13. general operational guidelines

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General Operational Guidelines

CHAPTERCHAPTERCHAPTERCHAPTER XIIIXIIIXIIIXIII

GENERAL OPERATIONAL GUIDELINESGENERAL OPERATIONAL GUIDELINESGENERAL OPERATIONAL GUIDELINESGENERAL OPERATIONAL GUIDELINES


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11113333.1.1.1.1 GENERAL OPERATIONAL GUIDELINESGENERAL OPERATIONAL GUIDELINESGENERAL OPERATIONAL GUIDELINESGENERAL OPERATIONAL GUIDELINES

TTTTips for operating personnel:ips for operating personnel:ips for operating personnel:ips for operating personnel:

Some useful tips for the operating personnel on duty-a systematic approach:

1. Receive instructions from reliever2. Check tools/equipment3. Check and analyze operating instructions, log book, log sheets, etc.4. Release equipments to maintenance5. Conduct checking tour of entire units.6. Mark log entries at the prescribed time7. Discuss unit operating conditions with all concerned8. Attend equipments requiring frequent checking9. Evaluate lab results and adjust operating conditions.10. Carry out necessary house keeping work11. Review work permits issued12. Follow up progress on equipment maintenance with maintenance department13. Collect required samples for lab analysis.14. Log all activities, carried out in the shift in the log book15. Check tools and equipment at the end of the shift and discuss unit conditions with

the reliever.

13131313....2222 Procedure for implementing a modification in process unit / offsite1. Based on the request for the job from the owner dept. the process Engg. Group will

make the process scheme.

2. The scheme is checked by Process/Advisory services-Inspection and Safety & ownerDept.

3. The Process Engg. Group will conduct the HAZOP study for the modification.The standard format (for HAZOP study) is used to analyse the scheme. Standardguide words-none, more, less, as well as, part of, reverse, other than, any othercriteria as applicable. Based on the findings, suitable automatic instrumentation


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/control and / or proper instructions for operation of the new system isrecommended and incorporated along with the scheme. The study is checked andapproved by the concerned section head of Process, Inspection, Manufacturing andOil Movement & Stock.

4. After incorporating the HAZOP study recommendations the scheme is approved bythe Heads of Process Engg., Owner Dept., Inspection & Safety and Advisory Services

5. Based on the approved scheme, detailed engg. Drawing and cost estimate are made bythe Engineering & Construction Department. The E&C/Process Engg. Checks thedetailed Engg. Drawing and the drawing is then approved by the heads of Process,Inspection & Safety, Owner Dept. & Advisory Services.

6. The owner dept. get necessary financial approval for implementation of the scheme.7. The job is then implemented depending on the urgency/nature of the job.8. 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.

13.313.313.313.3 Operating ProcedureOperating ProcedureOperating ProcedureOperating Procedure

13.3.113.3.113.3.113.3.1 PumpsPumpsPumpsPumps GeneralGeneralGeneralGeneral

1. How to check an electric motor in operationHow to check an electric motor in operationHow to check an electric motor in operationHow to check an electric motor in operation.

CHECK OBSERVE1. Lubrication Lubrication of electric motors will generally be done on a scheduled

basis by electricians. Any oil filled compartments will be checked byoperators and levels maintained by them.

2. Bearings Feel bearing housing to determine if there is any excessive heating orvibration.

a. Excessive heating of bearings1. Over greasing2. Insufficient lubrication3. Excessive belt tension4. Misalignment5. Lack of end play6. Excessive end or side thrust by coupling7. Report abnormal condition to Supervisor.

b. Excessive vibration


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1. Misalignment2. Vibration transmitted from machine being driven3. Excessive belt tension or worn belts4. Loose motor mounts5. Report abnormal conditions to Supervisor

3. Motorhousing

Feel motor housing to determine if there is excessive heating orvibration:

a. Overheating may be due to :1. Overload2. Impaired ventilation of motor3. Poor condition of coils

b. Vibration see b in 2 above:Report abnormal condition to Supervisor.

2. How to check a steam turbine in operationHow to check a steam turbine in operationHow to check a steam turbine in operationHow to check a steam turbine in operation

CHECK OBSERVE

1. Lubrication ofbearing

Maintain level with oil specified in lubrication schedule

*Avoid excessive high or low levels

2. Lubrication ofGovernor

Fill cup on top of outboard end of governor at least once every 8hours 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

4. Vibration Vibration in excess indicates the malfunctioning of the equipment

a. Report abnormal condition to Supervisorb. Vibration may be caused by malfunctioning of turbinec. Vibration may be transmitted to it by the machine being driven

5. Noise Noise of unusual nature indicates malfunctioning of the equipment.

a. Report abnormal noise to Supervisorb. Abnormal noise may be caused by malfunctioning of turbinec. Abnormal may be transmitted by machine being driven


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3.3.3.3. Centrifugal pumpsCentrifugal pumpsCentrifugal pumpsCentrifugal pumps

aaaa.... How to start an electric motorHow to start an electric motorHow to start an electric motorHow to start an electric motor----driven centrifugal pumpdriven centrifugal pumpdriven centrifugal pumpdriven centrifugal pump1. Check

discharge line

a. Discharge line is the smaller lineb. See that line to destination isclearc. Pump discharge valve should be blockedd. Never start a centrifugal pump with discharge valve open. It will

over load motor and may burn it out.

2. Check suctionline

a. Suction line is larger lineb. See that all valves on suction line are wide open

3. Check lube oillevels

If necessary, add type of oil specified in Lubrication schedule.

4. Check pumprotation

a. Turn pump at least one full turnb. See that both pump and motor turn freelyc.

Report to immediate Supervisor if pump or motor drags or isstuck

d. Do not start pump if it drags or is stuck5. Check pumpauxilliaries

a. If cooling water is provided, put in operationb. If gland oil is provided, put in operationc. If flushing oil is provided, put in operation

6. Vent pump a. Open vent line to fill pump with liquidb. Centrifugal pumps should never be allowed to run with a dry casec. Block off vent when pump is completed filled with liquid

7. Hot servicepumps

a. Heat to an even temperature allowing the hot liquid to flowthrough the pump

b. Never start a cold pump pumping hot liquid, always warm up8. Start motor a. Press start switch

b. If motor fails to start, check circuit breaker. Reset if necessary9. Check pumpdischargepressure

a. Vent pump through vent lineb. Check direction of pump rotation

10. Slowly openpump dischargevalve

a. Open discharge valve as soon as unit comes upto speed andpressure

b. A pump should never be operated for any length of time withdischarge valve blocked

11. Checkbearings of pump& motor

a. Feel with hand to see if bearings are overheating or are vibratingexcessively

b. If bearings overheat or vibrate, shut pump down and notify yourimmediate supervisor

12 Check pumppacking gland


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a. If ringpacking

b. If packingleaksexcessively

c. If mechanicalSeal

a. Feel gland to see if packing overheatingb. If overheated report it to your immediate supervisorc. Check gland oil pressure if gland oil is providedd. It may be necessary to start up and shutdown pump several times

to break in packing and allow lubrication of packing

a. Tighten gland nut one flat at a time. Allow sufficient time forgland pressure to become evenly distributed.

a. No adjustment is required.b. If seal leaks stop pump and start againc. If seal continuous to leak report it to your immediate supervisor

bbbb.... How to stop an electric motor driven centrifugal pumpHow to stop an electric motor driven centrifugal pumpHow to stop an electric motor driven centrifugal pumpHow to stop an electric motor driven centrifugal pumpStop motor.Close dischargevalveClose suctionvalveCut offauxiliaries

Press stop switchClose valve tightlyClose valve tightlyIf pump provided with gland oil shut downIf pump provided with flushing oil shut down

cccc.... How to start a steam turbine drive centrifugal pumpHow to start a steam turbine drive centrifugal pumpHow to start a steam turbine drive centrifugal pumpHow to start a steam turbine drive centrifugal pump1. Warm upturbine

For 5 to 10 minutes crack steam into turbine and drain off bottom

2. Check pumpdischarge line

a. Discharge line is smaller lineb. See that line to destination is clearc. See that pump discharge valve is blocked

3. Check pumpsuction

a. Suction line is the larger line on pumpb. See that all valves in suction line are wide open

4. Check lube oillevels

a. Check pump oil level and add oil if requiredb. Check turbine governor oil cup fill if necessary

5. Check pumprotation

a. Turn pump at least one full turn by handb. See that pump and turbine are free to turn and do not dragc. Report dragging or frozen pump to your immediate supervisor

6. Check pumpauxiliaries

a. If pump provided with water cooling, start waterb. If provided with gland oil, start gland oilc. If provided with flushing oil, start flushing oil.

7. Turbinecooling

Open valve in cooling water line to turbine bearings


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8. Vent pump a. Vent pump by opening vent valve and allow pump to fill withliquid

b. Close vent valve.c. A centrifugal pump should never be run with dry case

9. Pump in hotservice

If pump is in hot service pump should be heated up by bleeding hotliquid through pump

10. Turbineexhaust

Open steam exhaust valve on larger line from turbine

11. Start turbine Slowly open steam valve on turbine until pump is running at its ratedspeed and turbine takes control

12. Check pumppressure

If pressure does not come up, vent pump again.

13. Opendischarge valve

a. Slowly open pump discharge valveb. A centrifugal pump should never be operated for any length of

time with discharge valve blocked.

14. Check

bearings onpump andturbine

a. Feel with hands to see if bearings overheat or vibrate excessivelyb.

If bearings overheat or vibrate, shut pump down and notifyimmediate supervisor.

15. Check pumppacking gland

See item 12 How to start an Electric Motordriven centrifugalpump.

d.d.d.d. How to stop a steam turbine driven centrifugal pumpHow to stop a steam turbine driven centrifugal pumpHow to stop a steam turbine driven centrifugal pumpHow to stop a steam turbine driven centrifugal pump

1. Stop turbine. a. Trip the hand trip lever on the over speed governor of turbine onoutboard of turbine

b. Shut off steam to turbine2. Closedischarge valve

a. Smaller line on pumpb. Close valve tight

3. Close pumpsuction valve

a. Larger line on pumpb. Close valve tight

4. Shut steam offturbine

Close valve on steam line to turbine. Smaller line to turbine tightly

5. Close exhauststeam valve

a. Large line on turbineb. Close valve tightly

6. Reset handtrip lever

Pull reset lever up into position on governor of turbine

7. Drain turbine Release pressure on turbine. Open drain on bottom of turbine casing.Leave open

8. Close pumpauxiliaries

Shut off water, gland oil, flushing oil if provided

9. Bleed pressure a. Open vent line and bleed off pressure


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off pumps b. Close vent line

e. How to check a centrifugal pump in operatione. How to check a centrifugal pump in operatione. How to check a centrifugal pump in operatione. How to check a centrifugal pump in operation

CHECK OBSERVE

1. DischargePressure

Discharge pressure should be normal. Changes in discharge pressuremay 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 shaftb. 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 supervisorb. Tighten gland nut one flat at a time, allowing sufficient time for

gland pressure to become evenly distributed through the packing.

3. Mechanicalseal

1. No adjustment required2. Report prolonged or excessive leakage to supervisor.

4. Lubricating inbearing housing

Maintain level with oil specified in lubricating schedule:

a. Excessive high levels cause leakage at bearings wasting oil. Thisalso causes house keeping problems.

b. Low level causes poor lubrication and excessive wear on bearings5. Bearings 1. Feel bearing housing to determine if there is any excessive heat or

vibration:

a. Excess heat may indicate1. Low oil level2. False oil indicated level3. Worn bearings4. High oil level


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b. Vibration may indicate1. Worn bearings2. Misalignment3. Malfunctioning of other parts of pumpc. Report these to supervisor

6. Vibration ofpumps

1. Feel pump for excessive vibration:a. Report vibration to supervisorb. Vibration may cause by :

1. Worn bearings2. Misalignment3. Worn mechanical parts of pump4. Brocken or plugged impeller

7. Noise in pump 1. Listen to pump for abnormal noisea. Report abnormal noise to supervisorb. Abnormal noise indicates abnormal operation of a part of the

pump or driver.

4. Reciprocating Pumps4. Reciprocating Pumps4. Reciprocating Pumps4. Reciprocating Pumps

a. How to start a steam driven reciprocating pumpa. How to start a steam driven reciprocating pumpa. How to start a steam driven reciprocating pumpa. How to start a steam driven reciprocating pump

1. Warm up

steam end ofpump

a. Warm up 5-10 minutes. Crack open bleeder valve on steam end.b. Crack open bleeder valve on pump discharge between pump anddischarge valvec. Crack open line steam

2. Open exhauststeam valve

Open valve wide open

3. Open pumpsuction valve


4. Open pumpdischarge valve


5. Checkdischarge line

a. Make sure discharge line is open to destination. All valves ondischarge should be wide open

If pump is started with a valve closed the discharge line or pumpmay be damaged

6. check lube oil a. If necessary add oil to lubricatorb. Turn lubricator crank about 30 turns to lubricate steam end

before starting

7. Start pump Slowly open line steam to pump until pump reaches desired speed.


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8. Check pumpdischarge

Observe closely while opening line steam valve. If pressure goeshigh stop pump. Check discharge line up.

9. Close bleedervalves

Close same valves as opened in No. 1 above

b. How to stop a steam driven reciprocating pumpb. How to stop a steam driven reciprocating pumpb. How to stop a steam driven reciprocating pumpb. How to stop a steam driven reciprocating pump

1. Stop pump a. Close valve on line steam to steam end of pumpb. Close tightly

2. Exhaust steam a. Close exhaust steam valveb. Close tightly

3. Pump suction a. Close pump suction valveb. Close tightly

4. Pumpdischarge valve a.

Close pump discharge valveb. Close tightly5. Openbleeders

Open bleeders on both steam and pump end, to bleed off anypressure.

c. How to check a reciprocating pump in operationc. How to check a reciprocating pump in operationc. How to check a reciprocating pump in operationc. How to check a reciprocating pump in operation

CHECK OBSERVE

1. Dischargepressure

1. Discharge pressure should be normal. Any changes in dischargepressure may indicate:

a. Malfunctioning of pumpb. Poor line up on discharge of pump

2. Packing glandssteam and oilsides

1. If excessive leakage occurs in packing gland, adjust packing one flatat a time. Give ample time for pressure to be distributed evenlythrough the packing.

2. If packing gland is excessively hot the packing may be too tight orimproperly 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 prescribedin the lubrication schedule

b. Observe operation of lubricator, see that it is working. Makesure check valve is working in oil like to steam going to cylinder.

c. Lubricate rocker arms as necessary. Use medium weightlubricating oil.

4. Bearing and 1. Bearing should be checked and determined that they are properly


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moving parts lubricated.

a. Lubricate these bearings where necessary with proper lubricantb. Observe any malfunctioning of bearingsc. Report abnormal conditions to supervisor

5. Noise 1. Any abnormal noise should be investigated. If cause cannot be

determined and corrected report the incident to the supervisor. Shutthe pump down where possible. A minor repair may save a majorrepair.

6. Over speeding Over speeding of reciprocating pump

a. Uses excessive steamb. Breaks valves, valve springs, valve discs and etc.c. Deprives operator of use of pump in repair

7. Discharge andsuction

Discharge and suction valves should be wide open. Fluid pumped iscontrolled by throttle valve

5 Gear Pumps5 Gear Pumps5 Gear Pumps5 Gear Pumps

a. How to start a gear pumpa. How to start a gear pumpa. How to start a gear pumpa. How to start a gear pump

1. Check pumppreparatory tostarting

a. Check all flanges, pipings, heads and glandsb. Make sure they are ready to receive material

2. Check Bleeders Close all bleeders on pump except on discharge line

3. Fill pump casewith liquid

a. Crack open suction valve with discharge valve closedb. Allow liquid to enter the pump and fill the case

4. Turn pump byhand

a. Turn at least one complete turn to determine that pump is freeto turn and does not drag

b. If pump does not turn or drags do not start, report it to yourimmediate supervisor

5. Hot liquids a. In preparing to pump hot liquids the pump must be warmed upb. 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 shortperiods, 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 4above

6. Check oil andwater

a. Make sure water cooling systems are in operationb. That gland oil is going to the glands where provided


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c. That flushing oil is being used where provided7. Opendischarge valve

a. If discharge valve is not wide open, open wideb. Make sure discharge line is open to its correct destination

8. Start motor Press start switch

9. Observation a. Observe discharge pressureb. Do not let it built up due to some blockage of flow, blind in line,

valve closed, and etcc. If pressure builds up abnormally high shut down pump and

check line upd. Make sure pump is pumping and operating satisfactorye. Report any abnormal conditions to your immediate supervisor

b.b.b.b. How to shut down a gear pumpHow to shut down a gear pumpHow to shut down a gear pumpHow to shut down a gear pump

1. Stop motor Press stop switch2. Close suctionvalve

On large line close valve tightly

3. Closedischargevalve

On smaller lines close valve tightly

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 requiredc. Some pumps are steam traced to keep hot, these do not need to

be drained

5. Close oil andwaterconnections

a. Close off water coolingb. Close off any flushing oil or gland oil to pump

c. How to check a gear pump in operationc. How to check a gear pump in operationc. How to check a gear pump in operationc. How to check a gear pump in operation

CHECK OBSERVE


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1.Dischargepressure

Discharge pressure should be normal. Abnormal discharge pressuremay indicate:

a. Abnormal operation of pumpb. Heavy material in items due to cooling of oil in linec. Steam chased lines not functioning properlyd. Partly closed valves, etce. Suction line partly blocked

2. Packing glands 1. If excessive leakage on packing gland adjust packing one flat at atime giving ample time for the pressure to become evenlydistributed

If packing leakage is excessive or if packing is almosttaken up notify supervisor of this condition

2. If excessive heating of packing glanda.

report this condition to supervisorb. if cooling is supplied to gland make sure there is circulation

3. Lubricating oilin bearinghousing

Maintain level with oil specified in lubricating schedule

4. Bearings 1. Feel bearing housing to determine if there is excessive heat orvibration

a. Excessive heat may indicate:1. Low oil level2. False oil indicated level3. Worn bearings

b. Excessive vibration may indicate1. Worn bearings2. Misalignment3. Malfunctioning of other parts of pump

c. Report these conditions to supervisor

5. Vibration ofpump

Feel pump of excessive vibration

a. Report excessive vibration to supervisorb. Vibration may be caused by


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1. Worn bearings2. Misalignment3. Worn mechanical parts of pump4. Broken or worn gears

6. Noise in pump 1. Listen to pump for any abnormal noisea. Report abnormal noise to supervisorb. Abnormal noise mean abnormal functioning of a part of the

pump or driver

13.413.413.413.4 GUIDELINES FOR HANDLING MECHANICAL MAINTENANCE JOBSGUIDELINES FOR HANDLING MECHANICAL MAINTENANCE JOBSGUIDELINES FOR HANDLING MECHANICAL MAINTENANCE JOBSGUIDELINES FOR HANDLING MECHANICAL MAINTENANCE JOBS

Aim of this section is to improve Safety, co-ordination between departments/ sections andto 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

13.4.13.4.13.4.13.4.1111 ENTRY AND TRAY REPAIENTRY AND TRAY REPAIENTRY AND TRAY REPAIENTRY AND TRAY REPAIR INR INR INR IN DISTILLATION COLUMNDISTILLATION COLUMNDISTILLATION COLUMNDISTILLATION COLUMN ((((CRUDE FRACTIONATORCRUDE FRACTIONATORCRUDE FRACTIONATORCRUDE FRACTIONATOR))))

Sl.No. Activity Requirement/Purpose

1Oil out Stop the oil flow through various equipments as a first step of

the shutdown.

2 Oil pushing with To push out oil from the various equipments to the slop tanks.


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water

Initial steam out To remove a major portion of hydrocarbon vapour, to

facilitate opening of flange joints etc.

3

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 thevessel is carried out after the above steam out and before blinding. (This is

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 thePlant 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 theremaining system.


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Note:

i). Blind list shall be prepared by a group consisting of the Section Heads of theconcerned owner department, Safety and Fire and the executing department. If

the job is being handled by Maintenance Department, the representative ofexecuting 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.ii). No hot work permit shall be issued in the nearby areas or in the

system being blinded, when blinding is in progress.

5 Steam out after

blinding

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


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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

internal manways

Owner Department shall issue a permit to the service agency

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


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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

manways

Once the Column is cleared by all the three inspection

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

manways

Once the 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


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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

work permit shall

be issued in the

nearby areas or in

the system being

deblinded when

deblinding is in

progress.

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.

14 Steam out and

ensuring the

original status

Owner department, after ensuring the signing of the blind

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.


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15 Fuel gas backing up

referred

After 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.

13.4.213.4.213.4.213.4.2 ENTRY INSIDE AND REPAIRS IN HEATERENTRY INSIDE AND REPAIRS IN HEATERENTRY INSIDE AND REPAIRS IN HEATERENTRY INSIDE AND REPAIRS IN HEATER

Sl.No.Sl.No.Sl.No.Sl.No. ActivityActivityActivityActivity Requirement/PuRequirement/PuRequirement/PuRequirement/Purposerposerposerpose

1111 Oil Out As stated in example 1

2222 Initial steam out -do-

3333 Blinding for

isolation

-do-

4444 Steam out after

blinding

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 beprepared, 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 hoseis provided.

ii. Owner Department shall not allow any agency / person to perform a job in thePlant area (Manufacturing/ S & OM) without issuing a written Work Permit.


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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.

5555 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.

6666 Open manway

cooling

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.

7777 Entry and

providing

Scaffolding

Note : Only

tubular

scaffolding

material shall be

used inside the

heater for

providing

scaffolding.

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 issuedby the owner Department. Checks shall be carried out by the

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

heater, through a prearranged agency.


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8888 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.

9999 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.

10101010 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.

11111111 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.

12121212 Deblinding After boxing up, the nace is deblinded by the service


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Note: No hot

work permit shall

be issued in the

nearby area or in

the system being

deblinded when

deblinding is in

progress.

department. The water from the heater coils shall be drained to

extent possible by the owner before commencement of

deblinding. Vents shall be kept open while draining water.

Procedure as explained in the example 1 shall be adopted here

also for deblinding.

13131313 Air blowing,

steam out and

The heater tubes are blown with air to remove all the water

in them. Once owner is convinced that all water is removed,

the heater tubes are steamed out. Procedure for removal ofsteam hoses shall be as explained in Example 1.

14141414 Fuel gas backing As stated in the Example 1.

15151515 Cold Crude Once crude is taken into the Unit, cold crude is circulated

through the heater coils by the owner.

16161616 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


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Department.

13131313....4444....3333 CLEANING, REPAIR AND TESTINGCLEANING, REPAIR AND TESTINGCLEANING, REPAIR AND TESTINGCLEANING, REPAIR AND TESTING OF HEAT EXCHANGEROF HEAT EXCHANGEROF HEAT EXCHANGEROF HEAT EXCHANGERSl.No.Sl.No.Sl.No.Sl.No. ActivityActivityActivityActivity Requirement/PurposeRequirement/PurposeRequirement/PurposeRequirement/Purpose

1 Oil Out As stated in example 1

2 Water pushing -do-

3 Initial steam out -do-

Note: i. 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.


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5 Steam out after

blinding

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.

6 Opening all covers

and

tube cleaning (inside)

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.

7 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


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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 Fuel gas backing up As stated in Example 1.

12 Oil in -do-


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13.4.13.4.13.4.13.4.4 REPAIR4 REPAIR4 REPAIR4 REPAIR OF COMPRESSOROF COMPRESSOROF COMPRESSOROF COMPRESSOR

Sl.NoSl.NoSl.NoSl.No ActivityActivityActivityActivity Requirement/PurposeRequirement/PurposeRequirement/PurposeRequirement/Purpose1 Shutting down and

depressurisation

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 theequipment 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


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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

blinding

After blinding, the equipment is purged with nitrogen once

again by the owner department to push out all the

hydrocarbon vapours.

6 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


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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.

13.4.513.4.513.4.513.4.5 REPAIR OF PUMPREPAIR OF PUMPREPAIR OF PUMPREPAIR OF PUMP

Sl.NoSl.NoSl.NoSl.No ActivityActivityActivityActivity RRRRequirement/Purposeequirement/Purposeequirement/Purposeequirement/Purpose1 Stopping and draining

The pump is stopped and the suction and discharge valves

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 Electrical isolation. As stated in example 4

3 Decoupling and repairs 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.


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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.

4 Reinstallation, alignment

and coupling

The 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

leaks.

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 inform the

electrical section to energise the motor of the pump. The

electrical Maintenance section, after taking a work permit

from the owner shall energise the breaker at the motor

control centre and remove the tag installed at the local start

/ stop switch of the pump and shall close the work

permit thereafter.

13. general operational guidelines

Documents