MCOT 008 WL Crude Receiving 18 Inch

Operating Procedure MY SKO O 05 MCOT 008
Crude Receiving: 18” TK/SI/WL/4BCrude Line Rev. 0 Sept 2011
Any deviation from this procedure must follow the MANAGEMENT OF CHANGE PROCEDURE
or STANDING INSTRUCTIONS process before any deviation or change may be made.
OPERATING PROCEDURE
Contents
Foreword
Distribution List
Amendment Summary
Preface
Glossary
Reference Documents
Section 1 Introduction
Section 2 Procedure
Appendix A Checklist
Diagram
"UNCONTROLLED WHEN PRINTED"
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FOREWORD
Authority for original issue
Document Author
Issue of this document has been formally authored by:
Name: Mentor Solutions & Resources Sdn Bhd
Position: Technician/ Consultant/ Contractor
Date:
Issue Review
Issue of this document has been formally reviewed by:
Name:
Signature
Position: Production Supervisor/ Field Engineer
Date:
Issue Approval
Issue of this document has been formally approved by:
Name:
Signature:
Position: Head of Production
Date:
Document Custodian
The following person has been assigned as the document custodian:
Name:
Signature:
Position Onshore Installation Manager
Date

Distribution List
Copy No. Title Location
01 Central Control Room MCOT
AMENDMENT SUMMARY
This sheet must be completed in detail at each revision once this document has been
approved.
Details must include revision number, description and indication of which pages and
paragraphs have been revised, date of revision approval, approvers title and signature.
Rev Description Date Approver Title Name
Rev 0 Original Document
Notes: (1) Document Holders to update Amendment Record as and when

amendments/new revisions are received.
(2) For description of amendment the Document Holder should indicate
correction, modification, update or deletion issue.
(3) Document Holder to enter their company reference number, sign and date the
record of entry.
(4) Where part amendments are issued, the relevant page(s) will be identified
with a lower case letter in the revision status line in the header.

GLOSSARY
CCR Central Control Room

PSD Process Shutdown
PCMS Process Control and Monitoring System
SOS Start-up Override System
DCS Distributed Control System
WL West Lutong
TK Tukau
SI Siwa
BN Baronia
BO Bokor
BE Betty
BK Bakau
4B BN/BE/BO/BK
BA Baram
VB Ball Valve
VG Globe Valve
MOV Motor Operated Valve
CIMAH Control of Industrial Major Accident Hazard
FWKO Free Water Knock Out
REFERENCE
DOC. NO TITLE
MY SKO O 07016 Rev.1 April 2010 MCOT Operating Procedures Manual
MCOT CIMAH Safety Report PCSB MCOT CIMAH 2009 Rev 131109
SKO Rev. 0 November 2009
MCOT Rejuvenation Project Phase 2 Piping & Instrumentation Diagram (P&ID)
Process Drawing (Rev. No. 6)

Section 1
INTRODUCTION
Content Page
1.1 OBJECTIVE/PURPOSE................................................................................................ 6
1.2 SCOPE .......................................................................................................................... 6
1.3 OP CATEGORY ............................................................................................................ 6
1.4 PREREQUISITES ......................................................................................................... 6
1.5 LIMITATIONS ................................................................................................................ 6
1.6 ROLES/RESPONSIBILITY ........................................................................................... 6
1.7 HSE REQUIREMENTS ................................................................................................. 7

1 INTRODUCTION
1.1 OBJECTIVE/PURPOSE
1.1.1 This operating procedure outlines normal activities required to execute the task and actions to
be taken in event of abnormal situations that may arise during the execution of the task.
1.1.2 The task is to prepare MCOT for receiving crude from offshore TK/SI/WL/4B platforms.
1.2 SCOPE
1.2.1 The requirements in this procedure shall apply to MCOT.

1.2.2 This procedure refers to FWKO Start up for the following cases:
i. Case 1: FWKO vessels are empty

ii. Case 2: Baram and West Lutong are not producing
iii. Case 3: Either Baram or West Lutong is not producing
1.3 OP CATEGORY
Categories Normal / Start Up / Shutdown / Checklist Required: Yes / No

Emergency / Special / Temporary /
and attributes
Abnormal / Decommissioning
1.4 PREREQUISITES
1.4.1 MCOT to be informed minimum 24 hours prior to receiving offshore crude for preparing the
receiving facilities
1.4.2 Communication is established with TK, WL, BE, BO and BN CCRs.
1.5 LIMITATIONS
1.5.1 Available ullage in wet tanks for receiving.
1.6 ROLES/RESPONSIBILITY
1.6.1 Refer to Section 2: Procedure “Action party”.

1.7 HSE REQUIREMENTS
Hazards and The table below lists job hazards and the precautions that should be taken
precautions for safety, environmental, quality, ergonomics, Good Manufacturing
Practices, etcH before beginning this procedure.
Hazard Precaution
Flammable Ensure no hot work within the vicinity.
Chemical & toxic Avoid crude contact with skin.

Avoid inhalation.
PPE The following Personnel Protection Equipment (PPE) must be used to do

required this activity in addition to mandatory PPEs. List any special PPEs required,
PPE Use
N/A
Tools and The tools and equipment listed below are needed to do this job. List any
Equipment special tools required in addition to hand tools.
Tools and/or Equipment Use
Valve wrench To open stiff valves
ESD / ESD will close ABV-9230 Beach valve besides shutting down the Terminal.
Interlocks SDV-1010/20/30/40
SDV-1011/21/31/41/12/22/32/42

Unit: Oil Receiving Facility

Safe Operating Never Exceed SOL
and FWKO
Limit Limit Excursions
Area: Crude receiving
Equipment Inst.Tag # H L HH LL Consequence of Deviation Corrective Actions

18’ WL crude PAL-9232 2.0 Beach valve ABV-9230 trip when Find out the cause of the low pressure
trunkline barg pressure drop to 1.38 barg. alarm and rectify any fault found. Open
Associated upstream offshore back beach valve ABV-9230.
facilities trip on high trunkline
pressure
18’ WL crude PAH-9232 7.5 Alarm will be activated. Crude oil will Find out the cause of the high pressure
trunkline barg enter Surge Relief Vessel V-6310. alarm and rectify any fault found.
18’ WL crude PZALL- 1.38 Beach Valve ABV-9230 will trip Find out the cause of the low low
trunkline 9231 barg when pressure drop to 1.38 barg. pressure, rectify if possible and re-
open back beach valve ABV-9230.
18’ WL crude PZAHH- 9.3 Beach Valve ABV-9230 will trip Find out the cause of the high high
trunkline 9231 barg when pressure reaches to 9.3 barg pressure, rectify if possible and re-
Associated upstream offshore open back beach valve. ABV-9230.
facilities trip on high high trunkline Seek expert help if unable to rectify
pressure. fault.
V-1010 / 20 / PIAH- 7.5 Alarm will be activated. Find out the cause of the high pressure
30 / 40 FWKO 1011/12/13 barg alarm and rectify any fault found.
Vessels /14


and FWKO
V- PIAL- 0.3 Alarm will be activated. Inlet SDV- Find out the cause of the low pressure
1010/20/30/40 1011/12/13 barg 1010/20/30/40 and outlet SDV- alarm and rectify any fault found. Open
FWKO /14 1011/21/31/41/12/22/32/42 will trip. the inlet SDV-1010/20/30/40 and outlet
Vessels SDV-1011/21/31/41/12/22/32/42
V-1010 / 20 / PZAHH- 9.3 PSV-1010/11/20/30/40 will be Find out the cause of the high high
30 / 40 FWKO 1012/22/32 barg activated. pressure alarm and rectify any fault
Vessels /42 found. Re-calibrate PSV-
1010/11/20/30/40.
V-1010 / 20 / PZALL- 1.5 barg SDV-1012/22/32/42 will trip. The Find out the cause of the low low
30 / 40 FWKO 1013/23/33 liquid remain stagnant as there is not pressure alarm and rectify any fault
Vessels /43 enough pressure to push it out. found.
Start-up FWKO Vessels (refer to
FWKO Operating Procedure).
V-1010 / 20 / LZAHH(I/F) 75 % SDV-1012/22/32/42 will trip.Water Find out the cause of the high high
30 / 40 FWKO - carries over to wet tanks and interface level alarm and rectify any
Vessels 1012/22/32 reduces the water draining efficiency fault found.
/42 of MCOT.
V-1010 / 20 / LZALL(I/F)- 50 % SDV-1012/22/32/42 will trip. Find out the cause of the low low
30 / 40 FWKO 1013/23/33


and FWKO

Vessels /43 interface level alarm and rectify any
fault found.

Section 2
PROCEDURE
Content Page
2.1 CRUDE RECEIVING PREPARATION ....................................................................... 12
2.2 CRUDE RECEIVING OPERATION ............................................................................ 12
2.3 FWKO INITIAL START-UP OPERATION (CASE 1) .................................................. 13
2.4 FWKO START-UP AFTER NORMAL UNIT SHUTDOWN (CASE 2) ........................ 13
2.5 FWKO NORMAL SHUTDOWN OPERATION ............................................................ 14
2.6 FWKO ABNORMAL OPERATIONS ........................................................................... 14

2 PROCEDURE
2.1 CRUDE RECEIVING PREPARATION
No. Action Action Party
2.1.1 Ensure the PSD is healthy. Panel man 2
2.1.2 Ensure the following valves are as per Appendix A, item 1.1, Table 1. Panel man 2/
Area operator
2.1.3 Ensure the Surge arrestors SPR-13250/51 are ready for operation and Area operator
Surge Relief Vessel V-6310 is lined-up for relief operation.
NOTE:
The surge arrestor is set at 7.6 barg (110 psig ) and relief to the Surge
Relief Vessel V-6310
2.1.4 Ensure the FWKO vessels V-1010/1020/1030/1040 are ready to receive Panel man 2 /
crude from the incoming line. Area operator
2.1.5 Ensure the nominated wet tank is ready to receive crude from FWKO. Panel man 2 /
Area operator
2.2 CRUDE RECEIVING OPERATION
2.2.1 Ensure PSD push buttons (HZ-4500/PSD-0141/0142/0143/0144/0149) and Panel man 2

fusible plug (HZ-4507) and LIA-6703 are healthy. Reset PSD system by
activating HZ-4502/4503.
2.2.2 Slowly open MOV-9231 the incoming line isolation valve to full open. Area operator
2.2.3 Activate the operation start-up override key switch at the push buttons Panel man 2
panel to override the low low pressure trip.
Description Tag Barg Psig
Low Low pressure trip PZALL-9231 1.38 20
Low pressure alarm PZAL-9232 2.0 29
2.2.4 Slowly open 2” VG the start-up throttling bypass isolation valve to Area operator
pressurise the downstream system.
2.2.5 Visual check for any abnormality. Area operator
2.2.6 Open MOV-9232 the main inlet valve downstream of ABV-9230 Area operator
2.2.7 Close 2” VG the by-pass start-up throttling valve which was opened as per Area operator
2.2.4.

2.2.8 Confirm all parameters are normal (Refer to SOL). Panel man 2
2.2.9 Return the operation start-up override key switch to normal position, when Panel man 2
the pressure is healthy.
2.2.10 Inform WL OS once MCOT is ready to receive the crude. Panel man 2
2.3 FWKO INITIAL START-UP OPERATION (CASE 1: EXAMPLE V-1010)
NOTE:
Case 1: FWKO vessel is empty (e.g. DOSH inspection)
2.3.1 Ensure all related upstream and downstream manual valves are lined up. Area operator
2.3.2 Ensure SDV-1010 in MOS. Panel man 2
2.3.3 Set oil/water interface level (LIC-1010) at 80% of range in DCS. Panel man 2
2.3.4 Open 2” vent valve to surge relief header. Area operator
2.3.5 Ensure LCV-1010 water outlet control valves are closed in manual mode. Panel man 2
2.3.6 Ensure PCV-1010 inlet control valves are closed. Panel man 2
2.3.7 Confirm that the following valves are in the following position as per Area operator
Appendix A, item 1.2, Table 2.
2.3.8 Open inlet valve PCV-1010 to introduce crude from the distribution header. Panel man 2
2.3.9 Open SDV-1010 and local reset. Panel man 2 /

Area operator
2.3.10 Monitor level of the interface from LIC-1010. Panel man 2
2.3.11 Normalized SDV-1010 and put LCV-1010 on auto after the interface level Panel man 2
reaches 80%.
2.4 FWKO START-UP AFTER NORMAL UNIT SHUTDOWN (CASE 2)
NOTE:
• Baram and West Lutong are not producing.
• All FWKO V-1010/1020/1030/1040 have shutdown and full of liquid

2.4.1 Ensure the following valves: FWKO V-1010/1020/1030/1040 is as per Area operator
checklist in Appendix A, item 1.2, Table 3.
2.4.2 Manually close PCV-1010/20/30/40 FWKO inlet control valve and manually Panel man 2 /
open SDV-1010/1020/1030/1040 the inlet shutdown valves via the reset Area Operator
button.
2.4.3 Manually open crude outlet SDV-1011/21/31/41 via the reset button. Panel man 2 /
Area Operator
2.4.4 Manually open water outlet SDV-1012/22/32/42 via the reset button. Panel man 2/
Area Operator
2.4.5 Slowly open the PCV-1010/20/30/40 FWKO inlet control valve manually to Panel man 2
introduce crude into the vessels one by one.
2.4.6 When the process has stabilised, set PCV-1010/20/30/40 FWKO inlet and Panel man 2
LCV-1010/20/30/40 water outlet control valves on auto-control.
2.5 FWKO NORMAL SHUTDOWN OPERATION (EXAMPLE: V-1010)
NOTE:
Normal shut down of FWKO V-1010 for maintenance (e.g. DOSH
inspection).
2.5.1 Close water outlet SDV-1012 manually to displace most of the crude to
Panel man 2
YP21.
2.5.2 Close crude outlet SDV-1011 manually. Panel man 2/

Area operator
2.5.3 Close crude inlet SDV-1010 manually. Panel man 2/

Area operator
2.5.4 Carry out depressurise and draining as per respective Work Method
Area operator
Manual (WMM) to depressurise V-1010.
2.6 FWKO ABNORMAL OPERATIONS
NOTE:
When an operating upset occurs, the appropriate safety shutdown devices
will automatically act. Refer to Appendix A, item 1.4, Table 4: FWKO
Shutdown Causes and Effect.

2.6.1 When all FWKO’s are isolated by their SDVs, the incoming crude can be Area operator
diverted to the receiving tank via interconnection line with hand valve (HV- / Shift
1004). supervisor
2.6.2 If only 1 out of 3 FWKOs are isolated by their SDVs, the remaining 2 Area operator
FWKOs are able to cope with the incoming crude flow. However, need to / Shift
monitor the flow rate and pressure of the incoming crude flow. Line-up the supervisor
standby FWKO if required.
2.6.3 If 2 out of 3 FWKOs are isolated by their SDVs, pressure build-up may Area operator
occur in the incoming trunkline. Line-up the standby FWKO if required. / Shift
supervisor
END OF PROCEDURE

Appendix
APPENDIX A
Content Page
1 CHECKLIST ................................................................................................................ 17
1.1 TABLE 1: VALVE CONFIGURATION FOR CRUDE RECEIVING

PREPARATION........................................................................................................... 17
1.2 TABLE 2: VALVE CONFIGURATION FOR CASE 1 .................................................. 18
1.3 TABLE 3: VALVE CONFIGURATION FOR CASE 2 .................................................. 18
1.4 TABLE 4: FWKO V-1010 VALVES CHECKLIST ....................................................... 18
1.5 TABLE 5: FWKO SHUTDOWN CAUSES AND EFFECT .......................................... 19
2 DIAGRAMS ................................................................................................................. 21
2.1 FIGURE 1: 18” TK/SI/WL/4B INCOMING CRUDE LINE ........................................... 21
2.2 FIGURE 2: FREE WATER KNOCK OUT (FWKO) VESSELS ................................... 22

1 CHECKLIST
1.1 TABLE 1: VALVE CONFIGURATION FOR CRUDE RECEIVING PREPARATION

Tag No. Description Open Close
MOV-9231 Main incoming line isolation valve Close
2"VB Drain valve Close
ABV-9230 Beach valve (shutdown valve) Open
MOV-9232 Main inlet valve downstream of ABV-9230 Close
2"VO MOV-9232 bypass throttling starting valve Close
MOV-9233/34 R-9230 inlet Close
12"VB R-9230 outlet Close
18"VB R-9230 bypass line Open
3 300VX131638 / 643 / 028 TK/SI/WL/4B's surge arrestor inlet LO
4 300VX131539 TK/SIWL/4B's surge arrestor inlet LC
5 300VX621606 / 351637 / TK/SI/WL/4B's surge arrestor outlet LO
030 / 540
6 450VX131038 Crude distribution header inlet valve Open
7 450VX131008 / 016 Bypass FWKO isolation valve (to line YP-21) Close
8 HV-1004 Bypass FWKO hand valve (to line YP-21) Close
9 400VX131040 / 050 / 053 Inlet valve to FWKO V-1010 Open
SDV-1010 Shutdown valve on inlet to V-1010 Open
13 300VX132504 / 131080 V-1010 inlet FCV-1010 bypass valve Close
14 300VX132506 V-1020 inlet FCV-1020 bypass valve Close
/ 131085
15 300VX132509 V-1030 inlet FCV-1030 bypass valve Close
/ 131113
16 300VX132512 / 131145 V-1040 inlet FCV-1040 bypass valve Close
17 EOV Nominated Receiving Tank by Operation Open
(e.g. T-76 the EOV is 7610)
12” VG Tank side receiving manual valve Open
(e.g. T-76 the tank side manual valve is 12”)

1.2 TABLE 2: VALVE CONFIGURATION FOR CASE 1 (EXAMPLE: V-1010 UNDER

INSPECTION)
Valve Description Open Close

400VX131040 / 050 / 053 Inlet valve to FWKO V-1010 Open
450VX131016 Bypass FWKO isolation valve (to line YP-21) Close
HV-1004 Bypass FWKO hand valve (to line YP-21) Close
SDV-1010 Shutdown valve on inlet to V-1010 Close
300VX132504 / 131080 V-1010 inlet PCV-1010 bypass valve Close
1.3 TABLE 3: VALVE CONFIGURATION FOR CASE 2

1.4 TABLE 4 : FWKO V-1010 VALVES CHECKLIST

300VX132504 / 131080 V-1010 inlet FCV-1010 bypass valve Close

1.5 TABLE 4: FWKO SHUTDOWN CAUSES AND EFFECT

2 DIAGRAMS
2.1 FIGURE 1: 18” TK/SI/WL/4B INCOMING CRUDE LINE


2.2 FIGURE 2: FREE WATER KNOCK OUT (FWKO) VESSELS


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Operating Procedure MY SKO O 05 MCOT 008

Crude Receiving: 18” TK/SI/WL/4BCrude Line Rev. 0 Sept 2011

"UNCONTROLLED WHEN PRINTED"

30/07/2012 9:05 AM PETRONAS CARIGALI SDN BHD Page 1 of 23

Name: Mentor Solutions & Resources Sdn Bhd

Position: Technician/ Consultant/ Contractor

Position: Production Supervisor/ Field Engineer

Position: Head of Production

Position Onshore Installation Manager

"UNCONTROLLED WHEN PRINTED"

30/07/2012 9:05 AM PETRONAS CARIGALI SDN BHD Page 2 of 23

Rev Description Date Approver Title Name

Rev 0 Original Document

Notes: (1) Document Holders to update Amendment Record as and when

"UNCONTROLLED WHEN PRINTED"

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CCR Central Control Room

"UNCONTROLLED WHEN PRINTED"

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1.2 SCOPE .......................................................................................................................... 6

1.3 OP CATEGORY ............................................................................................................ 6

1.4 PREREQUISITES ......................................................................................................... 6

1.5 LIMITATIONS ................................................................................................................ 6

1.6 ROLES/RESPONSIBILITY ........................................................................................... 6

1.7 HSE REQUIREMENTS ................................................................................................. 7

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1.2.1 The requirements in this procedure shall apply to MCOT.

i. Case 1: FWKO vessels are empty

Categories Normal / Start Up / Shutdown / Checklist Required: Yes / No

1.5.1 Available ullage in wet tanks for receiving.

1.6.1 Refer to Section 2: Procedure “Action party”.

"UNCONTROLLED WHEN PRINTED"

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1.7 HSE REQUIREMENTS

Flammable Ensure no hot work within the vicinity.

Chemical & toxic Avoid crude contact with skin.

PPE The following Personnel Protection Equipment (PPE) must be used to do

Valve wrench To open stiff valves

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Unit: Oil Receiving Facility

Equipment Inst.Tag # H L HH LL Consequence of Deviation Corrective Actions

"UNCONTROLLED WHEN PRINTED"

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Unit: Oil Receiving Facility

Equipment Inst.Tag # H L HH LL Consequence of Deviation Corrective Actions

"UNCONTROLLED WHEN PRINTED"

30/07/2012 9:05 AM PETRONAS CARIGALI SDN BHD Page 9 of 23

Unit: Oil Receiving Facility

Equipment Inst.Tag # H L HH LL Consequence of Deviation Corrective Actions

"UNCONTROLLED WHEN PRINTED"

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2.1 CRUDE RECEIVING PREPARATION ....................................................................... 12

2.2 CRUDE RECEIVING OPERATION ............................................................................ 12

2.3 FWKO INITIAL START-UP OPERATION (CASE 1) .................................................. 13

2.4 FWKO START-UP AFTER NORMAL UNIT SHUTDOWN (CASE 2) ........................ 13

2.5 FWKO NORMAL SHUTDOWN OPERATION ............................................................ 14

2.6 FWKO ABNORMAL OPERATIONS ........................................................................... 14