stop distillate extraction & H.P. distillate pumps, then isolate the headers V/V.NOS:-(VDM-13/DP-26/DP-105/QQ-VPage 56 of 320

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Q.E.W.C



608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP14/DP-13/DP-14/NA/NA) H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQ-V-641) .. Follow normal shutdown completion work.


D1-025 Page 57 of 320

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Steam Supply Failure Isolate the main steam supply line (S-8&9/S4002/S8&9/S-252,254,256,258/LQ-V-600),, close ejectors steam isolation valves(S-15,17,19,16,18,20/VHS-11A,11B/S15,17,19,16,18,20/S-10,S13,S-11,S-14/LQ-XV779,783,781,785). and the vapour section isolation valves(VA-12,VA13/VAE-2,VAE-3/VA-12,VA13/VA7,VA-8,LQ-XV-794,LQ-XV-796),, and then depressurise the isolated sections. Close LCV (condensate) (C-11*LCV-003/VCH-8*LCV354/C-11/LCV-003/ LCV-101/LT-LV-822)(U/S:C10/VCH-7/C-10/C-7/LT-V-610)& TCV (cooling water to super heater) (C-17*TCV-073/VCH-16*TCV-009/C17/TCV-073/TCV-101/LT-TV-814), turn CRV (C-9/VCH11/C-9/CRV-103-B/LT-XV-841) to dump position, and stop condensate pump and isolate the headers(V/V. NO:C-22/VCH-21/C-22/ Tag No N/A /LT-XV-614). Turn H.P CRV (HD-14/VDH-14/HD-14/CRV-101-B/QQXV-788) to dump position of H.P. distillate. Stop the operation of ball tube cleaning system, and set it for ball collection. Reduce the brine recirculation flow and proceed to shut down one brine recirculation pump. Turn Dist. CRV (DP-8/VDM-12/DP-8/CRV-101-B/QQXV-719) to dump position of distillate when conductivityPage 58 of 320

* * * * * * * * * * *

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Q.E.W.C



becomes high. Close LCV (distillate) (DP-11*LCV-002/VDM8*LCV353/DP-11*LCV-002/LCV-104/QQ-LV-702),and stop distillate extraction & H.P. distillate pumps, then isolate the headers distillate header.V/V.NOS:-(VDM-13/DP26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA).& H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD17/HD-51/QQ-V-641) Keep the plant on cold circulation or follow normal shut down completion work.


D1-026



DSCE/PERMIT ENGINEER/CCR/DCR/DIST SUPERVISORS CCR/DCRLocation Field CCR/DCR

Instrument Air Supply Failure In case of instrument air supply failure, each control valve will performs in accordance with fail safe operation as shown below. Plant can no more be kept on continuous operation.

Fail safe operation of control valves are as following: TCV (cooling water to desuper heater) (HM-6/VCHPage 59 of 320

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Q.E.W.C



19/HM-6/O-HM-287/LT-V-625) full open. TCV (SEAWATER RECIRCULATION) TCV(SW16*TCV-066/VSW-5*HI-010/SW-16/TCV-066/TCV103/QL-TV-605) CLOSE TO MINIMUM FLOW. TCV (SEAWATER TO REJECT) (SW-19FCV102A/SW-2TCV-005/SW-19FCV1002A/TCV104/QLFV-604) LOCKED & TAGGED. LCV (condensate) (C-11*LCV-003/VCH-8*LCV-354/C11/LCV-003/ LCV-101/LT-LV-822)(U/S:C-10/VCH-7/C10/C-7/LT-V-610) locked & tagged. LCV (brine blowdown) (BD-8,LCV-001/VBD-8,LCV352/BD-8,LCV-001/LCV-103/QN-LV-52)locked & tagged. LCV (distillate) (DP-11*LCV-002/VDM8*LCV-353/DP11*LCV-002/LCV-104/QQ-LV-702),locked & tagged. LCV (S/W M/U from deaerator to last stage) (LCV106)full open at Phase IV PCV (steam to ejector)(VHS-7/PCV-101) full close at Phase II & IV. PCV (steam to brine heater) PCV (S-10,TCV-071/VHS2,TCV-004A; VHS-2,TCV-004B/S-10,TCV-071/PCV102A,PCV-102B/LQ-TV-679) full close. FCV (SW-22,FCV012/VFW2,FCV-502/SW-22,FCV012/FCV-104/QL-V-619) (seawater make up) full close. FCV (brine recirculation) FCV(B-14,FCV-001/VBR7,FCV-503/B-14FCV-107/QM-FV-666) locked & tagged. CRV (distillate) (DP-8/VDM-12/DP-8/CRV-101-B/QQXV-719) dump. CRV (H.P. distillate) (HD-14/VDH-14/HD-14/CRV-101B/QQ-XV-788) dump. CRV (C-9/VCH-11/C-9/CRV-103-B/LT-XV-841) (condensate) dump. Isolate the steam line to brine heater PCV(S-10,TCV071/VHS-2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) up-stream isolation valve(s(S-8/VHS-1A,VHS-1B/S-8/S1,S3/LQ-MV603), Steam PCV down stream isolation valve(s) (S-12/VHSPage 60 of 320

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Q.E.W.C



3,VHS-4/S-12/S-2,S-4/--) . Stop the operation of ball tube cleaning system, and set it for ball collection. Keep the brine recirculation with one BRP by adjusting brine FCV (B-14,FCV-001/VBR-7,FCV-503/B-14FCV107/QM-FV-666) manually or by its bypass isolation valve(B-16/NA/B-16/NA/NA) if available, and keep ejectors system in service for cooling down the recirculating brine (at Phase II & IV maintain steam to ejector through PCV bypass line)(VHS-9/S-9). Maintain Brine shell level by adjusting blowdown LCV (BD-8,LCV-001/VBD-8,LCV-352/BD-8,LCV-001/LCV103/QN-LV-52) and seawater make-up FCV (SW-22,FCV012/VFW2,FCV502/SW-22,FCV-012/FCV-104/ QL-V-619) manually or by adjusting their bypass isolation valve(SW-24/VFW4/SW-24/SW-4/QL-V-631). Stop seawater recycle pump if it is running, and stop condensate pump, H. P. distillate pump and distillate extraction pump then isolate the headers Condensate Header(V/V. NO:-C-22/VCH-21/C-22/ Tag No N/A /LTXV-614) H.P. distillate header (ISO.V/V. NO:HD17/TagNo. NA/HD-17/HD-51/QQ-V-641) distillate header.V/V.NOS:-(VDM-13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP13/DP-14/NA/NA).. After performing the above, follow normal shutdown completion work. After the instrument air supply restoration, all control valves should be checked for full operations.

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D1-027



DSCE/PERMIT ENGINEER/CCR/DCR/DIST LOCAL SUPERVISORS CCR/DCRLocation Field CCR/DCR

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Two Brine Recirculation Pumps Trip When interlock is cancelled or not available, the other pumps will continue to run in case of two BRPs trip. Isolate the steam line to brine heater PCV(S-10,TCV071/VHS-2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) up-stream isolation valve(s(S-8/VHS-1A,VHS-1B/S-8/S1,S3/LQ-MV603), Steam PCV down stream isolation valve(s) (S-12/VHS3,VHS-4/S-12/S-2,S-4/--). - Open the water boxes vent valves of heat recovery section and close discharge motorised valves of BRPs(B-7/VBR-5/B-7/B-3/QM-MV603 & B8/VBR-6/B-8/B-4/QM-MV-607). . Stop the ball tube cleaning system, if it is running. Isolate the main steam supply line (S-8&9/S4002/S-8&9/S252/LQ-V-600),, close ejectors steam isolation valves(S15,17,19,16,18,20/VHS-11A,11B/S-15,17,19,16,18,20/S10,S13,S-11,S-14/LQ-XV-779,783,781,785). and the vapour section isolation valves(VA-12,VA13/VAE2,VAE-3/VA-12,VA13/VA-7,VA-8,LQ-XV-794,LQ-XV796),, and then depressurise the isolated sections.. Close LCV (condensate) (C-11*LCV-003/VCH-8*LCV354/C-11/LCV-003/ LCV-101/LT-LV-822)(U/S:C10/VCH-7/C-10/C-7/LT-V-610) & TCV (cooling water to desuper heater) (HM-6/VCH-19/HM-6/O-HM-287/LT-V625), turn CRV (C-9/VCH-11/C-9/CRV-103-B/LT-XV841) to dump position, and stop condensate pump then isolate the headers(V/V. NO:-C-22/VCH-21/C-22/ Tag No N/A /LT-XV-614). Turn CRV to dump position of distillate (DP-8/VDM12/DP-8/CRV-101-B/QQ-XV-719) and H.P. distillate (HD-14/VDH-14/HD-14/CRV-101-B/QQ-XV-788). Close LCV (distillate) (DP-11*LCV-002/VDM8*LCV353/DP-11*LCV-002/LCV-104/QQ-LV-702), and stop distillate extraction & H.P. distillate pumps then isolate the headers distillate header.V/V.NOS:-(VDM-13/DP-26/DPPage 63 of 320

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105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA). H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD-17/HD-51/QQ-V641). Close LCV (blowdown) (BD-8,LCV-001/VBD-8,LCV352/BD-8,LCV-001/LCV-103/QN-LV-52)and stop brine blowdown pump. Make sure to leave the level in the brine shell at the working level. After performing the above, follow normal shutdown and complete the work.


D1-028



DSCE/PERMIT ENGINEER/CCR/DCR/DIST LOCAL SUPERVISORS CCR/DCRLocation Field CCR/DCR

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Q.E.W.CTwo Brine Blowdown Pumps Failure



Open emergency blowdown isolation valve (B-9/VEB-1/B9/B-7/--) and continue on-load operation. Attention to be paid to the brine recirculation pump motor load. Operating under this condition should not be for long time, because of abnormal brine blowdown; the concentration of brine will increase with the time.

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D1-029




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Q.E.W.C



Two Condensate or Distillate Extraction Pumps Failure Load-down followed by cold run is to be applied.* *


D1-030




Page 66 of 320

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Q.E.W.CUnit Power Supply Failure



Unit power supply failure will cause BRP-A and all 415V pumps to trip and the motorised valves will not function. If the power supply cant be restored immediately, plant to be de-loaded and put on cold circulation with BRP-B. Cut steam to brine heater PCV (S-10,TCV-071/VHS2,TCV-004A; VHS-2,TCV-004B/S-10,TCV-071/PCV102A,PCV-102B/LQ-TV-679) and isolate the steam to brine heater line. - Close discharge valve of BRP-A (B-7/VBR-5/B7/B-3/QM-MV603 )manually. Isolate all headers; distillate header.V/V.NOS:-(VDM13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso. V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA); H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD17/HD-51/QQ-V-641);Condensate Header (V/V. NO:-C22/VCH-21/C-22/ Tag No N/A /LT-XV-614).. Keep circulation with BRP-B and maintain the last stage brine level through emergency blowdown line (B-9/VEB1/B-9/B-7/--) and blowdown LCV (BD-8,LCV-001/VBD8,LCV-352/BD-8,LCV-001/LCV-103/QN-LV-52). When circulated brine temperature becomes close to seawater temperature, seal plant vacuum or follow normal shutdown completion work.

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D1-031

ACTIVITY

EMERGENCY SITUATIONSPage 67 of 320

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DSCE/PERMIT ENGINEER/CCR/DCR/LOCAL DIST SUPERVIOSRS CCR/DCRLocation Field CCR/DCR

BlackoutIsolate the steam line to brine heater PCV(S-10,TCV071/VHS-2,TCV-004A; VHS-2,TCV-004B/S-10,TCV071/PCV-102A,PCV-102B/LQ-TV-679) up-stream isolation valve(s(S-8/VHS-1A,VHS-1B/S-8/S1,S3/LQ-MV603), Steam PCV down stream isolation valve(s) (S-12/VHS3,VHS-4/S-12/S-2,S-4/--). - Fully open the water boxes vent valves and close discharge motorised valves of BRPs (B-7/VBR5/B-7/B-3/QM-MV603 & B-8/VBR-6/B-8/B4/QM-MV-607). . Isolate the main steam supply line (S-8&9/S4002/S8&9/S-252/LQ-V-600),, close ejectors steam isolation valves(S-15,17,19,16,18,20/VHS-11A,11B/S15,17,19,16,18,20/S-10,S13,S-11,S-14/LQ-XV779,783,781,785). and the vapour section isolation valves(VA-12,VA13/VAE-2,VAE-3/VA-12,VA13/VA7,VA-8,LQ-XV-794,LQ-XV-796),, and then depressurise the isolated sections. Close the seawater main isolation valve(SW-1/VSW1/SW-1/SW-1/QL-MV-600), and close the cooling seawater to ejector condensers isolation valve(SW2,3,6,4,5,8/SW-7,VSW-8&9,VSW-11/SW-2,3,6,4,5,8/ SW-8,9,10,11/QL-W-618,QL-W-616). Isolate all headers distillate header.V/V.NOS:-(VDM13/DP-26/DP-105/QQ-V-608) OR (DP-25/DP-106)Iso.Page 68 of 320 * * * * * *

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Q.E.W.C



V/v Sleeper way (DP-14/DP-13/DP-14/NA/NA). H.P. distillate header (ISO.V/V. NO:HD-17/TagNo. NA/HD17/HD-51/QQ-V-641)Condensate Header(V/V. NO:-C22/VCH-21/C-22/ Tag No N/A /LT-XV-614) . Shutdown completion work is to follow to keep the plant ready for start up.


D1-032


Operational Checks

CCR/DCR SUPERVISORS/ OPERATORS CCR/DCRLocation Field CCR/DCR

Local and CCR/DCR indicators are to be regularly read and their indication values are to be recorded on the log form. Rotating machines are to be checked for the following items: - Suction and discharge pressure. - Electric current. - Flow rate.Page 69 of 320

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Q.E.W.C-


Production/Operation * * * * * * * * * * *

Bearing temperature and noise. Shaft seal. Vibration. Lubricant colour and level. Gas pressure in the accumulator for reciprocating pumps to be checked regularly. Strainers to be changed over and cleaned once a week where applicable. Chemical level of the local day tanks to be checked at regular intervals. Chemical dosing rate should be checked and adjusted as process requirement. All instruments should be checked regularly. Plant to be checked frequently for symptom of leakage The site to be kept clean at all the time.TITLE: DISTILLERS SOP No

D1-033


Operation of Venting System

DIST LOCAL SUPERVISORS CCRLocation Field CCR/DCR

Operating of Ejectors at Phase I & III Starting Hogger Ejector Make sure all vapour valves(VA-1,2,3,4,5,6,7,8,11/ VA1,2,3,4,6,7,8,11)of the distiller connected to venting system are in open position and service ejectors (VA-12/VAPage 70 of 320 *

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Q.E.W.C


Production/Operation * * *

12)OR VA-13/ VA13)(VA-16/VA-16) OR VA-17/VA-17) are isolated and ensure sufficient sea water flow to surface condensers by opening inlet and outlet valves (SW-8/SW/8)&(SW-10/SW-10)(SW-11/SW-11)(SW-12/SW-12) Line up stage No. 1 & 2 vapour line (Tag No. N/A)to pre-condenser. Open steam isolation valve(S-14/S-14) to hogger ejector. Open vapour isolation valve (VA-11/VA-11)to hogger ejector.


D1-033



DIST LOCAL SUPERVISORS CCRLocation Field CCR/DCR

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Changing Over from Hogger to Service Ejectors Set-A Close vapour isolation valve to hogger ejector(VA-11/ /VA-11) Close steam isolation valve to hogger ejector(S14/ S-14). Put tertiary ejector-A in service by opening steam isolation valve (S-19 /S-19/ then vapour isolation valve (VA-20/VA-20). Put secondary ejector-A in service by opening steam isolation valve(S-17/S-17) then vapour isolation valve(VA16/ VA-16 ) Put primary ejector-A in service by opening steam isolation valve(S-15/ S-15) then vapour isolation valve(VA-12/ VA-14). Change over stage No. 1 & 2 vapour line(Tag No. N/A) from pre-condenser to inter condenser-A.* * * * * *


D1-033

ACTIVITY REFERENCE RESPONSIBILITY


DIST LOCAL SUPERVIOSRS Page 72 of 320

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Q.E.W.CCOMMUNICATION OPERATION



CCRLocation Field CCR/DCR

Changing Over from Service Ejectors Set-A to Set-B*

Put tertiary ejector-B in service by opening steam isolation valve(S-20/S-20) & discharge valve (VA-23/VA-23/) then opening vapour isolation valve(VA-21/ /VA-21) then stop tertiary ejector-A by closing vapour isolation valve(VA-20/VAE-20) then closing steam isolation valve(S-19/ S-19) Put secondary ejector-B in service and Stop secondary ejector-A . Put primary ejector-B in service and stop primary ejectorA.

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D1-033

ACTIVITY REFERENCE


Page 73 of 320

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Q.E.W.CRESPONSIBILITY COMMUNICATION OPERATION




Stopping Service Ejector & Sealing the Plant Vacuum Stop primary ejector by closing vapour isolation valve (VA-12,13/VA-12,13) then close steam isolation valve(S15,16/S-15,16). Stop secondary ejector. Stop tertiary ejector. Change over stage No. 1 & 2 vapour line(Tag No. N/A ) to pre-condenser.* * * *


D1-033

ACTIVITY

Operation of Venting SystemPage 74 of 320

Effective

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LOCAL DIST SUPERVISOR CCRLocation Field CCR/DCR

Releasing Plant Vacuum Release plant vacuum by slowly opening the vapour suction isolation valve(VA-11/VA-11) of the hogging ejector.

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D1-034 Page 75 of 320

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Operating of Ejectors at Phase II


Operating of Ejectors at Phase - II Starting Hogger Ejector Make sure all vapour valves(,VAE2,VAE3,VAE4)of the distiller connected to venting system are in open position and service ejectors(VAE-2 ,VAE3)are isolated. Open steam isolation valve to hogger (VHS-10)ejector. Open vapour isolation valve(VAE-1) to hogger ejector.* * *


D1-034 Page 76 of 320

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Changing Over from Hogger to Service Ejectors Set-A Close vapour isolation valve to hogger (VAE-1)ejector and then close steam isolation valve (VHS-10)to hogger ejector. Establish sea water flow to the condensers by opening Inlet valves(VSW-8/9,VSW-11/12) Put secondary ejector-A in service by opening vapour outlet isolation valve(N/A), then steam isolation valve(VHS-11) and then vapour isolation valve(VAE-4) to inter condenser-A. Put primary ejector-A in service by opening steam isolation valve(VHS-11) and then vapour isolation valve to pre-condenser-A.(VAE-2) Line up after condenser level control float valve (VAE8,10) to inter condenser-A. Line up Pre-condenser-A shell drain (VAE-20,24,26) connected to last stage brine shell.

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Page 77 of 320

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Q.E.W.CSOP No



TITLE: DISTILLERS

D1-034




Changing Over from Service Ejectors Set-A to Set-B Confirm that S/W is lined up to condensers set-B. Seal the vacuum by closing vapour isolation valves of pre-condenser-A(VAE-2) and inter condenser-A(VAE-4) then close steam isolation valves.(VHS-11,VHS-11) Close after condenser shell drain line to inter condenserA isolation valve(VAE-8,10) and close pre-condenser-A shell drain to last stage brine shell isolation valve(VAE20,24,26). Put secondary ejector-B in service by opening vapour outlet isolation valve(N/A), then steam isolation valve(VHS-12,VHS-12) and then vapour to inter condenser-B isolation valve(VAE-5). Open after condenser shell drain to inter condenser-B isolation valve(VAE-9,11) and line up Pre-condenser-B shell drain (VAE21,25,27)connected to last stage brine shell. * *

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D1-034




Stopping Service Ejector & Sealing the Plant Vacuum Seal the vacuum by closing vapour isolation valves of pre-condenser(VAE-2,3) and inter condenser(VAE4,5) then close steam isolation valves(VHS-11,11,VHS-12,12). Close after condenser shell drain line to inter condenser isolation valve(VAE8,10,VAE-9,11) and close precondenser shell drain to last stage brine shell isolation valve(VAE-20,24,26,VAE21,25,27).

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D1-034




Releasing Plant Vacuum Release plant vacuum by slowly opening the suction isolation valve of the hogging ejector(VAE-1).

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Q.E.W.C




D1-035



LOCAL DIST SUPERVISOR DCRLocation Field CCR/DCR

Operation of Ejectors at Phase IV Starting Hogger Ejector Make sure all vapour valves (V-5,51) of the distiller connected to venting system are in open position and service ejectors (V-7,8712,13) are isolated. Open steam isolation valve (S-12) to hogger ejector. Open vapour isolation valve(VA-11) to hogger ejector.* * *

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Q.E.W.C




D1-035




Changing Over from Hogger to Service Ejectors Set- A Open all ejector outlet vapour isolation valves (VA9,10,14,15). Establish sea water flow in contact condensors by opening inlet valves (SW-9/SW-10/SW-11) Close vapour isolation valve (VA-11) to hogger ejector and then close steam isolation valve (S-12) to hogger ejector. Put secondary ejector-A in service by opening steam isolation valve (S-13) then open vapour isolation valve(VA-12). Put primary ejector-A in service by opening steam isolation valve(S-10) then open vapour line isolation valve(VA-7).* * * *

Page 82 of 320

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Q.E.W.C




D1035




Changing Over from Service Ejectors Set-A to Set-B Put secondary ejector-B in service by opening steam isolation valve (S-14)then opening vapour isolation valve(VA-13).Stop secondary ejector-A by closing vapour isolation valve(VA-12) then closing steam isolation valve(S-13). Put primary ejector-B in service and stop primary ejectorA.

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D1-035




Stopping Service Ejector & Sealing the Plant Vacuum

Stop secondary ejector by closing vapour isolation valve(VA-12,VA13) then close steam isolation valve(S13,S-14). Stop primary ejector.

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D1-035




Releasing Plant Vacuum Release plant vacuum by slowly opening the suction isolation valve(VA-11) of the hogging ejector.

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D1-036



DCR/LOCAL DIST SUPERVISORS DCRLocation Field CCR/DCR

Operating of Ejectors at Phase - V Line diagram of ' VACUUM SYSTEM ' Starting Hogger Ejector Make sure all vapour valves(QG-V-605,606,607,608,LQV-600 ) of the distiller connected to venting system are in open position and service ejectors are isolated. Open steam isolation valve(LQ-XV-777) to hogger ejector. Open vapour isolation valve(LQ-XV-793) to hoggerPage 86 of 320 * * *

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Q.E.W.Cejector.




D1-036



DCR/LOCAL DIST SUPERVISOR DCRLocation Field CCR/DCR

Changing Over from Hogger to Service Ejectors Set-A Open all ejector vapour outlet isolation valves(LQ-V635,638,642,645) locally. Establish sea water to suface condensers by opening valves QLV-616 &QLV-617 Close vapour isolation valve(LQ-XV-793) to hogger ejector and then close steam isolation valve(LQ-XV-777) to hogger ejector. Put secondary ejector-A in service by opening steamPage 87 of 320 * * * *

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isolation valve(LQ-XV-783) then open vapour isolation valve(LQ-XV-798). Put primary ejector-A in service by opening steam isolation valve(LQ-XV-779) then open vapour isolation valve(LQ-XV-794).


D1-036



DCR SUPERVISOR FIELDLocation Field CCR/DCR

Changing Over from Service Ejectors Set-A to Set-B Put secondary ejector-B in service by opening steam isolation valve(LQ-XV-785) then open vapour isolationPage 88 of 320

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valve(LQ-XV-800), and then stop secondary ejector-A by closing vapour isolation valve(LQ-XV-798) then close steam isolation valve(LQ-XV-783). Put primary ejector-B in service and then stop primary ejector-A.

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D1-036




Stopping Service Ejector and Sealing the Plant Vacuum Stop secondary ejector by closing vapour isolationPage 89 of 320

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Q.E.W.Cvalve(LQ-XV-798,800) then valve(LQ-XV-783,785). Stop primary ejector. close



steam

isolation

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D1-036




Releasing Plant Vacuum Release plant vacuum by slowly opening the suctionPage 90 of 320 *

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isolation valve(LQ-XV-793) of the hogging ejector.


D1-037


Operation of CO2 Recovery System at Phase I, II & III

LOCAL DIST SUPERVISOR DCR

Loca

Field C

CO2 CompressorsPage 91 of 320

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Q.E.W.CStart-Up



Confirm that: - Sealing water isolation valve (DW1013A&1015A,/DW1013C,1015C,DW1013E,1015E/DW1013G,1015 G)is opened. - CO2 recirculating valve(C-101A/B//C-101C/D,E/F//C-101G/H) is closed. - Water separator drain(C-O-1003A,1003B,1046A,1046B//C-O1003C,1003D,1003E,1003F,1046C,1046D,1046E,1046F//C-O1003G,1003H,1046G,1046H) and vent valves(C-101A,101B/C101C,101D,101E, 101F /C-101G,101H)are closed. - Water separator L.C. float V/v and sealing water solenoid valve are de isolated. Line up CO2 from distiller. Open suction (C-101A,101B/C-101C,101D,101E, 101F /C-101G,101H) and discharge valves C-101A,101B/C-101C,101D,101E, 101F /C-101G,101H) of the CO2 compressor. Open sealing water solenoid valve and maintain flow at 4 T/hr. Start the CO2 compressor. Open CO2 recirculation valve(C-101A/B//C-101C/D,E/F//C-101G/H) and maintain flow as required. Open all relevant valves of the standby CO2 compressor and keep the standby selector switch on auto mode for emergency auto-change over.

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D1-038


Operation of CO2 Recovery System at Phase I, II & III

LOCAL DIST SUPERVISOR DCR / BOP SUPERVISOR

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Q.E.W.COPERATION



Loca

Field C

Shutdown Keep the standby selector switch on manual mode. Stop the CO2 compressor. Isolate gas line from distiller venting system(CO-1001A&B/CO-1001C&D,CO1001E&F/CO-1001G&H). Close sealing water isolation valve and all relevant isolation valves and drain the system if required.* * * *


D1-039

ACTIVITY REFERENCE RESPONSIBILITY

OPERATION OF TAPROGGE SYSTEM

LOCAL DIST SUPERVISOR Page 93 of 320

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Q.E.W.CCOMMUNICATION OPERATION



CCR/DCRLocation Field CCR/DCR

Taprogge Operation ( Tube Cleaning System) The following are to be ensured before and during the operation of taprogge plant: The ball strainer is on opposite position. P across the ball strainer is normal. All control valves(B-11,B-12,B-19,B-20/VTR-5,VTR-6, VTR-10,VTR-11/ B-11,B-12,B-19,B-20/HCV-105,HCV106,HCV-107,HCV-108,HCV-109,OB-58/QW-MV601,604,607,612,615620) are available to the mode of selection and all indication lights for them are available on the panel. None of the control valves(B-11,B-12,B-19,B-20/VTR5,VTR-6, VTR-10,VTR-11/ B-11,B-12,B-19,B-20/HCV105,HCV-106,HCV-107,HCV-108,HCV-109,OB-58/ QWMV-601,604,607,612,615620) pass. All hand-operated isolation valves(B-10,B-22,B-23,,B21,B-17,B-18,BV-2,BV-3/ VTR-1,VTR2,VTR3,VTR9,VTR-12,VTR-13,VTR-14,VTR-15/ B-10,B-22,B-23,,B21,B-17,B-18,BV-2,BV-3/B-8,B-53,B-54,B-65,B-66,B-67, B-68,B-58,B-60,B-59,B-61B-62,BV-10,BV-11/QW-V600,602,605,608,609,610,611,613,614,616,617,618,619) are open.* * * * *

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ITLE: DISTILLERS SOP No

D1-039




Normal Operation of Taprogge System Select the mode of operation: either auto or manual. Select the type of cleaning cycle: either through recovery stages with brine heater or brine heater only (except Phase I & III). Place ball catcher on catching position. Make one ball circulating pump standby (except Phase I, II & III). Line up the pipelines as per requirement of the system. Box up the vessel with the required numbers of good balls by properly venting the vessel. Check all control valves(B-11,B-12,B-19,B-20/VTR5,VTR-6, VTR-10,VTR-11/ B-11,B-12,B-19,B-20/HCV105,HCV-106,HCV-107,HCV-108,HCV-109,OB-58/ QWMV-601,604,607,612,615620) are in shut position. Reset the alarm switch.Page 95 of 320

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In case of auto mode, press the auto start switch, and check that the pump has started and it is taking proper load, the control valves (B-11,B-12,B-19,B-20/VTR-5,VTR-6, VTR-10,VTR-11/ B-11,B-12,B-19,B-20/HCV-105,HCV106,HCV-107,HCV-108,HCV-109,OB-58/ QW-MV601,604,607,612,615620) are operating on time as per selection, and balls are releasing and returning as usual. Press the auto stop switch after releasing of the balls from the vessel (not required at Phase V).In manual mode the pump needs to be started and control valves(B-11,B12,B-19,B-20/VTR-5,VTR-6, VTR-10,VTR-11/ B-11,B-12,B-19,B20/HCV-105,HCV-106,HCV-107,HCV-108,HCV-109,OB-58/ QW-MV601,604,607,612,615620) are opened or closed by pressing the open or close button for each valve.TITLE: DISTILLERS SOP No

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D1-039



LOCAL SUPERVISOR DSCE/PERMIT ENGINEERLocation Field CCR/DCR

Checking of Taprogge Balls Daily, the balls are counted and checked for their suitability to keep them in circulation. New balls are used instead of the balls with following criteria: broken, undersize, soft, hard, heavy, damaged, oversize or lost shape.

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D1-039



LOCAL DIST SUPERVISOR

Location OPERATION Field CCR/DCR

Ball Strainer Backwashing After ball collection, if the ball counting is considered good, backwash can be performed for the ball strainer. The backwash is done to clean the ball strainer from any debris, the ball strainer is put on backwash manually by hand operated valves(Tag No. N/A// Tag No. N/A// Tag No. N/A//Tag No. N/A ) during idle hour of the taprogge system (except Phase V). Also the backwash is performed when pressure differentialPage 97 of 320

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Q.E.W.C



across the ball strainer exceeds specified limit. Also when taprogge is not in operation, the ball strainer is generally kept on backwash position to keep the catchers clean by flushing out the debris.


D1-039



LOCAL DIST SUPERVISOR CCR/DCR/DSCE/PERMIT ENGINEERLocation Field CCR/DCR

Special Operation Cycles Beside the normal operation, there are special operations, which are performed when required. These operations are described below:

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D1-039



LOCAL DIST SUPERVISOR DSCE/PERMIT ENGINEERLocation Field CCR/DCR

Blank Cycle Whenever during routine checks the ball collection is poor, the system is put into service for collection cycle, in order to recover the lost balls. This operation is continued up to 3 to 4 times so as to recover most of the lost balls as practicable. Sometime on plant demand or due to any big leakage or fault/defect in the taprogge system, the operation is stoppedPage 99 of 320

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A Desal SOP

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