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SITE SPECIFIC SAFE OPERATING PROCEDURE OPERATION SECTION: LPG DEPARTMENT

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Moderated on 11th

May, 2015

INTRODUCTION:

LPG Operation section performs smooth and

trouble free operation of LPG Recovery Plant to

produce quality product and help to meet

production target in efficient manner.

SOP for the Operation Section has been prepared such a manner

that a new person can approach and perform a job safe manner. In

this SOP it has been given top priority to the safety of man and

machine. However there are always remaining possibility of

improvement and any new recognized practice, procedure/

method are always welcome. This SOP should be reviewed at

least once in a year.


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CONTENTS:

Chapter 1: Activities of Operation Section & Brief Process Description

with Flow Diagram

Chapter 2: Hazards & General safety precaution for Operation Section

Chapter 3: SOP for startup & shutdown Procedure of Plant.

Chapter 4: SOP for Equipment start-up.

Chapter 5: SOP for Equipment change-over.

Chapter 6: SOP for dispatch product to Filling Plant.

Chapter 7: SOP for handling of emergency situation.


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CHAPTER –I

ACTIVITIES OF OPERATION SECTION

Smooth and trouble free operation of LPG Recovery plant

Planning of schedule annual maintenance of the plant

Planning of resources for meeting the MOU target for LPG

Production

Delivery of quality products to the market on a regular basis

Following are the objectives of the section

To maintain consistency in various works of the section

To keep good relation and understanding with other sections of the

department.

To keep good relation with the customers, vendors and other

departments who are directly or indirectly associated with LPG

production.


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Brief Process Description and Operation :

The process of LPG recovery plant comprises of following :

a) Compression

b) Dehydration

c) Product extraction through

(i) On stream cooling by heat exchange

(ii) Turbo expansion

(iii) Removal of non-condensable and Undesired lighter fractions

d) Product fractionation

a) Compression

Inlet gas at 14 Kg/ cm2 enters into inlet gas compressor suction scrubber

and then compressed in two stages from two different sources. First it is

compressed from 14 Kg/ cm2 to 33.8 Kg/ cm2 in a (4 stage) centrifugal

compressor driven by a 4500 HP electric motor operating on 11 KV power

supply. The heat of compression is partly used in re-boiling the bottom


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liquid of deethanizer and then cooled to 37.80C in water cooled heat

exchanger before entering the booster compressor suction scrubber. It is

then compressed again to 41.9 Kg/ cm2 with the help of booster

compressor driven by the turbo expander. No external energy source is

required for this operation. The compressed gas is cooled to 37.80C in a

water cooled exchanger and then sent through an inlet filter separator

wherein any water that may condense out from compression is knocked

out.The gas is then dried in the dehydrators, (two Nos ). installed for

cyclic operation and regeneration.

(b)Dehydration

The dehydrators are filled with Davidson grade 513 molecular sieve of 4

A0 size and contains approximate 11650 Kg of molecular sieve in each

dehydrator. The dryness obtained is to a dew point of less than -101C.

While one of the dehydrators is on line for drying the inlet gas the other

one goes for re-generation, through a cycle of heating by hot residue gas to

remove the water particles retained within the molecular sieve during the

previous operation and then cooling.The dehydrated gas passes through a

dust filter to remove sieve dust etc.

(c) Product extraction

The gas stream after the dust filter is split into two streams. One stream

(70% by volume) exchanges heat with cold residue gas from the

deethanizer overhead and expander separator overhead in the cold gas/gas

and warm gas/gas heat exchangers.

The other stream (30% by volume) exchanges heat with the cold separator

liquid in the gasliquid exchanger and also with the expander separator

liquid in the deethanizer feed preheater. These two streams then combine

to enter the cold separator. By this heat exchange the temperature of the

inlet stream to cold separator drops down to (-47) 0C and the temperature

of the cold residue gas increases to 320C. The liquid condensed by

lowering the temperature of the inlet gas is separated in the cold separator.

These liquids are flashed through the deethanizer reflux condenser and

gas-liquid exchanger into the deethanizer tower. Inlet gas from the top of

the cold separator is then allowed to expand in the turbine wheels of the

single stage turbine expander to 13.7 Kg/cm2. At the other end of

expander shaft is

mounted the single stage booster compressor. The horse-power released

by expansion is used for second stage pressure boost up. At the designed


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condition horse-power developed would be around 1670 HP. The

expander rotates

at a speed of 27,000 rpm. Due to the expansion in the turbine wheel the

temperature of the gas stream drops down to around -84 0C and additional

liquefaction takes place. The gas liquid mixture out of the expander is

separated in the expander separator. Liquids thus collected, flow to the

deethanizer feed pre-heater and then to the deethanizer. The noncondensed

gas at the top of the expander separator goes tojoin the residue gas stream

from deethanizer.

(d)Product Fractionations

The product fractionation consists of :

(i) A deethanizer column with three separate packed sections and a

reboiler.

(ii)A debutanizer column having 34 Glitch ballast trays and reboiler

provision through closed circuit hot oil systems with direct fired heater.

The liquids formed at the cold separator and the expander separator enters

the deethanizer column through the pre-designed section of the column

packing. By maintaining proper bottom temperature with the help of

deethanizer reboiler and reflux, undesirably liquefied

fraction of C1H4, C2H6 and the excess of C3H8 which is not required for

production of LPG is knocked out from the top.

This stream meets the gas stream from the expander separator and forms

the residue gas for the plant. Temperature of the residues as it comes out

of expander separator and deethanizer remains in the range of -760 C.

Before letting it out of the plant this additional refrigeration is recovered in

the cold gas & warm gas exchangers explained earlier. The bottom liquid

from deethanizer flows on level control to debutanizer tower where LPG

and condensate are separated out. LPG comes out at the top which is

cooled to ambient temperature and sent for storage in Bullets & Horton

Spheres. The bottom condensate is similarly cooled and stored in separate

storage tanks.


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Process Control Through DCS –

Distributed control system(DCS) is a state of the art technology in

the field of Automation & Process control. As a part of

modernization of instrument system of LPG Recovery Plant,DCS

was commissioned in the Plant in 1997.

DCS is physically and functionally distributed over the entire

plant process in such a way that failure or malfunction of any single

control loop does not have any effect on functioning of rest of the

other loops or plant process and this special feature of DCS is

important for safe and efficient operation of process plant.

In DCS of LPG Recovery Plant, there are there functional block

of the system-Data Acquisition(DAS),Direct Digital Control(DDC)

and Programmable logic controller(PLC) are integrated together with

a very high speed Decentralized Communication Network(DCN).

DAS function is for continuous on line monitoring of the plant and

provides most reliable and timely information of the process


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parameters of the plant along with their historical storage.DDC is a

microprocessor based digital controller(AC 460 of M/L ABBL)

having very high processing and wide ranging capabilities. It

receives various input signal from trasmiters,switchs and relays and

other input devices located in the plant performs control

functions/algorithms run by the MOD 300 system software and

finally sends output signal to the final control elements e.g. control

valve, solenoid valve and motor etc.PLC provides adequate and

reliable protection and safeguard of various plant equipment,

sequence control as well as sequence control of the plant(ESD) in

case of any emergency.


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CHAPTER –II

GENERAL SAFETY PRECAUTION & HANDLING OF

EMMERGENCY SITUATION IN CASE OF FIRE OR

HYDROCARBON LEAKAGE

2.01 Use appropriate PPE during working. Safety shoes must be used all the

times.

2.02 Respect ‘No Smoking Zone’

2.03 In case of LPG leakage and any other emergency situation, immediately

inform Shift Engineer, break the glass of fire alarm near the location. Shout

and draw attention of others for help.

2.04 Isolate the source of leakage if possible by closing appropriate valve.

2.05 Shut down the plant by pushing ESD either from control room or Expander

panel if the situation is beyond under control

2.06 Inform Fire station – Dial 7333

2.07 Inform Head-LPG,Installation Manager,CE(O) & CE (S & T)

2.08 Remove/extinguish all sources of ignition such as internal combustion

engines,movement of vehicle,hot job like welding,gas cutting etc.

2.09 Any non-flame proof electrical appliances in the vicinity should be

considerd as a potential source of ignition and hence should be de-

energized immediately.

2.10 Un-authorized persons should not be allowed in the working area.

2.11 Outsiders / Trainees / Visitors should be always under supervision.


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CHAPTER- III

SOP FOR PLANT START-UP AND SHUT-DOWN

GENERAL OPERATIONS

ACTIVITY 3.01 Startup Procedure of Inlet Gas Compressor

PURPOSE To compress inlet gas

HAZARDS

1) Hazard of falling material on the body

2) Noise 3) Leakage of LPG

4) Fall due to Lube oil leakage

PPEs

Safety shoe,Ear plug, Helmet,Dungaree

PREPARATION

1) All instruments are in service 2) Carry out physical inspection & Gas testing of the

Plant to confirm about no hydrocarbon leakage in the Plant

3) Reset ESD if the ESD is ON 4) Power supply to the Inlet Compressor panel is on

5) Lube oil./Gear oil to be charged. 6) Place PRV Auto/Manual switch to Manual Mode and

set the PRV output at 5 psi. 7) All Safety Relife Valves are to be on line.

8) Inform Power house and Gas Off take point about the readiness of the Plant for start up.


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STEP BY STEP PROCEDURE

1) After getting clearance from all three maintenance section and if there is no problem we can proceed for

start-up of inlet compressor. 2) Determine that there is positive gas flow through the

plant and that SDV-213(inlet gas shutdown valve),SDV-364(Residue gas shutdown valve) and

FICV-301 are open.

3) Place FIC301 manual 50%output,FIC200 manual 50% output,PIC202 manual 40% output,TIC442 manual

50% output,FIC502 manual 70% output at DCS.

4)Blow down low points of suction line from inlet gas

scrubber to compressor and also open all 5 compressor blow down valves individually,when there is no liquid

visible,close all valves. 5)Check suction pressure on York Panel and bring

pressure back up to 6 kg/cm2 pressure. 6) PRV switch to manual and set at 6PSI

7) 6) Now run both the auxiliary lube oil pump in manual mode. In this stage all shut down indication of the

York panel should be gone. 8)Inform electrical section for power clearance

9)After getting clearance from electrical press compressor bypass switch in the bottom control room.

10)Then press Compressor Start Button in the York

panel and hold it for minimum 1 sec.This will initiate the compressor startup.After 30sec,the Star Breker will on and

the compressor start rotating.Then after 15secs Star Breaker operation,the Ran Breaker will ON and motor goes

into full speed.At that time pull the amot of SDV-215 and hold it until compressor inlet and outlet valves are

opening.After achieving the discharge pressure above 20kg/cm2 shift PRV and both auxiliary oil pumps to AUTO.


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GENERAL OPERATIONS

ACTIVITY

3.02 Expander Compressor Start-up Procedure

PURPOSE

To boost-up compress inlet gas

HAZARDS



4) Fall due to Lube oil leakage. 5) Slip,fall due to spillage of water.

PPEs

Safety shoe, Ear plug, Helmet, Dungaree

PREPARATION

1) Power supply to HMI is on 2)Place INLET GUIDE VANE (I.G.V.) selector in the

manual position in HMI panel and put at 0% value. 3) Make sure the water valves to the Lube oil cooler

are open and cooling water is available.

4)Residue gas line of the Lube oil Surge tank is open 5) Lube oil and seal gas lines are checked for proper

line up 6) Hot oil circulation is on outlet tempressure properly

achieved. 7)All three control valves should be in AUTO position in

HMI panel.

STEP BY STEP

PROCEDURE

1)Open SEAL GAS trip valve by pressing push button from

HMI.

2)Open SEAL GAS manual valve from cold separator line slowly so that rate of pressurization and depressurization

shall not be more than 3.5 bar/min.

3)Before starting lube oil pump ensure whether seal gas

D/P should not less than 2.4bar.Normal seal gas DP shall be around 3.5bar.

4)LUBE OIL pump starting sequence:

Open the Lube Oil pump manual by-pass valve.

Ensure whether lube oil control valve is on AUTO.


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Start the one lube oil pump.

Slowly close the manual by-pass valve to build up pressure.

Check the lube oil pressure and maintain the lube oil

DP of 28.1 kg/cm2 differential minimum.

Put the other pump in ‘Auto’

5) In this stage all shut-down should be cleared.

6)Open the Expander discharge valve SDV478 --- from HMI panel (Most important)

7) Open the Compressor discharge valve --- Manually (Most important).If this valve is not open and Expander is

started, machine will surge and damage to machine.

8)Now press ‘RESET’ buttom, in this stage ‘Expaner is ready to start’ message appear at HMI panel.

9)Now press Expander start buttom, then SDV479,SDV476,SDV477 will open simentaniously.

10)Then IGV output increase gradually and when Local and Remote signel matches put Expander in AUTO

mode.Now it will be controlled from DCS.


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GENERAL OPERATIONS

ACTIVITY

3.03: Plant Shut down(Normal) Procedure of LPG

Recovery Plant

PURPOSE To stop Recovery Plant

HAZARDS



4) Fall due to Lube oil leakage.

5) Cold Burn 6) Striking object.

PPEs

Safety shoe, Hand gloves , Helmet, Dungaree

PREPARATION

End Dehydrator Heat Cycle. Inform Power house and Off take point about

readiness to stop the plant. Inform all sectional in charge specially instrument

section readiness to stop the plant. Maintain overflowing of water seal drum.

STEP BY STEP PROCEDURE

1)Shut down Expander as per procedure given in Turbo

expander/Booster Compressor Operation procedure.

2)Allow sometime(approximately 30 minutes) for liquid transfer then shut down Inlet Compressor by pressing

COMPRESSOR STOP switch on the local panel of Inlet Gas Compressor.Pull the ‘amot’ on the local panel of

Inlet Gas Compressor to CHARGE and VENT to avoid overpressure in Inlet Gas Compressor suction

Scrubber.This operation is done intermittently to avoid excessive flaring.

3)Reduce hot oil tempressure to maintain Debutanizer top tempressure to 54°C.

3) Stop Deethanizer reflux pump once the De ethanizer Reflux Accumulator level comes down to 40%

4) Stop Debutanizer Reflux Pump when the level comes down to minimum position.

5)Transfer condensate to condensate storage tank as long as long as Debutanizer Bottom tempressure is

130°C.

6)Close LPG product line valve when the top

tempressure of Debutanizer tower goes beyond


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allowable range (53 -56)°C 7)Stop both the Heaters.

7)Close SDV213,SDV365,SDV365 respectively by pulling

amot nob.

8) Stop Regen fan,Cooling water pump &Cooling water fans, Hot oil Pump should be stopped when Hot oil

tempressure comes down to 100°C. 9)Instrument air compressor,Air compressor for Deluge

unit should be on line. 10)Keep all Fire Water Pumps on AUTO as per normal

practice.

GENERAL OPERATIONS

ACTIVITY 3.04 Shutdown Procedure of Expander Compressor

PURPOSE To stop Expander-Compressor

HAZARDS

1)Hazard of falling material on the body

2)Noise 3)Leakage of LPG

4)Slip, fall due to Lube oil leakage. 5) Cold Burn

PPEs

Safety shoe, Hand gloves , Helmet, Dungaree

PREPARATION

End Dehydrator Heat Cycle.

Inform Power house and Off take point about readiness to stop the plant.

Inform all sectional in charge specially instrument section readiness to stop the plant.

Maintain overflowing of water seal drum.

1) Change from ‘Remote’ to ‘Local’ for IGV control in EXP – Compressor HMI panel.

2)Gradually close the IGV slowly. Doing this speed will

decrease 3) Constantly keep touching with Top control room and when

the PIC402 output comes more than 50% & JT will tend to


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STEP BY STEP

PROCEDURE

open then stop expander.

4)The all three shut down valves of Expander (SDV477/476/479) will close immediately.

5)Close compressor discharge valve manually. 6) Allow sufficient time(Minimum 5 minutes) to run the lube oil

pump.The stop the Lube oil pump in HMI panel. 7)Close Expader discharge valve and then seal gas trip control

valve from HMI panel 8)Close seal gas manual valve.


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CHEPTER –IV

SOP FOR EQUIPMENT START UP

GENERAL OPERATIONS

ACTIVITY

4.01Start-up procedure of Instrument Air Compressor

PURPOSE To make pressure rise instrument air network of Recovery

Plant

HAZARDS

1)Hazard of falling material on the body 2)Noise

3)Leakage of Instrument air 4) Fall due to Lube oil leakage.

PPEs Safety shoe, Dungaree, Helmet.

PREPARATION

1) Make Visual check of the machine,ensure that all guards are secure and that nothing is obstructing the proper

ventilation of/or free access to the machine. 2) Ensure that the discharge valve of the compressor is on

Open condition 3)Ensure that ‘READY TO START’ is appearing at the

compressor panel. 4)Take one hand set to communicate with top control room

in case of emergency. 5)To inform electrical shift personnel before start-up.

1) Push switch ON.The compressor will start and load automatically

2) Observe the loading & unloading cycle ,note down the time taken by each cycle.

3) Observe the motor load of the compressor on loading.


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GENERAL OPERATIONS

ACTIVITY

4.02Start up procedure of Regeneration & Hot oil Heater

PURPOSE To make ready Regeneration & Hot oil system of LPG Recovery Plant

HAZARDS

1)Fire hazard

2)Hazard of burn injury 3)Hazard of falling material on the body

4)Noise 5) Fall due to Hot oil leakage.

PPEs

Safety shoe, Dungaree, Hand gloves, Helmet.

PREPARATION

1)Check all the fuel and air supply, all valves should be in open position.

2)The panel power MCB for air blower fan should be in ‘ON’ position

3)The ‘Local/Off/Auto’ selector switch should be on ‘ON’ 4)Check for the panel power on indication lamp to be ‘ON’

in Top Control Room Heater PLC panel. 5)Check for ‘Clear to start’ in BMS of Top Control Room

6)One competent person should be present to observe the heater operation at site

STEP BY STEP

PROCEDURE

1)Press the start Push Buttom in BMS 2)For 24 second pre-purge of the combustion chamber

takes place and this will remove any combustible gases that may be present in the combustion zone.

3)Upon completion of the purge cycle,the air valve and fuel gas valve will be driven to the low firing position.

Consequently , a permissive switch will confirm the minimum firing position and allow the logic to continue for

pilot ignition sequence.The pilot ignition sequence is as follow :

High voltage spark ignition will be energized for 10 seconds

Pilot gas block valve (SDV-103/203) will be energized allowing pilot fuel to the pilot tip.

Five seconds after pilot flame is confirmed,the main

fuel gas block valve (SDV-101/201 and SDV-102/202) will be energized to open and the vent

valve (BDV – 102/202) will be closed.In approximately 10 seconds,control of the burner,is


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released to the process temperature controller.To

increase or decrease the process tempressure ,reset tempressure as required.

The ‘pilot ignition’ sequence must be confirmed in 20 second trial period,otherwise the logic will trip.Reset

and restarting will be required.

GENERAL OPERATIONS

ACTIVITY

4.03 Start up of Deluge Air Compressor

PURPOSE To make pressure rise deluge air network

HAZARDS

1)Fire hazard 2)Hazard of burn injury


PPEs

Safety shoe, Dungaree, Helmet.

PREPARATION

Wear Helmet before starting the job Take the clearance from Electrical section.

Check the Belts.

Check the Dryer status and keep the dryer online.

Check compressor discharge valve and it should be in open

position.

Keep the Dryer bypass valve in close position

STEP BY

STEP PROCEDURE

1) If everything ok then press the start button to start the compressor

2)After starting, check the compressor maximum discharge pressure.

3)Observe loading and unloading time and idle time. 4)Observe dryer bed change over sequence and its

operation.


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CHAPTER –V

SOP FOR EQUIPMENT CHANGE-OVER

GENERAL OPERATIONS

ACTIVITY

5.01 Changeover of De-ethanizer reflux pump

PURPOSE To distribute equal running hours of both De-ethanizer pump

HAZARDS

1) Fire hazard

2) Hazard of burn injury 3) Hazard of falling material on the body

4) Noise 5) Cold Burn

6) Leakage of gas

PPEs


PREPARATION

Wear Helmet before starting the job

STEP BY STEP

PROCEDURE

1) The liquid inside the casing of the standby pump is to be

drained totally through the drain line provided at the pump.

The drain line valve is to be closed when the pressure of the pump is shown Zero.

2) Open the suction valve gradually to fill the fresh liquid in the pump and at that time the valve (drain line) is to be

opened slightly to confirm that there is no vapour in the pump casing. Then closed the drains valve.

3) Then stop the pump which in on line and close the

suction, discharge and pump return valves of the pump.

4) Immediately open both in and out cooling lines of the pump and at the same time start the pump.

If the pump takes suction then open the discharge valve

and pump return valve respectively. Gradually open the discharge valve to full open condition. Communicate with the top control room

Now the flow can be controlled from DCS. Check the motor load of the pump. Motor load should be less

from its full load.


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GENERAL OPERATIONS

ACTIVITY

5.02Change over of De-Butanizer Reflux Pump

PURPOSE To distribute equal running hours of both De-butanizer pump

HAZARDS

1) Fire hazard 2) Hazard of burn injury

3) Hazard of falling material on the body 4) Noise

5) Cold Burn 6) Leakage of Gas

PPEs


PREPARATION


STEP BY STEP

PROCEDURE

1) Switch on the motor of the pump which is to be run and

see that discharge valve of the pump is closed.

2)Now discharge valve of the pump which is on line is to be closed and discharge valve of the new pump is to be

opened simultaneously.

3)Observe the reflux flow at the local gauge which is near by the pumps.

4)If the flow is steady, then the other pump is to be stopped.

5)Check the motor load of the pump.


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GENERAL OPERATIONS

ACTIVITY 5.03 Changeover of Hot Oil Pump

PURPOSE To distribute equal running hours of both Hot oil pumps

HAZARDS

1)Fire hazard

2)Hazard of burn injury


5) Fall due to Hot oil leakage.

PPEs


PREPARATION


STEP BY STEP

PROCEDURE

1)Start the stand by pump (at that time the discharge valve of the pump should be closed).

2)Constantly monitor FI - 500 as it is near to the pumps and easily seen at the time of operating the pumps

3)The discharge valve of the pump which was in the line is

to be gradually closed and at the same time the discharge valve of the new pump is to be opened in such a way that

the fluctuation of FI - 500 should be minimum.

4)At the time of operation, if the flow is found more at FI - 500, then close the discharge valve of the other

pump rapidly until the flow reaches the previous position. If the flow is

found less than open the discharge valve to obtain desired flow.

5)When the discharge valve of the pump which was on line is fully close, the pump is to be stopped.

6)Contract at the top control room whether the flow of

hot oil is proper or not. If less than the discharge valve is to be opened slightly and if more than to be closed

slightly. In such a way the hot oil flow is to be established.


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7)Then see the motor load of the pump at MCC room. The

motor load should be less than the full load.

8)Check the pump after few minutes whether there is any seal leakage or not.


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CHAPTER –VI

SOP FOR STORAGE AND HANDLING PRODUCT

GENERAL OPERATIONS

ACTIVITY

6.01 DESPATCH LPG TO FILLING PLANT

PURPOSE To pump LPG product to Filling Plant for Cylinder Filling

HAZARDS

1)Fire hazard

2)Leakage of LPG


5)Cold Burn

PPEs


PREPARATION


STEP BY STEP

PROCEDURE

1)Check the position of ROVs of suction line, product filling

line and vapour balance line of dispatch bullet. Normally those should be in open position and if not then open the ROVs from DCS.

2)Check all instrumentation system should be on line. 3)Open isolation valve of suction line near ROV and also open

the isolation valve of the same line near the pump (i.e. pump suction valve).

4)Check the differential pressure gauge. Normally, it should Be showing minimum DP, then only proceed further.

5)Open isolation valve of self venting line which is at top of the pump.

6)Open only 10% of pump discharge valve. 7)Check pump minimum flow controller position and it

should be in auto position with pre-defined set point in DCS and

both the isolation valve of controller should be in open position. 8)Crack open pump recirculation line manual valve at

downstream of pump discharge. 9)Open recirculation line and pump minimum flow line


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manual valves

into entry manifolds of product filling line of dispatch bullets. 10)Communicate with the top control room & ask to check

about the healthy condition of level switch of pump as well as bullets & if found healthy

then ask to activate bypass timer of the said pump (Do not bypass while running the pump).

11)Now start the pump in AUTO mode. 12)Open the pump discharge valve gradually to full open

position.Also, open carousal or tanker dispatch line manual valve at the downstream of pump discharge line and at the same

time close the recirculation manual valve.

13) Check the motor amps, any noise and pump discharge pressure. Communicate with filling plant for required pressure.

GENERAL OPERATIONS

ACTIVITY

6.02 Ethyle Mercaptan Injection Method

PURPOSE To mix-up Ethyle Mercaptan with LPG before dispatching to Filling Plant

HAZARDS

1)Inhale of Mercaptan can cause

Headache,nausea,vomiting and shortness of Breath 2)Hazard of skin irritation


PPEs

Wear protective glove

Wear Musk Safety shoe, Dungaree, Helmet.

PREPARATION

1) Use PPE during handling of Mercaptan.

2) Venting and draining of Mercaptan to atmosphere should be done under strict supervision and

preferably it should be done to flare header only. Unnecessary draining should be avoided

1)Ensure that all isolation valves of delivery line are closed


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STEP BY STEP

PROCEDURE

before starting the mercaptan dosing operation.

2)Check the Nitrogen cylinder pressure by opening the top

valve of the cylinder to ensure that its not empty. There are

2 nos of PG at the cylinder. The pressure should be above 5

kg/cm2.

3)Close the top Aluminium lid of the front PG in order to raise

the pressure between 4-6 kg/cm2.

4)Open the 1” isolation valve of the respective Nitrogen

cylinder.

5)Open the isolation valve prior to the PG displaying

mercaptan vessel pressure which should be above 0.2

kg/cm2.

6) Open the suction line of the pump.

7)Open the drain line at discharge of the pump till gas stops

coming and liquid starts coming.

8)Start the pump.

9)Close the vent line and open the discharge valve.

10)It takes about ½ an hour to develop the discharge

pressure.

11)If there is any problem with flow, 1st vent the drain line

at discharge of the pump till gas stops coming and liquid

starts coming.


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CHAPTER VII

SOP FOR HANDLING OF EMERGENCY SITUATION

GENERAL OPERATIONS

ACTIVITY

7.01Action to be taken in case Inlet Compressor trips

PURPOSE Steps to handle emergency situation in case of Inlet Compressor trip.

HAZARDS



5) Leakage of gas

PPEs


PREPARATION


STEP BY STEP

PROCEDURE

1) Put PRV from AUTO to MANUAL at local CM 11.01 panel.

2) Release Pressure in PV 16.01 (Inlet comp suction

scrubber) by pulling charge and vent Amot valve from

the same local panel

3) Follow the ‘expander compressor trip procedure’ as

mentioned in 3.1.3.

4) Shut down both Regen Gas and Hot oil heaters

5) Put PICV-430 on MANUAL at field when Level in

PV 16.07 (expander separator) comes below 40 %.

6) Stop De-ethanizer Reflux pump (PM 17.01/02)

when level in PV 16.08 (De-ethanizer Reflux

Accumulator) near Zero.

7) Stop De-butanizer reflux pump (PM 17.03/04)


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when level in PV 16.10 is zero.

8 )Close LPG and NG product line to storage isolation

valves.

9 )Open LCV-432 by-pass valve & PRCV-504 B to

Flare.

GENERAL OPERATIONS

ACTIVITY 7.02Action to be taken in case Expander Compressor trips

PURPOSE Steps to handle emergency situation in case of

Expander-Compressor trip.

HAZARDS

1)Fire hazard

2)Slip ,fall due to Lube oil leakage 3)Hazard of falling material on the body

4)Noise 5) Leakage of Gas

6)Slip fall due to spillage of water.

PPEs


PREPARATION



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STEP BY

STEP PROCEDURE

1)Change from ‘Remote’ to ‘local’ for IGV (inlet guide

vane) control in Expander-Comp HMI (human machine

interface) panel and gradually close the IGV up to Zero

%.

2)Close Booster compressor discharge valve

physically.

3)Allow sufficient time (about 10 min) to run the lube

oil pumps (PM 17.401/402). Then stop the Lube oil

pump in HMI panel, select off option for the both

pump and close the seal gas manual valve.

4)Close the expander discharge valve and then seal

gas trip control valve from HMI panel and also

isolate the seal gas supply valve physically from cold

separator top.

5)Reduce the hot Oil Heater temperature slowly to

around 100°C or stop the heater as required.

6)Put PICV-430 on MANUAL at field when Level in

PV 16.07 (expander separator) comes below 40 %.

7)Stop De-ethanizer Reflux pump (PM 17.01/02)

when level in PV 16.08 (De-ethanizer Reflux

Accumulator) near 20%

8)Stop De-butanizer reflux pump (PM 17.03/04)

when level in PV 16.10 is zero.

9)Close LPG & NG product line.


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GENERAL OPERATIONS

ACTIVITY

7.03Action to be taken for gas leakage from flange,line or vessel in LPG Recovery Plant

PURPOSE Steps to handle emergency situation in case of gas

leakage

HAZARDS



5) Striking.

PPEs


PREPARATION


STEP BY STEP

PROCEDURE

1)Shout and draw attention of others for help, break nearby break-glass box. 2)Try to isolate the source of leakage by closing appropriate valves. 3)Inform LPG Control Room/ Shift Engineer in-charge in LPG Recovery Plant or Dy.SE (PD)/ Sr E(PD) in LPG Filling Plant, as applicable, depending on whether the leakage is in LPG Recovery Plant or LPG Filling Plant. 4)In case of leakage in LPG Recovery Plant, Shift Engineer in-charge in LPG Recovery Plant will inform Fire Station. Give full details of the emergency. He will disconnect the telephone after Fire Service personnel repeats the message. He will raise the siren manually and intimate all the personnel of the installation about the leakage. He will inform Dy.SE (PD)/ SrE(PD) about the leakage. 5)In case of leakage in LPG Filling Plant, Dy.SE (PD)/ Sr.E(PD) in LPG Filling Plant will inform Fire Station. Give full details of the emergency. He will disconnect the telephone after Fire Service personnel repeats the message. Will raise the siren manually and intimate all the personnel of the installation about the leakage. He will inform Shift Engineer in-charge in LPG Recovery Plant about the leakage. 6)Collect all personnel up wind. 7)Stop all hot jobs such as welding, gas cutting etc. if there is any.


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8)Stop all internal combustion engines and movement of vehicles in the vicinity. Remove/ extinguish all sources of ignition. 9)Use deluge valves, monitors and hydrants --as applicable, for blanketing the area of leakage with water fog. 10)Any non-flame proof electrical appliances in the vicinity should be considered as a potential source of ignition and hence should not be operated. 11)The duties and responsibilities of various personnel in the LPG Department will be as per CRISIS MANAGEMENT PLAN (LPG PLANT)

GENERAL OPERATIONS

ACTIVITY

7.04Auto Start Testing of FW PM No-1,2,3,4 and DEFP

No-2

PURPOSE To test Fire water pumps 1,2,3,4 for Auto start

HAZARDS

1)Fire hazard

2)Hazard of burn injury 3)Hazard of falling material on the body

4)Noise 5)Slip,fall due to spillage of water.

PPEs


PREPARATION


Inform Filling Plant regarding the ‘AUTO START TESTING

OF FIRE WATER PUMPS AND DISEL ENGINE FIRE PUMP’ Go to the FIRE WATER pump house.

Put all the FWP in ‘MANNUAL’ position except the FWP which is to be tested.


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STEP BY STEP

PROCEDURE

1. Inform Filling Plant regarding the ‘AUTO START TESTING

OF FIRE WATER PUMPS AND DISEL ENGINE FIRE PUMP’

2. Go to the FIRE WATER pump house.

3. Put all the FWP in ‘MANNUAL’ position except the FWP which 4. is to be tested.

5. Water from the hydrant system to be drained in a very

minimum rate to reduce the pressure by any monitor or drain point.

6. Observe the activated pressure and pump starting pressure and record it .

7. If the system pressure increase to 4 - 8 Kg/cm2 g than the running pump is to be stopped by putting the

selector switch to manual position and at the same time pushing the stop switch.

8. Then try to another FWP for ‘AUTO STATRT’ testing and

follow the above sequence.

9. It the job is complete than observe whether the hydrant system pressure is steady or not by running the jockey pump

in ‘AUTO’position.

10. If the system is steady with sufficient idle time of jockey

pump(above 10 minutes) than all pumps are to be put in ‘AUTO’position.


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