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General Operational Guidelines

CHAPTER XIII GENERAL OPERATIONAL GUIDELINES

General Operational Guidelines

13.1

GENERAL OPERATIONAL GUIDELINES Tips for operating personnel: Some useful tips for the operating personnel on duty-a systematic approach: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Receive instructions from reliever Check tools/equipment Check and analyze operating instructions, log book, log sheets, etc. Release equipments to maintenance Conduct checking tour of entire units. Mark log entries at the prescribed time Discuss unit operating conditions with all concerned Attend equipments requiring frequent checking Evaluate lab results and adjust operating conditions. Carry out necessary house keeping work Review work permits issued Follow up progress on equipment maintenance with maintenance department Collect required samples for lab analysis. Log all activities, carried out in the shift in the log book Check tools and equipment at the end of the shift and discuss unit conditions with the reliever.

13. 13.2

Procedure for implementing a modification in process unit / offsite 1. Based on the request for the job from the owner dept. the process Engg. Group will make the process scheme. The scheme is checked by Process/Advisory services-Inspection and Safety & owner Dept. The Process Engg. Group will conduct the HAZOP study for the modification. The standard format (for HAZOP study) is used to analyse the scheme. Standard guide words-none, more, less, as well as, part of, reverse, other than, any other criteria as applicable. Based on the findings, suitable automatic instrumentation

2.

3.

General Operational Guidelines

/control and / or proper instructions for operation of the new system is recommended and incorporated along with the scheme. The study is checked and approved by the concerned section head of Process, Inspection, Manufacturing and Oil Movement & Stock. 4. After incorporating the HAZOP study recommendations the scheme is approved by the Heads of Process Engg., Owner Dept., Inspection & Safety and Advisory Services Based on the approved scheme, detailed engg. Drawing and cost estimate are made by the Engineering & Construction Department. The E&C/Process Engg. Checks the detailed Engg. Drawing and the drawing is then approved by the heads of Process, Inspection & Safety, Owner Dept. & Advisory Services.

5.

6. 7. 8.

The owner dept. get necessary financial approval for implementation of the scheme. The job is then implemented depending on the urgency/nature of the job. This is incorporated in the P&I diagram once the job is executed and as built drawings are prepared and the same is incorporated in the area drawing.

13.3 13.3.1

Operating Procedure Pumps General 1. How to check an electric motor in operation. operation

CHECK 1. Lubrication

2. Bearings

OBSERVE Lubrication of electric motors will generally be done on a scheduled basis by electricians. Any oil filled compartments will be checked by operators and levels maintained by them. Feel bearing housing to determine if there is any excessive heating or vibration. a. Excessive heating of bearings 1. Over greasing 2. Insufficient lubrication 3. Excessive belt tension 4. Misalignment 5. Lack of end play 6. Excessive end or side thrust by coupling 7. Report abnormal condition to Supervisor. b. Excessive vibration

General Operational Guidelines

1. 2. 3. 4. 5.

Misalignment Vibration transmitted from machine being driven Excessive belt tension or worn belts Loose motor mounts Report abnormal conditions to Supervisor

3. Motor Feel motor housing to determine if there is excessive heating or housing vibration: a. Overheating may be due to : 1. Overload 2. Impaired ventilation of motor 3. Poor condition of coils b. Vibration see b in 2 above: Report abnormal condition to Supervisor.

2.

How to check a steam turbine in operation

CHECK OBSERVE 1. Lubrication of Maintain level with oil specified in lubrication schedule bearing *Avoid excessive high or low levels 2. Lubrication of Fill cup on top of outboard end of governor at least once every 8 Governor hours with oil specified in lubrication schedule 3. Bearings Feel with hand to determine if bearings are over heating a. If bearings over heating notify Supervisor Vibration in excess indicates the malfunctioning of the equipment a. Report abnormal condition to Supervisor b. Vibration may be caused by malfunctioning of turbine c. Vibration may be transmitted to it by the machine being driven Noise of unusual nature indicates malfunctioning of the equipment. a. Report abnormal noise to Supervisor b. Abnormal noise may be caused by malfunctioning of turbine c. Abnormal may be transmitted by machine being driven

4. Vibration

5. Noise

General Operational Guidelines

3.

Centrifugal pumps

a.

How to start an electric motormotor-driven centrifugal pump

Discharge line is the smaller line See that line to destination isclear Pump discharge valve should be blocked Never start a centrifugal pump with discharge valve open. It will over load motor and may burn it out. 2. Check suction a. Suction line is larger line line b. See that all valves on suction line are wide open 3. Check lube oil If necessary, add type of oil specified in Lubrication schedule. levels 4. Check pump a. Turn pump at least one full turn rotation b. See that both pump and motor turn freely c. Report to immediate Supervisor if pump or motor drags or is stuck d. Do not start pump if it drags or is stuck 5. Check pump a. If cooling water is provided, put in operation auxilliaries b. If gland oil is provided, put in operation c. If flushing oil is provided, put in operation 6. Vent pump a. Open vent line to fill pump with liquid b. Centrifugal pumps should never be allowed to run with a dry case c. Block off vent when pump is completed filled with liquid 7. Hot service a. Heat to an even temperature allowing the hot liquid to flow pumps through the pump b. Never start a cold pump pumping hot liquid, always warm up 8. Start motor a. Press start switch b. If motor fails to start, check circuit breaker. Reset if necessary 9. Check pump a. Vent pump through vent line discharge b. Check direction of pump rotation pressure 10. Slowly open a. Open discharge valve as soon as unit comes upto speed and pump discharge pressure valve b. A pump should never be operated for any length of time with discharge valve blocked 11. Check a. Feel with hand to see if bearings are overheating or are vibrating bearings of pump excessively & motor b. If bearings overheat or vibrate, shut pump down and notify your immediate supervisor 12 Check pump packing gland

1. Check a. b. discharge line c. d.

General Operational Guidelines

a. If packing

ring a. b. c. d.

Feel gland to see if packing overheating If overheated report it to your immediate supervisor Check gland oil pressure if gland oil is provided It may be necessary to start up and shutdown pump several times to break in packing and allow lubrication of packing Tighten gland nut one flat at a time. Allow sufficient time for gland pressure to become evenly distributed. No adjustment is required. If seal leaks stop pump and start again If seal continuous to leak report it to your immediate supervisor

a. packing b. If leaks excessively a. b. c. If mechanical c. Seal b.

How to stop an electric motor driven centrifugal pump Press stop switch Close valve tightly Close valve tightly If pump provided with gland oil shut down If pump provided with flushing oil shut down

Stop motor. Close discharge valve Close suction valve Cut off auxiliaries

c.

How to start a steam turbine drive centrifugal pump

1. Warm up For 5 to 10 minutes crack steam into turbine and drain off bottom turbine 2. Check pump a. Discharge line is smaller line discharge line b. See that line to destination is clear c. See that pump discharge valve is blocked 3. Check pump a. Suction line is the larger line on pump suction b. See that all valves in suction line are wide open 4. Check lube oil a. Check pump oil level and add oil if required levels b. Check turbine governor oil cup fill if necessary 5. Check pump a. Turn pump at least one full turn by hand rotation b. See that pump and turbine are free to turn and do not drag c. Report dragging or frozen pump to your immediate supervisor 6. Check pump a. If pump provided with water cooling, start water auxiliaries b. If provided with gland oil, start gland oil c. If provided with flushing oil, start flushing oil. 7. Turbine Open valve in cooling water line to turbine bearings cooling

General Operational Guidelines

8. Vent pump

a. Vent pump by opening vent valve and allow pump to fill with liquid b. Close vent valve. c. A centrifugal pump should never be run with dry case 9. Pump in hot If pump is in hot service pump should be heated up by bleeding hot service liquid through pump 10. Turbine Open steam exhaust valve on larger line from turbine exhaust 11. Start turbine Slowly open steam valve on turbine until pump is running at its rated speed and turbine takes control 12. Check pump If pressure does not come up, vent pump again. pressure 13. Open a. Slowly open pump discharge valve discharge valve b. A centrifugal pump should never be operated for any length of time with discharge valve blocked. 14. Check a. Feel with hands to see if bearings overheat or vibrate excessively bearings on b. If bearings overheat or vibrate, shut pump down and notify pump and immediate supervisor. turbine 15. Check pump See item 12 How to start an Electric Motordriven centrifugal packing gland pump.

d.

How to stop a steam turbine driven centrifugal pump

a. Trip the hand trip lever on the over speed governor of turbine on outboard of turbine b. Shut off steam to turbine 2. Close a. Smaller line on pump discharge valve b. Close valve tight 3. Close pump a. Larger line on pump suction valve b. Close valve tight 4. Shut steam off Close valve on steam line to turbine. Smaller line to turbine tightly turbine 5. Close exhaust a. Large line on turbine steam valve b. Close valve tightly 6. Reset hand Pull reset lever up into position on governor of turbine trip lever 7. Drain turbine Release pressure on turbine. Open drain on bottom of turbine casing. Leave open 8. Close pump Shut off water, gland oil, flushing oil if provided auxiliaries 9. Bleed pressure a. Open vent line and bleed off pressure

1. Stop turbine.

General Operational Guidelines

off pumps

b. Close vent line

e.

How to check a centrifugal pump in operation

CHECK

OBSERVE

1. Discharge Discharge pressure should be normal. Changes in discharge pressure Pressure may indicate problems. 2. Packing gland 1. If ring packing: a. Feel gland to determine that packing is not overheated. Exercise care so as not to touch moving shaft b. Keep packing gland adjusted so that there is only sufficient leakage to lubricate packing and keep it from over heating.

2. If packing is overheating: a. Report it to Supervisor. b. If pump gland is provided with cooling water or with gland oil check to see that this is being supplied. 3. Packing, leaking excessively: a. Report it to supervisor b. Tighten gland nut one flat at a time, allowing sufficient time for gland pressure to become evenly distributed through the packing. 3. Mechanical 1. No adjustment required seal 2. Report prolonged or excessive leakage to supervisor. 4. Lubricating in Maintain level with oil specified in lubricating schedule: bearing housing a. Excessive high levels cause leakage at bearings wasting oil. This also causes house keeping problems. b. Low level causes poor lubrication and excessive wear on bearings 5. Bearings 1. Feel bearing housing to determine if there is any excessive heat or vibration: a. Excess heat may indicate 1. 2. 3. 4. Low oil level False oil indicated level Worn bearings High oil level

General Operational Guidelines

b. Vibration may indicate 1. Worn bearings 2. Misalignment 3. Malfunctioning of other parts of pump c. Report these to supervisor 6. Vibration of 1. Feel pump for excessive vibration: pumps a. Report vibration to supervisor b. Vibration may cause by : 1. Worn bearings 2. Misalignment 3. Worn mechanical parts of pump 4. Brocken or plugged impeller 7. Noise in pump 1. Listen to pump for abnormal noise a. Report abnormal noise to supervisor b. Abnormal noise indicates abnormal operation of a part of the pump or driver.

4. Reciprocating Pumps a. How to start a steam driven reciprocating pump 1. Warm steam end pump up of a. Warm up 5-10 minutes. Crack open bleeder valve on steam end. b. Crack open bleeder valve on pump discharge between pump and discharge valve c. Crack open line steam Open valve wide open Open valve wide open Open valve wide open a. Make sure discharge line is open to destination. All valves on discharge should be wide open If pump is started with a valve closed the discharge line or pump may be damaged a. If necessary add oil to lubricator b. Turn lubricator crank about 30 turns to lubricate steam end before starting Slowly open line steam to pump until pump reaches desired speed.

2. Open exhaust steam valve 3. Open pump suction valve 4. Open pump discharge valve 5. Check discharge line

6. check lube oil

7. Start pump

General Operational Guidelines

8. Check pump discharge 9. Close bleeder valves

Observe closely while opening line steam valve. high stop pump. Check discharge line up. Close same valves as opened in No. 1 above

If pressure goes

b. How to stop a steam driven reciprocating pump 1. Stop pump 2. Exhaust steam 3. Pump suction 4. Pump discharge valve 5. Open bleeders a. Close valve on line steam to steam end of pump b. Close tightly a. Close exhaust steam valve b. Close tightly a. Close pump suction valve b. Close tightly a. Close pump discharge valve b. Close tightly Open bleeders on both steam and pump end, to bleed off any pressure.

c. How to check a reciprocating pump in operation CHECK OBSERVE 1. Discharge 1. Discharge pressure should be normal. Any changes in discharge pressure pressure may indicate: a. Malfunctioning of pump b. Poor line up on discharge of pump 2. Packing glands 1. If excessive leakage occurs in packing gland, adjust packing one flat steam and oil at a time. Give ample time for pressure to be distributed evenly sides through the packing. 2. If packing gland is excessively hot the packing may be too tight or improperly packed. 3. Notify the supervisor of these conditions. 3. Lubrication Feel rod on steam to determine if it is coated with a film of oil a. Maintain oil level in lubricator to steam end. Use oil prescribed in the lubrication schedule b. Observe operation of lubricator, see that it is working. Make sure check valve is working in oil like to steam going to cylinder. c. Lubricate rocker arms as necessary. Use medium weight lubricating oil. and 1. Bearing should be checked and determined that they are properly

4.

Bearing

General Operational Guidelines

moving parts

lubricated. a. Lubricate these bearings where necessary with proper lubricant b. Observe any malfunctioning of bearings c. Report abnormal conditions to supervisor 1. Any abnormal noise should be investigated. If cause cannot be determined and corrected report the incident to the supervisor. Shut the pump down where possible. A minor repair may save a major repair. Over speeding of reciprocating pump

5. Noise

6. Over speeding

a. Uses excessive steam b. Breaks valves, valve springs, valve discs and etc. c. Deprives operator of use of pump in repair 7. Discharge and Discharge and suction valves should be wide open. Fluid pumped is suction controlled by throttle valve

5 Gear Pumps a. How to start a gear pump 1. Check pump preparatory to starting 2. Check Bleeders 3. Fill pump case with liquid 4. Turn pump by hand a. Check all flanges, pipings, heads and glands b. Make sure they are ready to receive material Close all bleeders on pump except on discharge line a. Crack open suction valve with discharge valve closed b. Allow liquid to enter the pump and fill the case a. Turn at least one complete turn to determine that pump is free to turn and does not drag b. If pump does not turn or drags do not start, report it to your immediate supervisor a. In preparing to pump hot liquids the pump must be warmed up b. Crack discharge valve with suction valve open; let liquid bleed slowly through the pump. c. If liquid will not bleed through pump, accomplish this warm up by opening discharge valve and starting pump for very short periods, shut pump down and let warm liquid warm up pump. Several starts of this type should be used on very hot oils. Check the pump for freedom of rotation after warm up as in 4 above a. Make sure water cooling systems are in operation b. That gland oil is going to the glands where provided

5. Hot liquids

6. Check oil and water

General Operational Guidelines

7. Open discharge valve 8. Start motor 9. Observation

c. That flushing oil is being used where provided a. If discharge valve is not wide open, open wide b. Make sure discharge line is open to its correct destination Press start switch a. Observe discharge pressure b. Do not let it built up due to some blockage of flow, blind in line, valve closed, and etc c. If pressure builds up abnormally high shut down pump and check line up d. Make sure pump is pumping and operating satisfactory e. Report any abnormal conditions to your immediate supervisor

b. How to shut down a gear pump

1. Stop motor Press stop switch 2. Close suction On large line close valve tightly valve 3. Close On smaller lines close valve tightly discharge valve 4. Bleeders a. Open bleeder to relieve pressure. b. Some pumps in heavy oil service have to be drained and sometimes steamed out. Do if required c. Some pumps are steam traced to keep hot, these do not need to be drained 5. Close oil and a. Close off water cooling water b. Close off any flushing oil or gland oil to pump connections

c. How to check a gear pump in operation

CHECK

OBSERVE

General Operational Guidelines

1.Discharge pressure

Discharge pressure should be normal. may indicate: a. b. c. d. e.

Abnormal discharge pressure

Abnormal operation of pump Heavy material in items due to cooling of oil in line Steam chased lines not functioning properly Partly closed valves, etc Suction line partly blocked If excessive leakage on packing gland adjust packing one flat at a time giving ample time for the pressure to become evenly distributed

2. Packing glands

1.

3. Lubricating oil in bearing housing 4. Bearings

If packing leakage is excessive or if packing is almost taken up notify supervisor of this condition 2. If excessive heating of packing gland a. report this condition to supervisor b. if cooling is supplied to gland make sure there is circulation Maintain level with oil specified in lubricating schedule

1.

Feel bearing housing to determine if there is excessive heat or vibration

a. Excessive heat may indicate: 1. Low oil level 2. False oil indicated level 3. Worn bearings b. Excessive vibration may indicate 1. Worn bearings 2. Misalignment 3. Malfunctioning of other parts of pump c. Report these conditions to supervisor

5. Vibration of pump

Feel pump of excessive vibration a. Report excessive vibration to supervisor b. Vibration may be caused by

General Operational Guidelines

6. Noise in pump

1.

1. Worn bearings 2. Misalignment 3. Worn mechanical parts of pump 4. Broken or worn gears Listen to pump for any abnormal noise

a. Report abnormal noise to supervisor b. Abnormal noise mean abnormal functioning of a part of the pump or driver

13.4

GUIDELINES FOR HANDLING MECHANICAL MAINTENANCE JOBS

Aim of this section is to improve Safety, co-ordination between departments/ sections and to improve productivity while handling maintenance Jobs. This is applicable to all maintenance jobs that are undertaken during turnarounds (shutdowns) and also during the normal running of the plants. The sequences of activities during the total shutdown / individual equipment shutdown are listed for each job, in consultation with the respective owner department & executing department. A few examples are given here indicating the listing of various activities. Examples 1, 2 and 3 are relating to jobs being carried out while the unit is under shut down and examples 4 and 5 are for individual equipment shutdown while the unit is running. The examples given here are only indicative and the activities listed for any job depends on the type of the equipment, its service and the type of repair intended to be performed 13.4.1 13.4.1 ENTRY AND TRAY REPAIR REPAIR IN DISTILLATION COLUMN (CRUDE FRACTIONATOR) FRACTIONATOR) Sl.No. Activity Oil out Requirement/Purpose Stop the oil flow through various equipments as a first step of the shutdown. Oil pushing with To push out oil from the various equipments to the slop tanks.

General Operational Guidelines

water Initial steam out To remove a major portion of hydrocarbon vapour, to facilitate opening of flange joints etc.
Note: A list of locations where steam hose connections are required shall be prepared, in the prescribed format, by the owner Department. The list shall clearly indicate the status/ description of the fitting/s to be removed from each location, for providing steam hose connections. The agency/person removing the fitting to provide steam hose connection and the person issuing the permit for the same shall sign on the list, for each steam hose location, after the hose is provided.

i). In all cases where pyrophoric materials are expected, water washing of the vessel is carried out after the above steam out and before blinding. (This is 3 important in the case of columns with packed sections.) Iron Sulphide (FeS) is called the pyrophoric material, which is self burning, when dry. Pyrophoric substances can be seen inside the Columns at its top sections, Column overhead systems, flare and fuel gas lines, inside FO and LAN tanks, effluent treatment and sewage systems. In general, pyrophoric can be present in the scales of all systems handling hydrocarbons containing Sulphur. ii). Owner Department shall not allow any agency/person to perform a job in the Plant area (Manufacturing/ S & OM) without issuing a written Work Permit. Similarly no person/ agency other than those belonging to the owner department shall undertake any activity in the plant area without a written work permit from the owner department. 4 Blinding The equipment shall be blinded by service agency as per the blind list prepared for the job to service agency as per the blind list prepared for the job, to isolate the same from the remaining system.

General Operational Guidelines

Note: i). Blind list shall be prepared by a group consisting of the Section Heads of the concerned owner department, Safety and Fire and the executing department. If the job is being handled by Maintenance Department, the representative of executing Department shall be the Section Head Maintenance Planning. The Blind list shall contain the types of positive isolations required like "blinding", "double block and keep bleeder open", "block and tag" etc. and any other type of isolation required, size of the flanges where blinds are to be installed and its pressure rating, the location of the flange with respect to the system, position of wedge in case wedging is required and the hydraulic test pressure of the equipment if the blind list is prepared for hydrotests. The list shall contain all procedural activities required for entry/hot work like purging of lines after blinding, activities to be ensured after blinding/steam out etc. The blind list shall also indicate the man ways to be opened for entry and the type of gasket (spiral wound, wire impregnated asbestos, corrugated etc.) to be used at each manway/flange joint, during boxing up/deblinding. Flange joints and manways other than those indicated in the blind list shall not be opened by the service agency. Owner of the equipment shall ensure this. After positive isolation of the equipment from the system, Safety and Fire section shall provide number tags at these locations and this number shall be entered by Safety and Fire section in the blind list against the description of the particular blind. The blind list shall be signed by representatives of the executing department, owner of the equipment and Safety and Fire section after the blinds are installed and isolations are effected. nearby areas or in the ii). No hot work permit shall be issued in the system being blinded, when blinding is in progress. 5 Steam blinding out after Once the equipment is isolated from the system by blinding as per blind list, steam out is carried out once again by owner department for pushing out all remaining

General Operational Guidelines

hydrocarbon vapours, to facilitate entry and hot work. 6 Water Washing Once the equipment is isolated from the system by blinding as per blind list, steam out is carried out once again by owner department for pushing out all remaining

hydrocarbon vapours, to facilitate entry and hot work. 7 Cooling The shell (external) manways are opened and air eductors are installed by service agency to cool down the equipment further to comfortable temperatures and to circulate sufficient air for man entry. The air eductor at the bottom is positioned in such a way as to push fresh air into the column and the one at the top is installed to suck out air from the inside of the column. 8 Entry & opening of Owner Department shall issue a permit to the service agency internal manways for entry into the vessel. (Checks shall be carried out by owner Department to ensure that sufficient oxygen is present in the column before issue of entry permit). The first job on obtaining entry permit is to open the internal tray manways to go up & down inside the column. A person of the service agency shall be present at the outside of the Column at the shell manway platform, as a safety stand by, as long as people are inside the Column. The service agency shall ensure two way communication facilities to the persons standing at the top of the column and the persons at the ground level. They shall also ensure adequate lighting inside the vessel with 24 volt lamps. 9 Inspection The Inspection section shall inspect the column thoroughly and recommend all the repairs that are to be carried out in

General Operational Guidelines

the Column. 10 Repairs Executing service department shall repair the column as

per the Inspection recommendations or shall carry out any other modifications planned earlier. 11 Inspection After all the repairs are carried out, the Column shall

beagain inspected by Inspection section, owner Department and Process Engineering, to ensure that the repairs carriedout are proper considering the mechanical and process requirements. A report shall be prepared by the owner department and signed by the above three agencies to record the acceptance of the equipment after the repair 12a Boxing up internal Once the Column is cleared by all the three inspection manways agencies cited at 11 above, the internal tray manways are boxed up. The owner, who issue the permit to box up the internal manways, shall physically inspect the column internally on all trays to ensure that all tools and tackles and other leftovers are removed and to ensure that all men have come out of the column, before issue of permit for boxing up internal manways. Once the permit for boxing up the internal manways is issued, a representative of the owner shall be available at the column outside to ensure that only personnel who are boxing up the internal manways are entering the column and that all of them come out once the boxing up is completed. 12b Boxing up of shell Once the manways internal manways are boxed up, the shell

manways shall be boxed up. Here again, before issuing the permit, the owner shall ensure that all personnel have come out of the column. A representative of the owner shall be

General Operational Guidelines

standing by the column to ensure that nobody enters the column once shell manway boxing up permit is issued, until boxing up is completed. 13 Deblinding Note: No hot Once all the shell manways are boxed up, the Column is

deblinded as per the same blind list prepared for blinding. After removal of each blind, the number tag removed shall be handed over to Safety and Fire section by the agency deblinding the equipment, for custody. The blind list shall be signed by the representative of the agency deblinding the Column, owner department and Safety and Fire section, on completion of removal of each blind/isolation. The tags received back shall be checked by Safety and Fire section to ensure that all blinds/isolation are removed from the system.

work permit shall be issued in the nearby areas or in the system being when is in

deblinded deblinding progress.

14

Steam ensuring

out

and Owner department, after ensuring the signing of the blind the list by all the three agencies, shall start steaming out the column with the connected facilities as a first step of start up of the unit . After steam out, the steam hoses are to be removed and at each location, the original status of closure shall be reinstated by the agency removing the steam hoses. Signatures of the owner and agency removing the steam hoses shall be put in the steam hose list, against each location, to indicate that the original status of closure of each steam hose point are reinstated. It shall be the responsibility of the owner department to ensure this condition.

original status

General Operational Guidelines

15

Fuel gas backing up After referred

completing

all activities referred under 14 above,

fuel gas is taken in the system. Each location, where a joint was opened, shall be gas checked to ensure zero leak, by the owner.

16

Oil In

The cold

crude circulation is started in the system.

13.4.2 ENTRY INSIDE AND REPAIRS IN HEATER Sl.No. Activity 1 Oil Out Requirement/Purpose Requirement/Purpose As stated in example 1

2 3

Initial steam out Blinding isolation

-dofor -do-

Steam blinding

out

after The heater coils shall be steamed out by the owner department on completion of the blinding. The fuel gas lines to the heater shall also be steamed out before issuing entry permit to enter the furnace box of the heater.

i. Note: A list of locations where steam hose connections are required shall be prepared, in the prescribed format, by the owner Department. The list shall clearly indicate the status/ description of the fitting/s to be removed from each location, for providing steam hose connections. The agency/person removing the fitting to provide steam hose connection and the person issuing the permit for the same shall sign on the list, for each steam hose location, after the hose is provided. ii. Owner Department shall not allow any agency / person to perform a job in the Plant area (Manufacturing/ S & OM) without issuing a written Work Permit.

General Operational Guidelines

Similarly no person/ agency other than those belonging to the owner department shall undertake any activity in the plant area without a written work permit from the owner department. 5 Steam purging of furnace box This is carried out by the owner department toensure that no Hydrocarbon or Fuel gas condensate is trapped inside box the furnace box. Separate purge connections are available for the radiant and convection sections of all heaters. Steam purging of radiant and convection section shall be done one after the other to ensure thorough purging. 6 Open manway The manways on the furnace floor and at convection areas shall be opened by the service agency to allow cooling by natural draft. Air eductors may be installed at the bottom of the heater to accomplish faster cooling. cooling 7 Entry providing Scaffolding Note tubular scaffolding : and Once the temperature inside the furnace and the skin temperature of the tubes have come down, permit for entry into the Furnace Box, for providing scaffolding, shall be issued by the owner Department. Checks shall be carried out by the Only owner to ensure that sufficient oxygen is present in the heater before the issue of entry permit. Maintenance Planning or the job executing agency shall arrange to put scaffolding inside the

material shall be heater, through a prearranged agency. used heater providing scaffolding. inside the for

General Operational Guidelines

Inspection

Once the scaffolding work is completed, Inspection section shall enter in the heater and carry out detailed inspection of the tubes, tube supporting clamps, refractory, burners etc. If any adjustment in scaffolding is required, the same shall be arranged by Maintenance Planning or the agency which provided the scaffolding. Inspectors shall look for bowing of tubes, overheating signs, bulging, abrasion grooves near the clamps, thickness of tubes, condition of clamps and refractory, burner condition etc.and for any other abnormal conditions. E&E section will conduct a detailed inspection of burner system and recommend repairs to be done.

Repairs

Based the

Inspection

recommendation Maintenance

Department/ executing agency shall carry out all the repairs indicated, like tube replacements, structural works, refractory/ lining repairs etc. 10 Hydro testing Hydro testing at the Test hall be carried out by Maintenance department/job executing agency after Tube Repairs. Even if no hot work is carried out on the tubes of the heater, as per OISD requirement, the heater tubes shall be hydrotested during all turnarounds, at the prescribed pressure. Inspection section will inspect the tubes under hydrotest pressure and certify the completion of the hydrotesting. 11 Scaffolding removal and boxing up Once the hydrotesting, Refractory repairs and all other

repairs are over, the scaffolding shall be removed from the heater and the heater shall be boxed up by

Maintenance/executing Department. 12 Deblinding After boxing up, the nace is deblinded by the service

General Operational Guidelines

hot department. The water from the heater coils shall be drained to work permit shall extent possible by the owner before commencement of be issued in the deblinding. Vents shall be kept open while draining water. Note: No nearby area or in Procedure as explained in the example 1 shall be adopted here the system being also for deblinding. deblinded when

deblinding is in progress. 13 Air blowing, The heater tubes are blown with air to remove all the water

steam out and

in them. Once owner is convinced that all water is removed, the heater tubes are steamed out. Procedure for removal of steam hoses shall be as explained in Example 1.

14

Fuel gas backing As stated in the Example 1.

15

Cold Crude

Once

crude is taken into the Unit, cold crude is circulated

through the heater coils by the owner.

16

Firing

of

the Once

cold

crude

circulation

is established, the

burners are lighted to raise the temperature of the crude, as per the procedure laid down in the manual of the Operating

General Operational Guidelines

Department.

13. 13.4.3 CLEANING, REPAIR AND TESTING OF HEAT EXCHANGER Sl.No. Activity Requirement/Purpose

1 2 3

Oil Out Water pushing Initial steam out Note: i.

As stated in example 1 -do-do-

A list of locations where steam hose connections are required shall be

prepared, in the prescribed format, by the owner Department. The list shall clearly indicate the status/ description of the fitting/s to be removed from each location, for providing steam hose connections. The agency/person removing the fitting to provide steam hose connection and the person issuing the permit for the same shall sign on the list, for each steam hose location, after the hose is provided. Owner Department shall not allow any agency/person to perform a job in the Plant

area (Manufacturing/ S & OM) without issuing a written Work Permit. Similarly no person/ agency other than those belonging to the owner department shall undertake any activity in the plant area without a written work permit from the owner department. 4 Draining and blinding As stated in the example 1.

General Operational Guidelines

Steam blinding

out

after Carried out by the owner to push out all the remaining hydrocarbon from the exchanger, to facilitate opening of covers and to ensure hydrocarbon free area in the surroundings during the shutdown period when the exchanger is in the opened up condition.

Opening and

all

covers Once

final

steam

out is over and the equipment has

cooled down, the covers are opened and tube cleaning is carried out by service agency by hydroblasting or by mechanical means. If the exchanger is at a higher elevation, the equipment as a whole unit is brought down for cleaning, testing, repairs etc Prior understanding shall be reached between the owner department, Inspection and Process Engineering sections and the service agency before commencement of the turnaround regarding the pulling out of tube bundle from the shell and cleaning of shell inside and tube outside.

tube cleaning (inside)

Hydro testing

Once

the

tubes and other parts of the exchanger are

cleared, the covers are put back for hydrotesting. If test ring is available, the floating head cover and shell cover are not installed. The shell side is pressurised first. If any leaks are observed during testing, the same shall be repaired by plugging of tubes / rerolling etc., depending upon the nature of leak and tested again. If number of tubes plugged in any pass is more than 10% of the total number of tubes in the pass, the bundle shall be retubed or an already retubed spare bundle, if available, shall be inserted before proceeding further. Once the pressure is holding, Inspection section will witness the test and certify that the tubes are in

General Operational Guidelines

healthy condition. The test ring is then removed and the floating head and channel covers are installed. The tube side of the exchanger is then tested and witnessed by Inspection section to ascertain that the floating head cover flange joint and the channel cover flange joint are intact. Finally the shell cover is installed and shell test is given once again to ensure that the shell cover flange joint is intact. 8 Deblinding The exchanger is blinded on completion of the testing as

per the procedure explained in Example 1. Prior to deblinding water shall be drained to the extent possible. Vents shall be kept open while draining water. All the fittings installed for testing purposes shall be removed and proper fittings shall be used to close all the openings in the exchanger. The owner shall ensure that the status of each opening is reinstated to the one which was present before shut down of the equipment, prior to closing the permit issued to the service agency for repairs/cleaning. Note: No hot work permit shall be issued in the nearby areas or in the system

being deblinded when deblinding is in progress. 9 Air Blowing Air is blown through the shell and tube sides separately to

remove all water from inside 10 Steam out The exchanger is steamed out to push all air and water

particles from inside. 11 12 Fuel gas backing up Oil in As stated in Example 1. -do-

General Operational Guidelines

13.4.4 13.4.4 REPAIR OF COMPRESSOR Sl.No Activity 1 Shutting down and depressurisation Requirement/Purpose Whenever an equipment is to be repaired, which calls for the stopping of the equipment, it is shut down and isolated mechanically by the owner department by closing all isolation valves. The equipment is then de-pressurised to facilitate blinding 2 Nitrogen purging The equipment is thoroughly purged with nitrogen to

push off all hydrocarbon vapours, before handing over the equipment to the service agency. 3 Electrical isolation The equipment shall be electrically isolated before the

commencement of any maintenance activities. The Maintenance Planning section shall coordinate with Electrical Section of P&U Dept. and get the equipment isolated electrically at the Motor Control Centre. The Electrical section crew shall take a work permit from the owner of the equipment to isolate the breaker of the drive motor of the compressor and install tags at the local start/stop switch to this effect after isolation of the breaker at the Motor control centre. The work permit shall be closed only after this. 4 Blinding The service agency, after getting a work permit from the owner department, shall blind the equipment at the

inlet/outlet and other required nozzles to effect positive isolation of the equipment from the connected system. The owner department shall issue a work permit to the service

General Operational Guidelines

agency for blinding only after the electrical section crew closes the work permit taken to isolate the breaker of the drive motor. 5 Nitrogen purging after After blinding blinding, the equipment is purged with nitrogen once

again by the owner department to push out all the hydrocarbon vapours.

Repairs

On completion of the nitrogen purging after blinding, the owner department shall issue a work permit to the service agency for undertaking the repairs. All small bore connections (threaded and socket welded) of Pressure gauges, thermo wells, vents, drains etc. shall be checked by the service agency for any defects. If required, they shall take the assistance of Inspection section for checking the fittings. If any

abnormalities are observed, the same shall be repaired before putting back the equipment into operation. Note: The opportunity shall be utilised and the drive motor and breaker shall be PM

checked by the electrical maintenance section before the compressor is put back into operation after repairs. 7 Deblinding On completion of the repairs, checking by owner department and after getting a work permit from the owner department, the equipment is deblinded by the service agency. 8 Nitrogen purging The equipment, after deblinding, is purged with nitrogen to push out all oxygen from inside 9 Electrical energisation After the deblinding, the service agency shall inform the Electrical section of P & U to energise the motor of the compressor. The electrical section, after taking a work permit from the owner shall energise the breaker at the motor

General Operational Guidelines

control centre and remove the tag installed at the local start/stop switch of the compressor and shall close the work permit thereafter. Work permit shall be issued by the owner department for energisation of the breaker only after the service agency closes the work permit taken for deblinding.

13.4.5 REPAIR OF PUMP Sl.No 1 Activity Requirement/Purpose pump is stopped and the suction and discharge valves

Stopping and draining The

are closed to isolate it from the connected system by the owner department. The liquid contained in the pump is drained completely into the OWS by the owner to keep it ready for maintenance by the service agency. 2 3 Electrical isolation. Decoupling and repairs As stated in example 4 The service agency, after getting a work permit from the owner department, start the repair of the pump. The pump is decoupled from its drive motor and is removed to shop for repairs or in situ repairs are carried out depending upon the nature of complaint. The owner department shall issue a work permit to the service agency for repairs only after the electrical maintenance crew closes the work permit taken to isolate the breaker of the drive motor.

General Operational Guidelines

Note:

i.

If the

suction and discharge

valves are passing, blinds shall be provided,

by the service agency, at the suction and discharge nozzles of the pump to avoid leakage of liquid into the atmosphere. In the case of volatile liquids, the pumps are blinded even if the valves are not passing. ii. All small bore connections on the pump casing shall be checked thoroughly.

Assistance from Inspection section shall be sought, if required. The opportunity shall be utilised and the drive motor and breaker shall be PM checked

by the electrical maintenance section before the pump comes back after repairs.

Reinstallation, alignment The and coupling


leaks.

pump, after repairs, is put back. All flanges are made up after

removal of blinds and the pump is pressurised by the owner to check for

If there are no leaks the pump is aligned with its drive motor and coupled by the service agency. 5 Electrical energisation After the deblinding, the service agency shall electrical section electrical from inform the

to energise the motor of the pump. The

Maintenance section, after taking a work permit breaker at the motor

the owner shall energise the

control centre and

remove the tag installed at the local start close the work

/ stop switch of the pump and shall permit thereafter.