Sop-Gtd 260613 R1
Sop-Gtd 260613 R1
Sop-Gtd 260613 R1
Ship unloading line has to be cooled to tank product temperature, before the
ship berths.
3. Start Intank pump which is inline, after ensuring the following (If pump is not
running for tanker loading).
SAFETY CHECKS
1. Take trial for D.G. operation and ensure emergency back up power supply is
available.
2. Ensure that all compressors are in operating condition (check oil level in
comp oil separator)
3. Check fire water system. Ensure that fire tender is in operating condition with
all fire fighting equipments.
5. During the chilling operation check for any leakage (by portable LEL meter as
well as visually) at new jetty, old jetty, valve station and along the pipelines.
6. While chilling operation in progress, keep watch on line pressure at jetty end
and valve station. Monitor new jetty temperature at regular interval.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/001
PRE-CHILLING & SAFETY CHECKS
Page 3 of 4
Ship unloading line has to be cooled to tank product temperature, before the
ship berths.
3. Start Intank pump which is inline, after ensuring the following (If pump is not
running for PLT).
a) Storage tank pressure is 50 mbar to 90 mbar.
b) Liquid level of storage tank is higher than 1525 mm.
c) Open respective I/V of intank pump discharge line on tank top.
d) Ensure that HCV 1501 is in closed position.
e) After five minutes, Put FCV 1501 on auto mode keeping set point 40
m3/hr.
f) Open FCV 1503 slowly 5% to 10% and slowly increase the chilling flow
to 90 m3/hr.
SAFETY CHECKS
1. Take trial for D.G. operation and ensure emergency back up power supply is
available.
2. Ensure that all compressors are in operating condition (check oil level in
comp oil separator)
3. Check fire water system. Ensure that fire tender is in operating condition with
all fire fighting equipment.
5. During the chilling operation check for any leakage (by portable LEL meter as
well as visually) at new jetty, old jetty, valve station and along the pipelines.
6. While chilling operation in progress, keep watch on line pressure at jetty end
and valve station. Monitor new jetty temperature at regular interval.
Reference :
1. P&ID – Storage Tank LPG 101
2. P&ID – Storage Tank Propane 102
3. P&ID – Ship unloading arm
1. Check ship manifold flange rating and size, if size is not compatible, check
requirement of gasket and reducer.
2. Check that manifold should remain within operating envelope range. (check
as per envelope drawing)
6. Purge the loading arm with Nitrogen and take leak test.
7. After ensuring leak test is OK, depressurize and line up for ship unloading.
Reference :
1. Drawing of H201 (Loading arm)
1. Before ship unloading operation ship unloading line has to cool down to a
temperature within 8o C of the tank product temperature.
5. Check that ball valve on discharge side of PSV 2001 is in LOCKED OPEN
POSITION.
10. Put respective intank pump on minium bypass mode & if there is no tanker
loading or PLT, stop respective intank pump close chilling supply control
valve and its isolation valve at tank top and open PCV 1010/ 1510 isolation
valve. Then open PCV 1010/ 1510 to the required extent.
13. Before starting ship pump bring down tank pressure at 50 m bar by
reliqufication system lineup compressor to tank.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/003
PROPANE / LPG SHIP UNLOADING
Page 2 of 6
14. Start D.G. for utilities and one LPG compressor on D.G. load only in case of
power problem.
15. Line up ship unloading line (12”) for ship unloading operation in terminal.
c. Check unloading arm for any leak with portable LEL meter.
d. Check & log the pressure & temperature of ship manifold & shore (jetty
manifold).
h. Monitor product temperature profile in the tank, start intank pump, if TDA
exceeds 1o C on circulation mode.
2. Before hot gas blowing inform terminal incharge about starting of blowing.
ii) Chilling return Cooler E 1023 shell side outlet vent valve should be
open.
vi) Ensure PCV P1010 / PCV P1510 is open and controlled as per
tank pressure.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/003
PROPANE / LPG SHIP UNLOADING
Page 4 of 6
ix) Ensure chilling return sub cooler E1023, shell side outlet isolation
valve towards T102 is closed.
d. Stop hot gas blowing once above condition in points no. ‘c’ are fulfilled.
ii) Chilling return cooler E 1023 shell side outlet vent valve.
10. After completion of hot gas blowing, depressurize 12” ship unloading line and
6” chilling return line in respective tank.
Reference :
1. P&ID – Storage Tank LPG 101
2. P&ID – Storage Tank Propane 102
3. P&ID – Ship unloading arm
I. Control Room Officer to ensure the cooling water system line up for
Heaters from Operation Officer / Plant Operator, as per following
1. Ensure the cooling water inlet & outlet isolation valves to Propane heater
E1024 / E1024B are in open condition.
2. Ensure that isolation valve on cooling water return header from heater circuit
to cooling tower is open.
3. Ensure that all cells are in line on cooling tower deck.
4. Ensure that drain valves & vent valves in heater cooling water circuit are in
closed condition.
5. Start cooling water pump P801 A/B/C or P803 A/B & establish cooling water
flow by deaeration through vents in heater circuit as required.
6. Run the cooling tower fans as per cooling water temperature.
II Control Room Officer to ensure the Heater and Air Fin Heater system
line up from Operation Officer / Plant Operator as per following:
1. Ensure propane heaters E 1024/E & 1024B are in line.
2. Ensure Air Fin Heater E 404 & E 407 are in line.
3. Ensure that instruments are fixed and are in line.
4. Ensure that PSV at u/s and d/s of HCV – 4501 are in line.
5. Ensure that 3” bypass ball valve of Air Fin Heater is in closed condition.
6. Ensure that HCV-4501 is storke-checked and operated normally.
7. Start the Air Fin Heater fan (if heater outlet temperature falls to less than 10 o
C) and observe for any abnormal sound.
8. Ensure that HCV-4501 hand control valve is in closed condition.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/004
PROPANE TANKER LOADING
Page 2 of 5
9. Open the isolation valve on u/s and d/s of HCV-4501.
Truck loading operator shall fill the checklist every time for Truck Loading Operation
(for each Truck)
I) Control Room Officer to ensure the cooling water system line up for
Heaters from Operation Officer / Plant Operator, as per following
1. Ensure the cooling water inlet & outlet isolation valves to LPG heaters E402
and / or E1024A are in open condition.
2. Ensure that isolation valve on cooling water return header from heater circuit
to cooling tower is open.
3. Ensure that all cells are in line on cooling tower deck.
4. Ensure that drain valves & vent valves in heater cooling water circuit are in
closed & blinded condition.
5. Start cooling water pump P801 A/B/C or P803 A/B & establish cooling water
flow by deariation through vents in heater circuit as required.
6. Run the cooling tower fans as per cooling water temperature.
II) Control Room Officer to ensure the heater and air fin heater system line
up from Operation Officer / Plant Operator, as per following
5. Inform Control Room Officer and close all valves on loading arm and tanker
side. Record the final tanker level, pressure & temperature.
6. De-pressurise spool piece between loading arm valve and tanker loading
valve to vent stack. Check the Pressure gauge on de-pressurization line. If
the pressure is more than 0.5 bar, check the isolation valves for passing. If
the valve passing is observed, don’t disconnect the loading arm, inform S/I
and after confirmation decant the tanker and then disconnect the loading arm
and send back the tanker.
7. Disconnect liquid and vapour loading arm (if connected) and put back on rest.
8. Disconnect earthing cable.
9. Remove wheel blocks.
10. Handover ignition key to the truck driver.
11. Stop the Air-Fin Heater fan after completion of LPG tanker loading.
References :
1. P&ID for send out system.
2. P&ID for Truck loading system
I. Control Room Officer to be ensured the cooling water system line up for
condensers from Operation Officer / Plant Operator as follows:
1. Ensure the cooling water inlet & outlet isolation valves to all condensers are in open
condition.
2. Ensure that all cells are in line on cooling tower deck.
3. Ensure that drain valves & vent valves in heater & condenser cooling water circuit
are in closed condition & blinded.
4. Start cooling water pump P801 A/B/C & established cooling water flow in heater &
condenser circuit as required.
5. Deareate individual condenser and condenser cooling water by opening the
respective vent valves and cooling water flow to be established.
6. Vent valve to be closed and blinded once the cooling water flow is established.
7. Ensure the cooling water line up of compressor oil cooler.
8. Run the cooling water fan as per requirement.
4. Check line up for cooling water to compressor oil cooler and LPG condenser.
5. Ensure that of condensate return line XV and its isolation valve to storage tank is
open.
7. Compressor suction line up to be checked and ensured with the respective tank.
8. Check and line up condenser LCVs d/s isolation valve as per compressor suction
line up.
12. While running the compressor ensure that following settings should be strictly
followed for avoiding any compressor damage.
j. High condensate liquid level - 850 mm for E331 and E332 condenser and
7. Ensure that capacity control of the compressor is 10% when compressor is not in
operation.
10. Following set points for operating compressor should be followed strictly.
1. Before starting the compressor ensure that capacity control of the compressor
is 10% & storage tank pressure is higher than pressure 25 mbar.
V Operating procedure for LPG compressor Super manual operation refer check
list – Super Manual operation of Compressor C320 / C1022.
Reference :
1. P&ID for LPG Compressor system
2. P&ID for Condenser system
Nagothane).
2. Ensure the cooling water inlet & outlet i/v to Propane heaters
E1024/E1024B are in open condition.
3. Ensure that 14” isolation valve on cooling water return header for old CT &
6” i/v for new CT from heater circuit are open.
4. Ensure that all cells are in line on cooling tower deck.
5. Ensure that drain valves & vent valves in heater cooling water circuit are in
closed condition.
6. Start cooling water pump P801 A/B/C, P803A/B & established cooling
water flow in heater circuit as required.
7. Run the cooling tower fans as per cooling water temperature.
Startup operation
1. Start line out for pipeline send out operation after receiving request from RIL
control room.
2. Ensure shell side level of E1024 / E1024B is between 80% - 90%.
3. Check communication system between RIL and ALL.
4. Ensure the line up of Air fin Heater E407 & its bypass valve is closed (if
necessary).
5. Ensure all instruments are in line.
6. Log tank level readings before starting intank pump.
7. Start intank pump which is in line after ensuring the following :
XV 4601 / XV 4602 are in open condition.
Inform RIL control room and obtain reconfirmation.
Storage Tank pressure is 50 m bar to 70 m bar.
Liquid level in storage tank is higher than 2000 MM.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/007
PIPELINE TRANSFER OPERATION
Page 2 of 5
Intank pump send out valve H 1501 / H 1502 are in closed position.
Chilling supply valve F 1503 is in closed position.
Intank pump by-pass valve FCV F 1501 / F 1502 are in open
position.
8. Run intank pump on by-pass mode with FCVF 1501 / F1502 are in manual
mode.
9. After 5 minutes put FCV F 1501 / F 1502 in auto mode.
1. Open HCV H 1501 slowly and pressurize gradually the suction line of
booster pump to 18 - 20 bar g.
2. Start oil pump of booster pump.
3. Ensure all alarms are healthy from control room.
4. Start booster pump from local switch.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/007
PIPELINE TRANSFER OPERATION
Page 3 of 5
5. Open the FCV 4602 by observing the pump discharge flow & reduce FCV
4601 manually. Then put FCV 4601 on auto mode (set flow must be 21
m3 / hr).
6. Adjust the FCV 4602 manually to get the flow around 18 mt / hr to avoid
two phase flow.
7. Ensure XVX 4621 discharge pressure is around 45 bar.
8. Stop oil pump of booster pump.
9. Divert the seal flush line to suction of booster pump.
10. After normalizing the first pump inform RIL control room & get the
clearance to start the second booster pump.
Remark : During tanker loading and or chilling operation, booster pump suction
pressure to be monitored & maintain above 12 bar.
Reference :
1. P&ID for T102
2. P&ID for Send out system
2. The hydrant pump is kept isolated from the suction, discharge and
recirculation sides.
4. The pump side is completely depressurized through the vent and drain
plugs.
10. In presence of maintenance the hydrant pump’s trial run is taken if found
satisfactory the work permit completion is accepted by the issuer.
1. The Ethyl Mercaptan dosing pump motor stop push button is kept locked and
tagged.
3. The system mercaptan liquid is collected through the drains. Any spillage of
liquid is absorbed with Ekoperlite powder and cryssal solution and
completely recovered.
5. The mercaptan pump P 790 A/B motor starters kept de-energised and
tagged.
7. After completion of the job the work permit is returned by the maintenance
team.
9. The mercaptan pump motor is kept energised and trial run is taken in
presence of maintenance. If found satisfactory the work permit job
completion is accepted.
5. After the completion of maintenance the work permit is returned. The air
compressor system discharge is lined up. Cooling water to cooler and
compressor jackets kept lined up. The instrument air to compressor
loading / unloading systems is kept lined up.
Remarks: Before hand over to maintenance, please take clearance from Liquid
Terminal Division.
2. The LPG compressor and oil pump motors of C-310 / C-320 / C-1021 /
-1022 / C - 1023 is kept de-energised.
5. Compressor suction filter inlet and outlet pressure gauge tapping valves to
be closed.
10. The compressor / condenser system is purged with nitrogen till % O 2 level
is below 1%. The % O2 level is checked with portable oxygen analyser.
11. The suction isolation valve of the LPG / Propane compressor is opened
and nitrogen in the system is displaced with LPG vapours to vent stack.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/011
DECOMMISSIONIG, HANDOVER TO MAINTENANCE &
COMMISSIONING OF LPG / PROPANE COMPRESSOR
CONDENSER SYSTEM
Page 2 of 2
12. Leak test / % LEL check is done to ensure no leakages in the system after
maintenance.
14. Ensure Compressor suction filter inlet and outlet pressure gauge tapping
valves are opened.
16. The LPG / Propane compressor and oil pump motor is kept energised.
18. The LPG / Propane compressor / condenser system trial run is taken in
presence of maintenance.
Reference:
1. P&ID for Condenser system
2. P&ID for Compressor system
2. Ensure XVX 2001 ESD (Emergency shut down) system valve kept in
closed position.
3. The ship unloading arm 1” I/V is connected with nitrogen and the
unloading arm system is pressurized to 2.0 bar N 2 pressure.
4. The unloading arm is depressurized through the 1” I/V at the stand post
portion.
6. A work permit is made for maintenance and the unloading arm is handed
7. to maintenance.
9. The unloading arm is pressurized to 2.0 bar nitrogen pressure and the
loading arm joints and leak tested, in presence of maintenance.
10. After the satisfactory checks on leaks the loading arm nitrogen pressure is
depressurized through the 1” vent valve on the stand post portion.
Reference:
1. P&ID for Ship unloading Arm
1. The Booster pump P 1022 (A/B) and oil pump P 1025 (A/B) motors are
kept de-energised, isolated and tagged.
2. The Booster pumps P 1022 A/B suction and discharge lines are kept
depressurized to tank through minimum bypass line valves F 4601 /
F4611.
3. The Booster pump suction and discharge isolation valves near the pump
is closed.
4. Minimum bypass line valves F 4601 / F 4611 are kept closed and isolation
valves on the downstream side kept closed.
5. Ensure seal flush line is kept positive isolated from Propane header.
6. A nitrogen hose connection is made to the suction line 1” spare nozzle and
the booster pump system is pressurized to 2.0 bar nitrogen pressure and
depressurized through the ½” vent valve on the seal flush line till % LEL
becomes nil.
9. The Booster pump suction and discharge systems are purged with Nitrogen
and % oxygen checked with portable oxygen analyser till % oxygen in the
loop becomes less than 1%.
11. The Booster pump suction / discharge loops are pressurized to 4.5 bar
nitrogen pressure and leak tested in presence of maintenance.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/013
DECOMMISSIONIG, HANDOVER TO MAINTENANCE &
COMMISSIONING AFTER MAINTENANCE OF BOOSTER PUMP
P1022 (A/B)
Page 2 of 2
12. The Booster pump loops nitrogen is displaced with propane vapours by
opening the suction line isolation valve and % LEL checked to ensure
leak free.
13. The Booster pumps P 1022 (A/B) and oil pumps P 1025 (A/B) motors are
kept energised.
14. Trial run of Booster pumps P 1022 (A/B) and oil pumps P 1025 (A/B)
taken in presence of maintenance.
Reference :
1. P&ID for Send out system
6. The loading arm is purged with nitrogen with the opening of 1” I/V till %
oxygen in the loading arm becomes less than 1%. The nitrogen flow is
isolated after leak test of joints at 4.5 bar N 2 pressure.
7. The loading arm / pipeline nitrogen is displaced slowly with LPG / Propane
vapour and the joints are leak tested with portable % LEL meter (gas
detector).
9. The LPG / Propane tanker loading arm is brought back into service after
opening the isolation valve upstream of XV 6002 / XV 6012 / XV 6022 / XV
6032 / XV 6042.
Reference:
1. P&ID for Truck Loading system
1. The intank pump P-101 A/B is run forLPG-101 tank. The intank pump
P-1021 A/B is run for T-102 tank.
2. The sampling personnel should use cotton clothes, goggles, hand gloves
during the sampling.
3. The sampling point / sample container bomb is connected to the (1”) vent
valve down stream of
a. HV 1001 / F 1001 for LPG-101 sampling
b. HV 1501 / HV 1502
OR
F 1501 / F 1502 for T-102 sampling.
5. The 1” isolation valve is slightly opened and the sample container valves
are slightly opened and the container is purged with LPG vapour.
6. The sample container vent valve is closed and the container sample inlet
valve is fully opened, to allow the container be filled with liquid.
10. The sampling hose is disconnected from the 1” vent valve connection.
1. Open F 9001 N2 purge flow on LPG-101 tank top and keep the flow
at 3.0 Nm3/hr.
2. Open F 9011 the N2 purge flow on T-102 tank top and keep the flow
at 3.0 Nm3/hr.
3. Open F 9005 N2 purge flow on the truck loading bay-I to keep the
flow at 3.0 Nm3/hr.
4. Open F 9007, F 9008 N2 purge flows in the LPG header area and
LPG compressor area to keep the nitrogen flow at 3.0 Nm3/hr.
5. Open F 9002 N2 purge flow on the cold vent stack seal drum to keep
the nitrogen flow at 3.0 Nm3/hr.
Check the date and dosing amount from the file “Monthly Cooling
Water Treatment Programme”.
To start always see the tag/label of the container before dosing the
chemicals.
It is to be slug dosed into C.T. basin water after sun set only (the
chemical will act better in absence of sunlight, when the
microbiological activity is less).
After slug dose do not give any blow down (filler back wash) and
chlorination for 12 hours.
2. OXIDATIVE BIOCIDE
For dosing amount please refer the file “C.W. Monthly treatment
programme file” kept at GTD control room. It has been slug dosed into
C.T. basin in every day basis.
Personal safety care :- Always refer MSDS file of C.W. chemical kept at GTD
control room.
Always use rubber gloves, safety goggles & safety shoes during chemical
handling (kept near C.T. basin).
The product if come in contact with skin, or eye, the affected area should be
washed in eye fountain and shower situated near C.T. basin.
When the tubes getting chocked (flow become less) the tubes should be cleaned
and then it should be passivated. Before doing passivation with cathodic and
anodic inhibitor, ensure that the respective heat exchanger’s cooling water tubes
should be thoroughly cleaned with nylon brush and water. Smooth surface is
required for the formation of thin protective layer which will prevent corrosion.
1. Add Passivation Chemical - I (30 ppm PO4) as slug dose to the C.T. basin
water (considering 130 m3 hold up).
2. Ensure that there should not be any blow down or filter back wash for 24
hours within the passivation period.
3. Check the initial phosphate level of the re-circulating water just 10 minutes
after the dosing of Passivation Chemical - I and final phosphate level 24
hours after the dose. The difference is the PO4 absorbed for passivation,
50% absorption is desirable.
To start chlorination of cooling water please follow the procedure as given below.
Starting of chlorination
2. a. Open CLV-1 and maintain the C.W. pressure down stream line
between 4 to 5 bar.
b. Check for the vacuum creation at ejector, chlorine PVC tube
(transparent).
c. Check the C.W flow to basin through 1” line.
d. If every thing is in order open CLV-5 slightly and check cylinder
connection with regulator for any leak with ammonium hydroxide
solution.
e. If there is no leak, adjust the regulator knob for 100 gms/hour flow.
f. Note the time and continue chlorination for 30 minutes and stop. In
the meantime check FRC (Free Residual Chlorine) level at C.W.
return line. It should be around 0.5 ppm. If FRC level is more than
0.8 ppm stop chlorination.
Stopping of chlorination
5. a. Stop chlorination
b. Give C.W. blow down
c. Start make up till PH >=7.5
d. Chlorination should be done to C.W if the P H is between 7.5 to 8.0.
Ejector problem
2. Open a buffer capsule by twisting and pulling apart, pour the content in
to the flask.
4. Immerse the pH meter up to the max level in pH buffer (H1 777P) and
stir gently and wait until the display stabilizes.
1. Take 5 ml of water (to be checked) into the test tube (the test tube should
be marked with 5 ml water part and one ml reagent part).
2. Add rapidly 1 ml chlorotex reagent in it and mix it well and wait for 20
seconds.
3. Compare the colour of the test tube mixture with colour comparator chart
given on the chlorotex bottle and determine the FRC in ppm.
Ethyl Mercaptan is received in 160 kgs. Drums well sealed. The drum contents
are transferred into Mercaptan storage tank by the following procedure.
9. Ensure that air pressure for barrel pump pneumatic motor is o.k. and open
inlet valve on air header. Open Mercaptan pump motor air inlet valve
slowly.
10. Observe that pump starts running and Mercaptan transfer is taking place
from Mercaptan drum to Mercaptan vessel.
11. Check for any Leakage on the joints with soap solution.
12. If there is any leakage, stop the transfer by closing the air connection
isolation valve and the Mercaptan vessel inlet isolation valve.
13. Spread the Peralite powder in case of any spillage/leakage.
14. Attend the leak & restart pumping operation.
15. Once the drum product is completely transferred to Mercaptan tank or if
maximum level (850 mm) reached in Mercaptan vessel stop pumping
operation.
16. Spray the “Chrysal “solution at the leak to absorb the spillage. Recover
the Pearlite powder/solution in a container.
17. In case there is no leakage, continue the transfer operation and watch the
level rise in the Mercaptan vessel. Also keep watch on the Mercaptan
vessel pressure.
18. Stop the transfer when the level rise in the system storage is stopped/
When the Mercaptan drum is empty.
19. Isolate the air connection and close the Mercaptan vessel inlet valve.
20. Disconnect the air connection from the pneumatic pump.
21. Remove SS hose from pneumatic pump discharge side to Mercaptan
vessel product inlet connection.
22. Close Mercaptan vessel vent isolation valve.
23. Open Nitrogen inlet valve to Mercaptan vessel.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/022
ETHYL MERCAPTAN STORAGE / HANDLING /
DECOMMISSIONING
Page 3 of 3
24. Remove Pneumatic pump from the drum and clean with hypochlorite
solution/water and preserve it safely.
25. After above operation shift the drum for decommissioning.
26. Using dilute Sodium Hypochlorite solution the empty Mercaptan drum
content should be absorbed and washed with plenty of water.
27. The empty and full Mercaptan drums should be kept separately and
marked accordingly.
28. All PPE’s after use to be decontaminated from Mercaptan smell & washed
thoroughly with soap solution & water and dried.
Page 1 of 1
I START-UP OPERATION
1. Start make up water to cooling tower basin to bring up the level to 70%
2. Open the suction line isolation valve u/s of the strainer at the suction of
pump P801A / B / C, P803 A / B & P802 as per required.
3. Remove the air from the pump systems P-801 A/B/C, P803 A/B & P802
and from the casing also.
4. Open the recirculation line isolation valve.
5. Start the pump P-801 A/B/C, P803 A/B & P802 as per requirement.
6. Observe the sound/bearing temperature, gland sealing liquid conditions.
7. Open the discharge isolation valve slowly; simultaneously reducing the
2 recirculation flow. Observe the current, vibration, noise etc.
8. Observe the pump/motor conditions viz current, vibrations, noise etc.
1. Heater E402, E1024 & E1024A, E1024B & condensers E331, E332,
E1021, E1027, Compressor oil coolers, booster pump oil coolers, air
compressor oil cooler are ready for service.
2. Open Heater E402 / E1024 / E1024A, E1024B & condensers E331 / E332
/ E1021 E1027, Compressor oil coolers, booster pump oil coolers, air
compressor oil cooler, tube side vents to release air.
3. Open heater E402, E1024, E1024A, E1024B & condensers E331 / E332 /
E1021 / E1027, cooling water inlet isolation valve slightly.
4. Ensure that E402/ E1024 / E1024A / E1024B bottom portion &
condensers E331 / E332 / E1021 / E1027, tube side are fully filled with
water by removing all the air from the system.
5. Open cooling water outlet line isolation valves of heaters.
6. Open isolation valve and control valves of condensers.
7. Close tube side vent valve and blinded.
8. Open the inlet, outlet isolation valves & control valves simultaneously.
9. Ensure drain and vent valves are closed and blinded after establishing
cooling water flow.
Reference:
1. P&ID for Cooling water system
Note : This procedure is prepared for both the heaters E-1024 and E-1024 B and
is applicable only to the heater under consideration.
1. Ensure air fin heater along with motor and fan is installed properly by
Engineering dept.
2. Keep inlet and outlet isolation valve closed and air blowing to be done by
pressurizing and depressurizing to remove any foreign particles through
vent and drain parts.
3. Nitrogen purging to be done till O 2 % less than 1% and due point reaches
to – 40 o C.
4. Purge the air fin heater till vapour to remove and to till 100% LEL.
5. Connect respective header as per requirement (LPG / C3) and ensure
other header is positively isolated.
6. Take electrical clearance and energize the air fin heater fan.
7. Ensure that instruments and PSV are fixed and taken in line.
8. Open inlet and outlet isolation valve of air fin heater.
9. Close and blind 1” vent valve.
10. Check the direction of rotation of fan by kick start.
11. Start air fin heater and observe for any abnormal sound.
f. Check % LEL with a portable gas meter at the air fin heater and
purge the system with nitrogen till %LEL becomes zero.
g. After preparing a permit to work the air fin heater can be handed
over for maintenance
Note : The commissioning and de-commissioning is for single air fin heater.
1. P501A suction, discharge line, instrument tappings leak tested & found
O.K.
2. P501A start up clearance from electrical / mechanical / instrumentation
sides obtained.
3. All (1”) vent isolation valves closed / blinds provided.
4. All instruments interlocks checked & kept ready for service.
5. Check PSV 5007 kept in line.
6. Close P501A suction bypass line (6”) isolation valve.
7. Check that the flow meter FT5021 in line with tapping I/Vs in open
condition.
8. Ensure sufficient level in MV501 as per level indication. (Level should be
more than 1000 mm)
9. Ensure 6” isolation valve of suction line is opened and then open XV 5004.
10. Open FCV 5021 manually on minimum bypass lines open its 3” u/s & d/s
isolation valve.
11. Start P501A with minimum bypass & observe its vibration, noise & flow
through FI5021, set the FCV5021 minimum flow at 50 m 3/hr on auto
mode.
12. Check that the LPG tanker is ready for filling at filling bay as per SOP–
GTD-5.
13. Start Ethyl mercaptan dosing pump P790 A/B & set the ethyl mercaptan to
LPG filling to give 12 ppm of mercaptan in tanker for odorizing purpose.
14. Stop P501A after filling LPG tanker loading. Close XV5004, ensure the
minimum bypass FCV5021 is wide open in auto mode releasing pressure
to vessel MV501.
1. P501B suction, discharge line, instrument tappings leak tested & found
O.K.
2. P501B start up clearance from electrical / mechanical / instrumentation
sides obtained.
3. All (1”) vent isolation valves closed / blinds provided.
4. All instruments interlocks checked & kept ready for service.
5. Check PSV 5015 kept in line.
6. Close P501B suction bypass line (6”) isolation valve.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/027
TANKER LOADING FROM MOUNDED VESSELS
Page 2 of 2
7. Check that the flow meter FT5022 in line with tapping I/Vs in open
condition.
8. Ensure sufficient level in MV502 as per level indication. (Level should be
more than 1000 mm).
9. Ensure 6” i/v of suction line is opened and then open XV 5014.
10. Open FCV 5022 manually on minimum bypass lines, open its 3” u/s & d/s
isolation valve.
11. Start P501B with minimum bypass & observe its vibration, noise & flow
through FI5022, set the FCV5022 minimum flow at 50 m 3/hr or on auto
mode.
12. Check that the C3 tanker is ready for filling at filling bay as per SOP–GTD-
4.
13. Start Ethyl mercaptan dosing pump P790 A/B & set the ethyl mercaptan to
Propane filling to give 12 ppm of mercaptan in tanker for odorizing
purpose.
14. Stop P501B after filling Propane tanker loading. Close XV5014, ensure
the minimum bypass FCV5022 is wide open in auto mode releasing
pressure to vessel MV502.
Design Parameters :
Capacity : 75 Mt of Propane
2. a) E1024A cooling water side line up. (Shell side line up)
1. Ensure 12” Butterfly valve at inlet & 10” butterfly valve at outlet of
E1024A are kept open for old cooling water system.
2. Ensure 6” Butterfly valve at outlet of E1024A towards new cooling
tower is closed.
3. Ensure that all cells are in line on cooling tower deck.
4. Ensure all isolation valves of cooling water circuit for deck
distribution are open.
5. Start cooling water pumps (if they are not running for other
equipment & or establish flow across E1024A by adjusting flow to
415 ~ 425 m3 / hr. and ensuring flow meter FT8004 readings.
6. Ensure that drain valves & vent valves in heater cooling water
circuit are closed & blinded after establishing flow.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/028
COMMISSIOING AND DECOMMISSIOING OF HEATER E 1024A
Page 2 of 5
Trips & Interlocks : If cooling water flow reduces to less than 100 m 3 / hr HCV
1001 will deenergize & product flow will stop.
Consequences : Generally during tanker loading & after tanker loading pressure
inside tubes will be 6 ~ 9 bars. Due to tube leaks, there is chance of water
seepage inside the tubes if shell side water pressure is more than that of tube
side product pressure. Tube choking due to ice formation and product
contamination (moisture in LPG mix) endanger with respect to quality.
Actions to be taken
At immediate outlet of cooling water side of E1024A a goose neck pipe along
with gas detection system is provided. Alarm of this gas detector is indication of
tube leak. Tube leak to be ensured by checking at other vent points & by close
observing pressure drop rate. Leak tube to be plugged.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/028
COMMISSIOING AND DECOMMISSIOING OF HEATER E 1024A
Page 4 of 5
Deaerate the system by throttling O/L valve at elevated point & normalize the O/L
valve after deaeration.
II) Air blowing to be done with pressurizing & depressurizing in both shell
side & tube side.
B) Tube Side
a) Erection of equipment with closed spectacle blinds as shown in
drawing.
b) Purge the tube side with N2 till O2 % reduces to less than 1.0%.
c) Pressurise the tube side with N2 till 3.0 bar.
d) Cooling water line up to be done as mentioned in Part A.
e) Vapours of propane to be purged in tube side to displace N 2.
Ensure LEL is 100%.
f) Open the spectacle blinds & put closed blinds as per requirement
(for LPG Service).
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/028
COMMISSIOING AND DECOMMISSIOING OF HEATER E 1024A
Page 5 of 5
2. Depressurize the LPG header from T-101 top to LPG tanker loading area
from respective vent point by connecting with metallic hose to LPG T-101
(Hose connection to be done under supervision the air inside the hose to
be purged before connection.)
4. Connect the N2 hose to tube side i/l 1” spare nozzle. Start N 2 & open heater
o/l 1” I/V to vent, pressurizing with N 2 & depressurizing to vent stack to be
done many times to displace hydrocarbon to nil level.
5. Continue the N2 purging till tube side becomes gas free ensured by LEL meter
(% LEL Nil & kept tube side under positive N2 pressure around 1.5 bar.)
6. Close the cooling water supply & return lines I/V & drain the s/s cooling water
after opening the cooling water side vent valve.
2. Ensure tube side & shell side of heaters are N 2 purged & are gas free.
3. Disconnect N2 supply.
4. Ensure cooling water supply / return are isolated & drained & blinded both
i/l & o/l side.