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SITE SPECIFIC SAFE OPERATING PROCEDURE OPERATION SECTION: LPG DEPARTMENT
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Moderated on 11th
May, 2015
INTRODUCTION:
LPG Operation section performs smooth and
trouble free operation of LPG Recovery Plant to
produce quality product and help to meet
production target in efficient manner.
SOP for the Operation Section has been prepared such a manner
that a new person can approach and perform a job safe manner. In
this SOP it has been given top priority to the safety of man and
machine. However there are always remaining possibility of
improvement and any new recognized practice, procedure/
method are always welcome. This SOP should be reviewed at
least once in a year.
SITE SPECIFIC SAFE OPERATING PROCEDURE OPERATION SECTION: LPG DEPARTMENT
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CONTENTS:
Chapter 1: Activities of Operation Section & Brief Process Description
with Flow Diagram
Chapter 2: Hazards & General safety precaution for Operation Section
Chapter 3: SOP for startup & shutdown Procedure of Plant.
Chapter 4: SOP for Equipment start-up.
Chapter 5: SOP for Equipment change-over.
Chapter 6: SOP for dispatch product to Filling Plant.
Chapter 7: SOP for handling of emergency situation.
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CHAPTER –I
ACTIVITIES OF OPERATION SECTION
Smooth and trouble free operation of LPG Recovery plant
Planning of schedule annual maintenance of the plant
Planning of resources for meeting the MOU target for LPG
Production
Delivery of quality products to the market on a regular basis
Following are the objectives of the section
To maintain consistency in various works of the section
To keep good relation and understanding with other sections of the
department.
To keep good relation with the customers, vendors and other
departments who are directly or indirectly associated with LPG
production.
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Brief Process Description and Operation :
The process of LPG recovery plant comprises of following :
a) Compression
b) Dehydration
c) Product extraction through
(i) On stream cooling by heat exchange
(ii) Turbo expansion
(iii) Removal of non-condensable and Undesired lighter fractions
d) Product fractionation
a) Compression
Inlet gas at 14 Kg/ cm2 enters into inlet gas compressor suction scrubber
and then compressed in two stages from two different sources. First it is
compressed from 14 Kg/ cm2 to 33.8 Kg/ cm2 in a (4 stage) centrifugal
compressor driven by a 4500 HP electric motor operating on 11 KV power
supply. The heat of compression is partly used in re-boiling the bottom
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liquid of deethanizer and then cooled to 37.80C in water cooled heat
exchanger before entering the booster compressor suction scrubber. It is
then compressed again to 41.9 Kg/ cm2 with the help of booster
compressor driven by the turbo expander. No external energy source is
required for this operation. The compressed gas is cooled to 37.80C in a
water cooled exchanger and then sent through an inlet filter separator
wherein any water that may condense out from compression is knocked
out.The gas is then dried in the dehydrators, (two Nos ). installed for
cyclic operation and regeneration.
(b)Dehydration
The dehydrators are filled with Davidson grade 513 molecular sieve of 4
A0 size and contains approximate 11650 Kg of molecular sieve in each
dehydrator. The dryness obtained is to a dew point of less than -101C.
While one of the dehydrators is on line for drying the inlet gas the other
one goes for re-generation, through a cycle of heating by hot residue gas to
remove the water particles retained within the molecular sieve during the
previous operation and then cooling.The dehydrated gas passes through a
dust filter to remove sieve dust etc.
(c) Product extraction
The gas stream after the dust filter is split into two streams. One stream
(70% by volume) exchanges heat with cold residue gas from the
deethanizer overhead and expander separator overhead in the cold gas/gas
and warm gas/gas heat exchangers.
The other stream (30% by volume) exchanges heat with the cold separator
liquid in the gasliquid exchanger and also with the expander separator
liquid in the deethanizer feed preheater. These two streams then combine
to enter the cold separator. By this heat exchange the temperature of the
inlet stream to cold separator drops down to (-47) 0C and the temperature
of the cold residue gas increases to 320C. The liquid condensed by
lowering the temperature of the inlet gas is separated in the cold separator.
These liquids are flashed through the deethanizer reflux condenser and
gas-liquid exchanger into the deethanizer tower. Inlet gas from the top of
the cold separator is then allowed to expand in the turbine wheels of the
single stage turbine expander to 13.7 Kg/cm2. At the other end of
expander shaft is
mounted the single stage booster compressor. The horse-power released
by expansion is used for second stage pressure boost up. At the designed
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condition horse-power developed would be around 1670 HP. The
expander rotates
at a speed of 27,000 rpm. Due to the expansion in the turbine wheel the
temperature of the gas stream drops down to around -84 0C and additional
liquefaction takes place. The gas liquid mixture out of the expander is
separated in the expander separator. Liquids thus collected, flow to the
deethanizer feed pre-heater and then to the deethanizer. The noncondensed
gas at the top of the expander separator goes tojoin the residue gas stream
from deethanizer.
(d)Product Fractionations
The product fractionation consists of :
(i) A deethanizer column with three separate packed sections and a
reboiler.
(ii)A debutanizer column having 34 Glitch ballast trays and reboiler
provision through closed circuit hot oil systems with direct fired heater.
The liquids formed at the cold separator and the expander separator enters
the deethanizer column through the pre-designed section of the column
packing. By maintaining proper bottom temperature with the help of
deethanizer reboiler and reflux, undesirably liquefied
fraction of C1H4, C2H6 and the excess of C3H8 which is not required for
production of LPG is knocked out from the top.
This stream meets the gas stream from the expander separator and forms
the residue gas for the plant. Temperature of the residues as it comes out
of expander separator and deethanizer remains in the range of -760 C.
Before letting it out of the plant this additional refrigeration is recovered in
the cold gas & warm gas exchangers explained earlier. The bottom liquid
from deethanizer flows on level control to debutanizer tower where LPG
and condensate are separated out. LPG comes out at the top which is
cooled to ambient temperature and sent for storage in Bullets & Horton
Spheres. The bottom condensate is similarly cooled and stored in separate
storage tanks.
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Process Control Through DCS –
Distributed control system(DCS) is a state of the art technology in
the field of Automation & Process control. As a part of
modernization of instrument system of LPG Recovery Plant,DCS
was commissioned in the Plant in 1997.
DCS is physically and functionally distributed over the entire
plant process in such a way that failure or malfunction of any single
control loop does not have any effect on functioning of rest of the
other loops or plant process and this special feature of DCS is
important for safe and efficient operation of process plant.
In DCS of LPG Recovery Plant, there are there functional block
of the system-Data Acquisition(DAS),Direct Digital Control(DDC)
and Programmable logic controller(PLC) are integrated together with
a very high speed Decentralized Communication Network(DCN).
DAS function is for continuous on line monitoring of the plant and
provides most reliable and timely information of the process
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parameters of the plant along with their historical storage.DDC is a
microprocessor based digital controller(AC 460 of M/L ABBL)
having very high processing and wide ranging capabilities. It
receives various input signal from trasmiters,switchs and relays and
other input devices located in the plant performs control
functions/algorithms run by the MOD 300 system software and
finally sends output signal to the final control elements e.g. control
valve, solenoid valve and motor etc.PLC provides adequate and
reliable protection and safeguard of various plant equipment,
sequence control as well as sequence control of the plant(ESD) in
case of any emergency.
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CHAPTER –II
GENERAL SAFETY PRECAUTION & HANDLING OF
EMMERGENCY SITUATION IN CASE OF FIRE OR
HYDROCARBON LEAKAGE
2.01 Use appropriate PPE during working. Safety shoes must be used all the
times.
2.02 Respect ‘No Smoking Zone’
2.03 In case of LPG leakage and any other emergency situation, immediately
inform Shift Engineer, break the glass of fire alarm near the location. Shout
and draw attention of others for help.
2.04 Isolate the source of leakage if possible by closing appropriate valve.
2.05 Shut down the plant by pushing ESD either from control room or Expander
panel if the situation is beyond under control
2.06 Inform Fire station – Dial 7333
2.07 Inform Head-LPG,Installation Manager,CE(O) & CE (S & T)
2.08 Remove/extinguish all sources of ignition such as internal combustion
engines,movement of vehicle,hot job like welding,gas cutting etc.
2.09 Any non-flame proof electrical appliances in the vicinity should be
considerd as a potential source of ignition and hence should be de-
energized immediately.
2.10 Un-authorized persons should not be allowed in the working area.
2.11 Outsiders / Trainees / Visitors should be always under supervision.
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CHAPTER- III
SOP FOR PLANT START-UP AND SHUT-DOWN
GENERAL OPERATIONS
ACTIVITY 3.01 Startup Procedure of Inlet Gas Compressor
PURPOSE To compress inlet gas
HAZARDS
1) Hazard of falling material on the body
2) Noise 3) Leakage of LPG
4) Fall due to Lube oil leakage
PPEs
Safety shoe,Ear plug, Helmet,Dungaree
PREPARATION
1) All instruments are in service 2) Carry out physical inspection & Gas testing of the
Plant to confirm about no hydrocarbon leakage in the Plant
3) Reset ESD if the ESD is ON 4) Power supply to the Inlet Compressor panel is on
5) Lube oil./Gear oil to be charged. 6) Place PRV Auto/Manual switch to Manual Mode and
set the PRV output at 5 psi. 7) All Safety Relife Valves are to be on line.
8) Inform Power house and Gas Off take point about the readiness of the Plant for start up.
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STEP BY STEP PROCEDURE
1) After getting clearance from all three maintenance section and if there is no problem we can proceed for
start-up of inlet compressor. 2) Determine that there is positive gas flow through the
plant and that SDV-213(inlet gas shutdown valve),SDV-364(Residue gas shutdown valve) and
FICV-301 are open.
3) Place FIC301 manual 50%output,FIC200 manual 50% output,PIC202 manual 40% output,TIC442 manual
50% output,FIC502 manual 70% output at DCS.
4)Blow down low points of suction line from inlet gas
scrubber to compressor and also open all 5 compressor blow down valves individually,when there is no liquid
visible,close all valves. 5)Check suction pressure on York Panel and bring
pressure back up to 6 kg/cm2 pressure. 6) PRV switch to manual and set at 6PSI
7) 6) Now run both the auxiliary lube oil pump in manual mode. In this stage all shut down indication of the
York panel should be gone. 8)Inform electrical section for power clearance
9)After getting clearance from electrical press compressor bypass switch in the bottom control room.
10)Then press Compressor Start Button in the York
panel and hold it for minimum 1 sec.This will initiate the compressor startup.After 30sec,the Star Breker will on and
the compressor start rotating.Then after 15secs Star Breaker operation,the Ran Breaker will ON and motor goes
into full speed.At that time pull the amot of SDV-215 and hold it until compressor inlet and outlet valves are
opening.After achieving the discharge pressure above 20kg/cm2 shift PRV and both auxiliary oil pumps to AUTO.
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GENERAL OPERATIONS
ACTIVITY
3.02 Expander Compressor Start-up Procedure
PURPOSE
To boost-up compress inlet gas
HAZARDS
1) Hazard of falling material on the body
2) Noise 3) Leakage of LPG
4) Fall due to Lube oil leakage. 5) Slip,fall due to spillage of water.
PPEs
Safety shoe, Ear plug, Helmet, Dungaree
PREPARATION
1) Power supply to HMI is on 2)Place INLET GUIDE VANE (I.G.V.) selector in the
manual position in HMI panel and put at 0% value. 3) Make sure the water valves to the Lube oil cooler
are open and cooling water is available.
4)Residue gas line of the Lube oil Surge tank is open 5) Lube oil and seal gas lines are checked for proper
line up 6) Hot oil circulation is on outlet tempressure properly
achieved. 7)All three control valves should be in AUTO position in
HMI panel.
STEP BY STEP
PROCEDURE
1)Open SEAL GAS trip valve by pressing push button from
HMI.
2)Open SEAL GAS manual valve from cold separator line slowly so that rate of pressurization and depressurization
shall not be more than 3.5 bar/min.
3)Before starting lube oil pump ensure whether seal gas
D/P should not less than 2.4bar.Normal seal gas DP shall be around 3.5bar.
4)LUBE OIL pump starting sequence:
Open the Lube Oil pump manual by-pass valve.
Ensure whether lube oil control valve is on AUTO.
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Start the one lube oil pump.
Slowly close the manual by-pass valve to build up pressure.
Check the lube oil pressure and maintain the lube oil
DP of 28.1 kg/cm2 differential minimum.
Put the other pump in ‘Auto’
5) In this stage all shut-down should be cleared.
6)Open the Expander discharge valve SDV478 --- from HMI panel (Most important)
7) Open the Compressor discharge valve --- Manually (Most important).If this valve is not open and Expander is
started, machine will surge and damage to machine.
8)Now press ‘RESET’ buttom, in this stage ‘Expaner is ready to start’ message appear at HMI panel.
9)Now press Expander start buttom, then SDV479,SDV476,SDV477 will open simentaniously.
10)Then IGV output increase gradually and when Local and Remote signel matches put Expander in AUTO
mode.Now it will be controlled from DCS.
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GENERAL OPERATIONS
ACTIVITY
3.03: Plant Shut down(Normal) Procedure of LPG
Recovery Plant
PURPOSE To stop Recovery Plant
HAZARDS
1) Hazard of falling material on the body
2) Noise 3) Leakage of LPG
4) Fall due to Lube oil leakage.
5) Cold Burn 6) Striking object.
PPEs
Safety shoe, Hand gloves , Helmet, Dungaree
PREPARATION
End Dehydrator Heat Cycle. Inform Power house and Off take point about
readiness to stop the plant. Inform all sectional in charge specially instrument
section readiness to stop the plant. Maintain overflowing of water seal drum.
STEP BY STEP PROCEDURE
1)Shut down Expander as per procedure given in Turbo
expander/Booster Compressor Operation procedure.
2)Allow sometime(approximately 30 minutes) for liquid transfer then shut down Inlet Compressor by pressing
COMPRESSOR STOP switch on the local panel of Inlet Gas Compressor.Pull the ‘amot’ on the local panel of
Inlet Gas Compressor to CHARGE and VENT to avoid overpressure in Inlet Gas Compressor suction
Scrubber.This operation is done intermittently to avoid excessive flaring.
3)Reduce hot oil tempressure to maintain Debutanizer top tempressure to 54°C.
3) Stop Deethanizer reflux pump once the De ethanizer Reflux Accumulator level comes down to 40%
4) Stop Debutanizer Reflux Pump when the level comes down to minimum position.
5)Transfer condensate to condensate storage tank as long as long as Debutanizer Bottom tempressure is
130°C.
6)Close LPG product line valve when the top
tempressure of Debutanizer tower goes beyond
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allowable range (53 -56)°C 7)Stop both the Heaters.
7)Close SDV213,SDV365,SDV365 respectively by pulling
amot nob.
8) Stop Regen fan,Cooling water pump &Cooling water fans, Hot oil Pump should be stopped when Hot oil
tempressure comes down to 100°C. 9)Instrument air compressor,Air compressor for Deluge
unit should be on line. 10)Keep all Fire Water Pumps on AUTO as per normal
practice.
GENERAL OPERATIONS
ACTIVITY 3.04 Shutdown Procedure of Expander Compressor
PURPOSE To stop Expander-Compressor
HAZARDS
1)Hazard of falling material on the body
2)Noise 3)Leakage of LPG
4)Slip, fall due to Lube oil leakage. 5) Cold Burn
PPEs
Safety shoe, Hand gloves , Helmet, Dungaree
PREPARATION
End Dehydrator Heat Cycle.
Inform Power house and Off take point about readiness to stop the plant.
Inform all sectional in charge specially instrument section readiness to stop the plant.
Maintain overflowing of water seal drum.
1) Change from ‘Remote’ to ‘Local’ for IGV control in EXP – Compressor HMI panel.
2)Gradually close the IGV slowly. Doing this speed will
decrease 3) Constantly keep touching with Top control room and when
the PIC402 output comes more than 50% & JT will tend to
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STEP BY STEP
PROCEDURE
open then stop expander.
4)The all three shut down valves of Expander (SDV477/476/479) will close immediately.
5)Close compressor discharge valve manually. 6) Allow sufficient time(Minimum 5 minutes) to run the lube oil
pump.The stop the Lube oil pump in HMI panel. 7)Close Expader discharge valve and then seal gas trip control
valve from HMI panel 8)Close seal gas manual valve.
SITE SPECIFIC SAFE OPERATING PROCEDURE OPERATION SECTION: LPG DEPARTMENT
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CHEPTER –IV
SOP FOR EQUIPMENT START UP
GENERAL OPERATIONS
ACTIVITY
4.01Start-up procedure of Instrument Air Compressor
PURPOSE To make pressure rise instrument air network of Recovery
Plant
HAZARDS
1)Hazard of falling material on the body 2)Noise
3)Leakage of Instrument air 4) Fall due to Lube oil leakage.
PPEs Safety shoe, Dungaree, Helmet.
PREPARATION
1) Make Visual check of the machine,ensure that all guards are secure and that nothing is obstructing the proper
ventilation of/or free access to the machine. 2) Ensure that the discharge valve of the compressor is on
Open condition 3)Ensure that ‘READY TO START’ is appearing at the
compressor panel. 4)Take one hand set to communicate with top control room
in case of emergency. 5)To inform electrical shift personnel before start-up.
1) Push switch ON.The compressor will start and load automatically
2) Observe the loading & unloading cycle ,note down the time taken by each cycle.
3) Observe the motor load of the compressor on loading.
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GENERAL OPERATIONS
ACTIVITY
4.02Start up procedure of Regeneration & Hot oil Heater
PURPOSE To make ready Regeneration & Hot oil system of LPG Recovery Plant
HAZARDS
1)Fire hazard
2)Hazard of burn injury 3)Hazard of falling material on the body
4)Noise 5) Fall due to Hot oil leakage.
PPEs
Safety shoe, Dungaree, Hand gloves, Helmet.
PREPARATION
1)Check all the fuel and air supply, all valves should be in open position.
2)The panel power MCB for air blower fan should be in ‘ON’ position
3)The ‘Local/Off/Auto’ selector switch should be on ‘ON’ 4)Check for the panel power on indication lamp to be ‘ON’
in Top Control Room Heater PLC panel. 5)Check for ‘Clear to start’ in BMS of Top Control Room
6)One competent person should be present to observe the heater operation at site
STEP BY STEP
PROCEDURE
1)Press the start Push Buttom in BMS 2)For 24 second pre-purge of the combustion chamber
takes place and this will remove any combustible gases that may be present in the combustion zone.
3)Upon completion of the purge cycle,the air valve and fuel gas valve will be driven to the low firing position.
Consequently , a permissive switch will confirm the minimum firing position and allow the logic to continue for
pilot ignition sequence.The pilot ignition sequence is as follow :
High voltage spark ignition will be energized for 10 seconds
Pilot gas block valve (SDV-103/203) will be energized allowing pilot fuel to the pilot tip.
Five seconds after pilot flame is confirmed,the main
fuel gas block valve (SDV-101/201 and SDV-102/202) will be energized to open and the vent
valve (BDV – 102/202) will be closed.In approximately 10 seconds,control of the burner,is
SITE SPECIFIC SAFE OPERATING PROCEDURE OPERATION SECTION: LPG DEPARTMENT
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released to the process temperature controller.To
increase or decrease the process tempressure ,reset tempressure as required.
The ‘pilot ignition’ sequence must be confirmed in 20 second trial period,otherwise the logic will trip.Reset
and restarting will be required.
GENERAL OPERATIONS
ACTIVITY
4.03 Start up of Deluge Air Compressor
PURPOSE To make pressure rise deluge air network
HAZARDS
1)Fire hazard 2)Hazard of burn injury
3)Hazard of falling material on the body 4)Noise
PPEs
Safety shoe, Dungaree, Helmet.
PREPARATION
Wear Helmet before starting the job Take the clearance from Electrical section.
Check the Belts.
Check the Dryer status and keep the dryer online.
Check compressor discharge valve and it should be in open
position.
Keep the Dryer bypass valve in close position
STEP BY
STEP PROCEDURE
1) If everything ok then press the start button to start the compressor
2)After starting, check the compressor maximum discharge pressure.
3)Observe loading and unloading time and idle time. 4)Observe dryer bed change over sequence and its
operation.
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CHAPTER –V
SOP FOR EQUIPMENT CHANGE-OVER
GENERAL OPERATIONS
ACTIVITY
5.01 Changeover of De-ethanizer reflux pump
PURPOSE To distribute equal running hours of both De-ethanizer pump
HAZARDS
1) Fire hazard
2) Hazard of burn injury 3) Hazard of falling material on the body
4) Noise 5) Cold Burn
6) Leakage of gas
PPEs
Safety shoe, Dungaree, Helmet.
PREPARATION
Wear Helmet before starting the job
STEP BY STEP
PROCEDURE
1) The liquid inside the casing of the standby pump is to be
drained totally through the drain line provided at the pump.
The drain line valve is to be closed when the pressure of the pump is shown Zero.
2) Open the suction valve gradually to fill the fresh liquid in the pump and at that time the valve (drain line) is to be
opened slightly to confirm that there is no vapour in the pump casing. Then closed the drains valve.
3) Then stop the pump which in on line and close the
suction, discharge and pump return valves of the pump.
4) Immediately open both in and out cooling lines of the pump and at the same time start the pump.
If the pump takes suction then open the discharge valve
and pump return valve respectively. Gradually open the discharge valve to full open condition. Communicate with the top control room
Now the flow can be controlled from DCS. Check the motor load of the pump. Motor load should be less
from its full load.
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GENERAL OPERATIONS
ACTIVITY
5.02Change over of De-Butanizer Reflux Pump
PURPOSE To distribute equal running hours of both De-butanizer pump
HAZARDS
1) Fire hazard 2) Hazard of burn injury
3) Hazard of falling material on the body 4) Noise
5) Cold Burn 6) Leakage of Gas
PPEs
Safety shoe, Dungaree, Helmet.
PREPARATION
Wear Helmet before starting the job
STEP BY STEP
PROCEDURE
1) Switch on the motor of the pump which is to be run and
see that discharge valve of the pump is closed.
2)Now discharge valve of the pump which is on line is to be closed and discharge valve of the new pump is to be
opened simultaneously.
3)Observe the reflux flow at the local gauge which is near by the pumps.
4)If the flow is steady, then the other pump is to be stopped.
5)Check the motor load of the pump.
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GENERAL OPERATIONS
ACTIVITY 5.03 Changeover of Hot Oil Pump
PURPOSE To distribute equal running hours of both Hot oil pumps
HAZARDS
1)Fire hazard
2)Hazard of burn injury
3)Hazard of falling material on the body 4)Noise
5) Fall due to Hot oil leakage.
PPEs
Safety shoe, Dungaree, Helmet.
PREPARATION
Wear Helmet before starting the job
STEP BY STEP
PROCEDURE
1)Start the stand by pump (at that time the discharge valve of the pump should be closed).
2)Constantly monitor FI - 500 as it is near to the pumps and easily seen at the time of operating the pumps
3)The discharge valve of the pump which was in the line is
to be gradually closed and at the same time the discharge valve of the new pump is to be opened in such a way that
the fluctuation of FI - 500 should be minimum.
4)At the time of operation, if the flow is found more at FI - 500, then close the discharge valve of the other
pump rapidly until the flow reaches the previous position. If the flow is
found less than open the discharge valve to obtain desired flow.
5)When the discharge valve of the pump which was on line is fully close, the pump is to be stopped.
6)Contract at the top control room whether the flow of
hot oil is proper or not. If less than the discharge valve is to be opened slightly and if more than to be closed
slightly. In such a way the hot oil flow is to be established.
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7)Then see the motor load of the pump at MCC room. The
motor load should be less than the full load.
8)Check the pump after few minutes whether there is any seal leakage or not.
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CHAPTER –VI
SOP FOR STORAGE AND HANDLING PRODUCT
GENERAL OPERATIONS
ACTIVITY
6.01 DESPATCH LPG TO FILLING PLANT
PURPOSE To pump LPG product to Filling Plant for Cylinder Filling
HAZARDS
1)Fire hazard
2)Leakage of LPG
3)Hazard of falling material on the body 4)Noise
5)Cold Burn
PPEs
Safety shoe, Dungaree, Helmet.
PREPARATION
Wear Helmet before starting the job
STEP BY STEP
PROCEDURE
1)Check the position of ROVs of suction line, product filling
line and vapour balance line of dispatch bullet. Normally those should be in open position and if not then open the ROVs from DCS.
2)Check all instrumentation system should be on line. 3)Open isolation valve of suction line near ROV and also open
the isolation valve of the same line near the pump (i.e. pump suction valve).
4)Check the differential pressure gauge. Normally, it should Be showing minimum DP, then only proceed further.
5)Open isolation valve of self venting line which is at top of the pump.
6)Open only 10% of pump discharge valve. 7)Check pump minimum flow controller position and it
should be in auto position with pre-defined set point in DCS and
both the isolation valve of controller should be in open position. 8)Crack open pump recirculation line manual valve at
downstream of pump discharge. 9)Open recirculation line and pump minimum flow line
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manual valves
into entry manifolds of product filling line of dispatch bullets. 10)Communicate with the top control room & ask to check
about the healthy condition of level switch of pump as well as bullets & if found healthy
then ask to activate bypass timer of the said pump (Do not bypass while running the pump).
11)Now start the pump in AUTO mode. 12)Open the pump discharge valve gradually to full open
position.Also, open carousal or tanker dispatch line manual valve at the downstream of pump discharge line and at the same
time close the recirculation manual valve.
13) Check the motor amps, any noise and pump discharge pressure. Communicate with filling plant for required pressure.
GENERAL OPERATIONS
ACTIVITY
6.02 Ethyle Mercaptan Injection Method
PURPOSE To mix-up Ethyle Mercaptan with LPG before dispatching to Filling Plant
HAZARDS
1)Inhale of Mercaptan can cause
Headache,nausea,vomiting and shortness of Breath 2)Hazard of skin irritation
3)Hazard of falling material on the body 4)Noise
PPEs
Wear protective glove
Wear Musk Safety shoe, Dungaree, Helmet.
PREPARATION
1) Use PPE during handling of Mercaptan.
2) Venting and draining of Mercaptan to atmosphere should be done under strict supervision and
preferably it should be done to flare header only. Unnecessary draining should be avoided
1)Ensure that all isolation valves of delivery line are closed
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STEP BY STEP
PROCEDURE
before starting the mercaptan dosing operation.
2)Check the Nitrogen cylinder pressure by opening the top
valve of the cylinder to ensure that its not empty. There are
2 nos of PG at the cylinder. The pressure should be above 5
kg/cm2.
3)Close the top Aluminium lid of the front PG in order to raise
the pressure between 4-6 kg/cm2.
4)Open the 1” isolation valve of the respective Nitrogen
cylinder.
5)Open the isolation valve prior to the PG displaying
mercaptan vessel pressure which should be above 0.2
kg/cm2.
6) Open the suction line of the pump.
7)Open the drain line at discharge of the pump till gas stops
coming and liquid starts coming.
8)Start the pump.
9)Close the vent line and open the discharge valve.
10)It takes about ½ an hour to develop the discharge
pressure.
11)If there is any problem with flow, 1st vent the drain line
at discharge of the pump till gas stops coming and liquid
starts coming.
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CHAPTER VII
SOP FOR HANDLING OF EMERGENCY SITUATION
GENERAL OPERATIONS
ACTIVITY
7.01Action to be taken in case Inlet Compressor trips
PURPOSE Steps to handle emergency situation in case of Inlet Compressor trip.
HAZARDS
1)Fire hazard 2)Hazard of burn injury
3)Hazard of falling material on the body 4)Noise
5) Leakage of gas
PPEs
Safety shoe, Dungaree, Helmet.
PREPARATION
Wear Helmet before starting the job
STEP BY STEP
PROCEDURE
1) Put PRV from AUTO to MANUAL at local CM 11.01 panel.
2) Release Pressure in PV 16.01 (Inlet comp suction
scrubber) by pulling charge and vent Amot valve from
the same local panel
3) Follow the ‘expander compressor trip procedure’ as
mentioned in 3.1.3.
4) Shut down both Regen Gas and Hot oil heaters
5) Put PICV-430 on MANUAL at field when Level in
PV 16.07 (expander separator) comes below 40 %.
6) Stop De-ethanizer Reflux pump (PM 17.01/02)
when level in PV 16.08 (De-ethanizer Reflux
Accumulator) near Zero.
7) Stop De-butanizer reflux pump (PM 17.03/04)
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when level in PV 16.10 is zero.
8 )Close LPG and NG product line to storage isolation
valves.
9 )Open LCV-432 by-pass valve & PRCV-504 B to
Flare.
GENERAL OPERATIONS
ACTIVITY 7.02Action to be taken in case Expander Compressor trips
PURPOSE Steps to handle emergency situation in case of
Expander-Compressor trip.
HAZARDS
1)Fire hazard
2)Slip ,fall due to Lube oil leakage 3)Hazard of falling material on the body
4)Noise 5) Leakage of Gas
6)Slip fall due to spillage of water.
PPEs
Safety shoe, Dungaree, Helmet.
PREPARATION
Wear Helmet before starting the job
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STEP BY
STEP PROCEDURE
1)Change from ‘Remote’ to ‘local’ for IGV (inlet guide
vane) control in Expander-Comp HMI (human machine
interface) panel and gradually close the IGV up to Zero
%.
2)Close Booster compressor discharge valve
physically.
3)Allow sufficient time (about 10 min) to run the lube
oil pumps (PM 17.401/402). Then stop the Lube oil
pump in HMI panel, select off option for the both
pump and close the seal gas manual valve.
4)Close the expander discharge valve and then seal
gas trip control valve from HMI panel and also
isolate the seal gas supply valve physically from cold
separator top.
5)Reduce the hot Oil Heater temperature slowly to
around 100°C or stop the heater as required.
6)Put PICV-430 on MANUAL at field when Level in
PV 16.07 (expander separator) comes below 40 %.
7)Stop De-ethanizer Reflux pump (PM 17.01/02)
when level in PV 16.08 (De-ethanizer Reflux
Accumulator) near 20%
8)Stop De-butanizer reflux pump (PM 17.03/04)
when level in PV 16.10 is zero.
9)Close LPG & NG product line.
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GENERAL OPERATIONS
ACTIVITY
7.03Action to be taken for gas leakage from flange,line or vessel in LPG Recovery Plant
PURPOSE Steps to handle emergency situation in case of gas
leakage
HAZARDS
1)Fire hazard 2)Hazard of burn injury
3)Hazard of falling material on the body 4)Noise
5) Striking.
PPEs
Safety shoe, Dungaree, Helmet.
PREPARATION
Wear Helmet before starting the job
STEP BY STEP
PROCEDURE
1)Shout and draw attention of others for help, break nearby break-glass box. 2)Try to isolate the source of leakage by closing appropriate valves. 3)Inform LPG Control Room/ Shift Engineer in-charge in LPG Recovery Plant or Dy.SE (PD)/ Sr E(PD) in LPG Filling Plant, as applicable, depending on whether the leakage is in LPG Recovery Plant or LPG Filling Plant. 4)In case of leakage in LPG Recovery Plant, Shift Engineer in-charge in LPG Recovery Plant will inform Fire Station. Give full details of the emergency. He will disconnect the telephone after Fire Service personnel repeats the message. He will raise the siren manually and intimate all the personnel of the installation about the leakage. He will inform Dy.SE (PD)/ SrE(PD) about the leakage. 5)In case of leakage in LPG Filling Plant, Dy.SE (PD)/ Sr.E(PD) in LPG Filling Plant will inform Fire Station. Give full details of the emergency. He will disconnect the telephone after Fire Service personnel repeats the message. Will raise the siren manually and intimate all the personnel of the installation about the leakage. He will inform Shift Engineer in-charge in LPG Recovery Plant about the leakage. 6)Collect all personnel up wind. 7)Stop all hot jobs such as welding, gas cutting etc. if there is any.
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8)Stop all internal combustion engines and movement of vehicles in the vicinity. Remove/ extinguish all sources of ignition. 9)Use deluge valves, monitors and hydrants --as applicable, for blanketing the area of leakage with water fog. 10)Any non-flame proof electrical appliances in the vicinity should be considered as a potential source of ignition and hence should not be operated. 11)The duties and responsibilities of various personnel in the LPG Department will be as per CRISIS MANAGEMENT PLAN (LPG PLANT)
GENERAL OPERATIONS
ACTIVITY
7.04Auto Start Testing of FW PM No-1,2,3,4 and DEFP
No-2
PURPOSE To test Fire water pumps 1,2,3,4 for Auto start
HAZARDS
1)Fire hazard
2)Hazard of burn injury 3)Hazard of falling material on the body
4)Noise 5)Slip,fall due to spillage of water.
PPEs
Safety shoe, Dungaree, Helmet.
PREPARATION
Wear Helmet before starting the job
Inform Filling Plant regarding the ‘AUTO START TESTING
OF FIRE WATER PUMPS AND DISEL ENGINE FIRE PUMP’ Go to the FIRE WATER pump house.
Put all the FWP in ‘MANNUAL’ position except the FWP which is to be tested.
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STEP BY STEP
PROCEDURE
1. Inform Filling Plant regarding the ‘AUTO START TESTING
OF FIRE WATER PUMPS AND DISEL ENGINE FIRE PUMP’
2. Go to the FIRE WATER pump house.
3. Put all the FWP in ‘MANNUAL’ position except the FWP which 4. is to be tested.
5. Water from the hydrant system to be drained in a very
minimum rate to reduce the pressure by any monitor or drain point.
6. Observe the activated pressure and pump starting pressure and record it .
7. If the system pressure increase to 4 - 8 Kg/cm2 g than the running pump is to be stopped by putting the
selector switch to manual position and at the same time pushing the stop switch.
8. Then try to another FWP for ‘AUTO STATRT’ testing and
follow the above sequence.
9. It the job is complete than observe whether the hydrant system pressure is steady or not by running the jockey pump
in ‘AUTO’position.
10. If the system is steady with sufficient idle time of jockey
pump(above 10 minutes) than all pumps are to be put in ‘AUTO’position.
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