Commissioning of Phenolic Sour Water Storage Tank 142-D-0022 (2) Latest - Docx New

Yanbu Aramco Sinopec Export Refinery Page 1 of 13
UTILITIES & OFFSITES DIVISION Unit:- Tank Farm

COMMISSIONING OF PHENOLIC SOUR WATER (SP-1) UNIT-142
STORAGE TANK 142-D-0022 BY FIRE WATER
SOP No: Rev. A 31 Aug 2014
COMMISSIONING OF PHENOLIC SOUR WATER STORAGE

TANK 142-D-0022
CONTENTS
1. PURPOSE & SCOPE
2. ABBREVIATIONS
3. ASSUMPTIONS
4. COMMISSIONING PREREQUISITES
5. SAFETY & ENVIRONMENTAL PRECAUTIONS.
6. COMMISSIONING PROCEDURE FOR DCU FEED STORAGE TANK
7. REFERENCES
8. ATTACHMENTS

SIGNATURES:
TANK FARM OPERATIONS FOREMAN

SANJEEV PADE
------------------------------------------
MANUFACTURING PLANNING SUPERINTENDENT PROCESS ENGINEERING MANAGER

SAAD MOHAMMED AL-SAYED Ali H Sairafi
------------------------------------------ ------------------------------------------
UTILITIES & OFFSITE OPERATIONS SUPERINTENDENT OPERATIONS MANAGER

MOHAMMED S. AL-GHAMDI MOHSEN M. AL-SHAYBAN
------------------------------------------ ------------------------------------------

1. PURPOSE & SCOPE:-
The Purpose of this SOP is limited to the Commissioning of Phenolic Sour water Storage
Tank 142-D-0022 by Fire water which includes:-
A. Commissioning of Phenolic Sour water Storage tank 142-D-0022:

Phenolic Sour water Storage tank 142-D-0022 will be done by connecting Fire water
connection to 6” tank sump drain line. Tank to be filled up to 3.5 m initially as per
operational decision.
B. MRT and Commissioning of Phenolic Sour water stripper feed pumps 142-G-
1022;142-G-0023;142-G-2022 :
1. Leak /Hold test of Phenolic sour water stripper feed pumps 142-G-022/2022/0023
Suction/Discharge line.
2. MRT of Pumps and followed by commissioning 142-G-1022; 142-G-0023; 142-G-
2022 will be done by circulation through SWS plant and receiving to tank 142-D-
0022.
The Circulation inside SWS will be done through 5 No. of loops. Loops are divided by
Loop-1: From Phenolic Sour water stripper feed pumps 143-G-1022 to Sour water stripper.
Loop-2: From Sour water stripper to Stripper bottom pump 142-G-1026A/B suction valve.
Loop-3: From Phenolic sour water Stripper bottom pump 142-G-1026A/B to De-
gassing drum startup line 8" isolation valve.
Loop-4: Phenolic Degassing drum to static mixer 142-IM-0021 at SWS B/L
Loop-5: Static mixer 142-IM-0021 in SWS to Phenolic tank inlet valve.
Note: Loop-1activity is under tank farm operations, while Loop-2/3/4/5 is under control of
SWS. Flushing to be done till get clear water at every loop end point.
Flushing loop end point preparation as shown in mark up drawing Appendix-I
 At the end of loop-1 the upstream isolation valve of FCV-1000, to be dropped to

clean the discharge header.
 At the end of loop-2, Suction valves of pumps 142-G-1026A/B to be dropped.
 At the end of loop-3 the 8”Isolation valve to be dropped before Degassing drum inlet
 At the end of loop-4 static mixer 142-IM-0021 to be dropped.
 At the end of loop-5 the 10” valve provided in inlet line at outside dyke to be dropped.
Diameter/ Safe filling Safe filling height

Equipment
Tank No. Height (m) No of Tank Capacity, (m)
Description
(BBL)
Phenolic sour
water Storage 142-D-022 73.4/15.33 1 208858 7.95
Tank

Equipment Discharge Pressure Discharge Capacity

Pump Tag No.
Description brag M3/Hr.
Phenolic sour water 142-G- 8.7
227
pumps 1022/2022/0023
2. ABBREVIATIONS:-
API: - American Petroleum Institute

BBL: - Barrel
BS&W: - Basic Sediment and Water
CCB: Central Control Building
CCTV: - Closed Circuit Television
DCU: - Delayed Coker Unit
DCS: - Distributed Control System
D/S: - Downstream
ESD: - Emergency Shutdown System
FFE:- Fire Fighting Equipment
GWR: - Guided Wave Radar Gauge
H: - Height
LI: - Level Indicator
LPD: - Low Point Drain
LT: - Level Transmitter
L: - Length
M: - Meter
m3:- Cubic meter
KBBL: - Kilo Barrels
MCC: - Mechanical Completion Certificate
M3/h: - Cubic Meter/Hour
MSDS: - Material Safety Data Sheet
MT: - Metric Ton
NRV: - Non Return Valve
O/L: - Outlet Line
OSO: - Outside Operator
OWS: - Oily Water Sewer
P&ID: - Process and Instrumentation Diagram
PMT: - Project Management Team
PO: - Panel Operator
PG: - Pressure Gauge
PI: - Pressure Indicator
PPE: - Personnel Protective Equipment
PSSR: - Pre Startup Safety Review
PVRV: - Pressure Vacuum Relieve Valve
PZV: - Pressure Relief Valve

SCBA: - Self Contained Breathing Apparatus

RFSU: - Ready For Startup Unit
SOP: - Standard Operating Procedure
TMB: - Top Middle Bottom Sample
U/S: - Upstream
RTG: - Radar Tank Gauging
W: - Width
3. ASSUMPTIONS:-
This SOP is prepared based on the following Assumptions:-

 Mechanical Completion is ready for Phenolic Sour water Storage Tank system and
all the related MCCs are signed with completion of all “YES” punch Items.
 Marked up P&IDs are available and attached herewith as Appendix-I
 Blind list is prepared and all the blinds are installed as per the list. Blind list is
attached herewith as Appendix -II
 Phenolic sour water Transfer Pumps Isolation Valves/Recycle line will be kept
closed, chain/locked, tagged and blinded as appropriate (Apply LOTO system).
 All instrumentation as mentioned are mounted, has been checked and lined up
accordingly. Appendix-III
 Functional Test for all the Instruments, Interlocks and ESD Logics is completed,
attached as Appendix-IV
 All related Pressure Safety Valves calibrated and aligned. Tank Top Pressure /
Vacuum Relief safety valves 142-PZV-0957 at 142-D-0022 is calibrated and aligned.
Appendix- V
 Ensure N2 blanketing system is ready and in service and lined up.
 Calibration Chart for the Tank is available and attached herewith as Appendix-
 Ensure cathodic protection system for tank and ancillaries are taken in line.
 Ensure Tank earth strip resistance is checked and it is normal as per the standard.
 MSDS is available and attached as Appendix-
 Ensure Tank water filling and Hydro testing Certificate for the inlet line is available as
Appendix-
 DCS system is commissioned and CCB is manned on round the clock basis.
 CCTV is installed for monitoring Phenolic Sour Water Tank.
 OWS system is commissioned, Flushed and ready to use.
 Fire Water Network is commissioned.
 Fire Fighting Equipment (FFE) should be available at appropriate locations.
 Standard Valve Keys are available of all sizes
 All Utilities are commissioned and available at Hose stations.
 Stenciling work for the equipment’s/lines /valves is completed.
 Communication can be established by means of Hotline/Radio/Landline/Mobile
between PMT/Operations/Maintenance teams and TKF panel/Producers/Receivers.

 PMT/Level Transmitter Vendor/Operations/Maintenance, Fire & Safety staff is

available on stand-by or on call-basis.
 Approved Emergency Response Plan (ERP) is available and all
Operating/Maintenance staff is aware of it.
 First Aid Box is available at site or at specified locations
 YASREF Work Permit Procedure is in place.
 Training on Phenolic Sour water handling is completed for all the Operations staff.
 TBT (Tool box talk) to be conducted prior to commissioning/start-up
 Confirm I/L and O/L blinds for 142-D-0022 are in open condition.
4. COMMISSIONING PRE-REQUISITES:-
The following activities to be completed before starting Commissioning of Phenolic Sour

water storage tank 142-D-0022 System:-
1. Gaskets- Install/Assure permanent gaskets are installed with proper nut bolts and
required sizes Gaskets are available in spares to avoid downtime.
2. Housekeeping: - Provide continuous cleanup of the construction and operation
area.
3. All Pre-commissioning Records for Phenolic Sour water storage tank 142-D-0022
system are available.
4. PSSR is completed and all observations are closed.
5. Management Clearance is obtained for Tank Commissioning.
6. Calibrated LEL/O2/H2S meter should be available
7. Certified Gauging tape should be available
5. SAFETY AND ENVIRONMENTAL PRECAUTIONS
Safety Precautions: -
 Outside Operators (OSO) and all other involved staff must use PPE’s as listed below:-
Basic PPE’s First Aid Emergency Equipment
Sr. No.
1. Helmet
2. Goggles First Aid Box
3. Safety Shoes
4. Hand Gloves
5. Uniform
6. Ear Muffs / Ear Plugs
7. Personalized H2S Monitor
 Use caution when opening bleeders and vents.
 No Mobile Phones are allowed in the Tank Dyke area.
 No Vehicle Movement is allowed inside the Tank Dyke area.
 The entire Phenolic Sour water Tank Receipt area is declared as NON-SMOKING Zone.
 Ensure tank shell manhole closed tightly

 Ensure Drain valves are closed.

 Ensure Inlet & outlet header drain valve and vent are closed and plugged, capped or
blinded.
 Ensure tank inlet XV are in remote as well as alarm & interlock is in line.
 Maximum flow to the tank to be restricted depending upon tank diameter (fluid
velocity should be less than 1m/sec) to avoid the generation of static charge.
 Ensure all pressure safety equipment (Vent PCV, PVRV) of tank are in healthy
condition and properly lined up.
 Controlled receipt rate as per tank designed.
Environmental Precautions:-
 Never drain hydrocarbon to the atmosphere.
 Clear all hydrocarbons to a closed system to prevent exposure to toxics and to protect
the environment.
 Prevent Soil contamination due to leak from valves/flanges/pipelines:
 Contain the leak on priority basis.
 In the meantime, drum/tray is to be placed below the leakage to collect liquid
hydrocarbon
 Collect contaminated soil in drums & send to hazardous waste disposal site.
 Spill Management (Oil Containment) Team is available with all the required
consumables.
Emergency Handling:-
 During receipt if any abnormality observed then stop the receipt and transfer the tank
quantity to another tank using Phenolic sour water Feed pump.
8. COMMISSIONING PROCEDURE: -
Detailed procedure is given below:-
Action By :
Sr. No. Description Start
Name End Time Sign
Time
A. Commissioning of Phenolic Sour water Storage tank 142-D-0022
Commissioning Activities
Ensure clearance is received from production
planning department/Utilities & off sites for Fire
water receipt from Utilities to feed tank 142-D-
0022.
1
Initial tank to be filled up to 3.5 meter level.
Calculate the Quantity and approximate flow to
calculate no of days require filling the Tank at
desired level.

Action By :
Name End Time Sign
Time
Ensure commissioning check list for Fire water
receipt from Utilities to Phenolic sour water feed
2 tank 142-D-0022 is filled prior to start
commissioning activities.
Check list attached as Appendix-VI
Ensure Walk through to be done for entire system
including tank inlet line. Ensure no vent and drain
3 points are opened and it shall be properly
plugged, no short bolting, gasket missing at flange
joints, ensure proper pipeline support etc.
Tank should not be commissioned in inclement
4
Weather condition.
Ensure that all Instrument are inline and in
healthy condition for Tank 142-D-0022
Ensure tank level high and high-high alarms are
5 enabled to monitor tank level to avoid tank
Overflow.
Ensure all interlocks are healthy and no trip logic
is bypassed and if it require, it has to be approved.
Confirm the receipt plan for Fire water to fill the
pipeline. Ensure connection done at 6” sump
6
drain header for filling up fire water to Phenolic
sour water Tank 142-D-0022
Ensure that one operator is available near tank
7 Platform with “BRAVO” for effective
Communication and fast action response.
Note down Tank parameter like Level,
8
Pressure , Temperature etc.
Ensure tank inlet 10” valve, tank outlet 12” &
Floating skimmer line outlet 6” isolation valves are
closed condition.
Ensure R/D header connection with Suction of
9
142-G-1022, 142-G-0023, 142-G-2022 suction line
10” Valve located at outside dyke area should be
closed.
Get clearance from utilities dept/ Fire dept

10 regarding using for fire water for commissioning
purpose into 143-D-0022
11 Start fire water through 6” sump header into tank

Action By :
Name End Time Sign
Time
Calculate the time required to fill the system to
Phenolic sour water feed tank 142-D-0022 as per
Receipt flow rate.
12  Walk through the system to detect any
leakage from flanges, vents, drain, etc.
 Monitor tank bottom area, nozzle flanges,
etc. for any leakage.
Monitor tank level, pressure and confirm PCV-
13
0532A & PCV-0532B functioning properly
Once level reach around 2 m stop receipt. Close
14 fire water supply line and then 6” sump drain
valve.
Monitor the tank condition at top and bottom
15
side by thorough round for any possible leak.
Manually gauge the tank and check for any
difference between manual dip and LT reading. If
16
difference is more ~ +/- 5 mm, it has to be
rectified.
A. MRT and Commissioning of Phenolic Sour water stripper feed pumps 142-G-1022;142-G-
0023;142-G-2022:
LOOP-1
Ensure that all Instrument are inline and in
healthy condition for Pumps 142-G-1022 / 2022
/0023
17
Ensure all interlocks are healthy and no trip logic
is bypassed and if it require, it has to be approved
Drop down Sour stripper feed pump discharge
18 header Spool piece near FIT-1000 to check water
and to clean header
Confirm the plan from production planning and
Sulphur for phenolic sour water to fill the pipeline.
19
Ensure line up from Phenolic sour water Tank 142-
D-0022
Ensure that one operator is available near tank
20 Platform with “BRAVO” for effective
Communication and fast action response.
Ensure Isolation valves of 6” header joining from
Non-phenolic water pumps 142-G-0002A/B to
21
discharge of 142-G-1022 discharge line are
closed/blinded

Action By :
Name End Time Sign
Time
Note: First Commissioning of Any one pump from
142-G-1022/2022/0023 to be carried out. We will
22 consider case of 142-G-1022 for commissioning.
For Rest pumps, procedure steps to be followed
are similar.
Before start filling header through gravity flow to
fill the system from Phenolic Sour Water storage
tank to Phenolic Sour water stripper feed pump
142-G-1022 ensure following valves are open for
142-G-1022
 12” manual isolation at tank 142-D-0022
out let
 10” suction manual isolation valve of 142-
23 G- 1022
 Ensure the manual warm up bypass valve
1” for NRV on 142-G-1022
 Pump casing vent valves discharge to
OWS.
Ensure following valves are close for 142-G-
1022/2022/0023
 8” manual isolation at discharge line of
142-G-1022
Keep pumps casing vent valve open to ensure that
the air removed from the system and to monitor
24 receipt of the phenolic sour water from tank to
phenolic sour water stripper feed pumps 142-G-
1022.
Communicate with Stripper feed (Train 1 & 2) PO
about commissioning activity and gradually filling
the system by gravity before utilizing Phenolic
Sour water pump 142-G-1022
 Ensure pumps 142-G-1022/2022/0023
25 auxiliaries are lined and healthy
 Ensure that all pump permission to start
interlocks are healthy
 Ensure tank level is sufficient to assure
minimum NPSH requirement of pumps.
Start filling the phenolic sour water stripper Feed

26
pump 142-G-1022 suction line by gravity
Note: Walk through the system to detect any
leakage from flanges, vents, drain, etc.

Action By :
Name End Time Sign
Time
Confirm receiving of Non-phenolic sour water,
27 close ¾” LPD and then gradually fill the system
then continue filling the system
Monitor the pressure differential indicator around
28 the pumps suction strainer to ensure that the
strainer is clean.
Once suction header of 142-G-1022 is filled,
29 discharge header to be filled and air to be
removed from the system.
Ensure from Sulphur operations that 142-FCV-
1000 upstream isolation valve removed and hose
connected to drain for flushing.
1” Vent valves of discharge header & ¾” LPD to be
30 keep open till air removal carried out from the
system.
Ensure 8” discharge manual isolation valve of 142-
31
G-1022 is open partially.
32 Start Phenolic sour water pumps 142-G-1022
Note :
After startup of pump, monitor pressure, Ampere,
DE/NDE side temperature and vibration for motor
and pumps etc. Check for any abnormalities like
seal leak, vibration, abnormal sound etc.
Ensure from Sulphur operations that flush water
33 coming out from 142-FCV-1000 upstream
isolation valve routed to open drain channel.
Continue the pump running till get clear water.
34
Water sample to be checked visually for clean.
If observed clear water from flushing point,Stop
35 the pump 142-G-1022.The lOOP-1 flushing activity
is completed.
LOOP-2-4 flushing
Inform sulphur operations to start flushing activity

36 for LOOP-2 to LOOP-4 .Mark up drawing attached
as appendix-
LOOP-5 flushing
Drop Phenolic tank inlet line 10” valve as
37 specified, and route the loop-5 end to open drain
channel.
Inform sulphur operations to start flushing activity
38
of Loop-5
39 Observe the clear water coming from LOOP-5 end

Action By :
Name End Time Sign
Time
Check oil skimmer line outlet flange at tank

nozzle, Instrument and bottom plate etc. In case
26
of any abnormality inform to Operations
Foreman/Superintendent.
Line-up again 10” Tank inlet valve by opening
27
manually and resume receipt to tank.
Fill the tank up to normal operating level 51% of
28
tank or 205400 BBL.
Note: Start the Phenolic sour water stripper feed pump to SWS per procedure TKF-ISP-
7. REFERENCES
Unit 142 – P&IDs
Phenolic Sour Water Storage Tank P&ID no. 142-SP1-PE-PID-0029.
Sour Water Stripper Degassing Drums & Tank PFD no.142-SP1-PE-PFD-0001.
Sour Water Storage Tank Stream Summaries PFD no.142-SP1-PE-PFD-0002
Sour Water Storage Tank Stream Summaries PFD no.142-SP1-PE-PFD-0003.
Simplified Process Flow Diagram – Degassing Drums and Storage Tank no. 142-YER-PE-
PDB-0001
Unit Operating Philosophy 142-YER-PE-DOP-001
Unit 143 – Operating Manual Volume 1 – 143-SP1-PE-OPM-0001
Unit 143 – Operating Manual Volume 2 – 143-SP1-PE-OPM-0002
Unit 148 – P&ID
Interconnecting Pipe ways SWS interconnecting II- 148-EP3-PE-PID-0267
Material Safety Data Sheet
Equipment Data Sheet
8. ATTACHMENTS:-
 Appendix- I :- Marked up P&IDs

 Appendix- II :- Blind list
 Appendix- III :- Status of Instruments
 Appendix- IV :- Functional Test records,ESD&Interlocks
 Appendix-V :- Tank PZV Data sheet and calibration records.
 Appendix- V :- Tank Calibration chart
 Appendix- VI :- Volume calculation Report
 Appendix- VII :- MSDS

 Appendix- VIII:- Pressure Test Report

_______________________________________________________________

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Yanbu Aramco Sinopec Export Refinery Page 1 of 13

UTILITIES & OFFSITES DIVISION Unit:- Tank Farm