Pre-Comm., Comm. Start Up & Opertion Manual R2 Terminal

HAZEL INTERNATIONAL FZE
PRE-COMMISSIONING, COMMISSIONING & OPERATING MANUAL
1
Preamble
It is customary to begin with details of Project installations as a prelude to all the Project documents.
But such details at this Commissioning stage, which is the business end of the Project, not only dilute
the focus on the current affairs but also occupy space and time. Having come to the Commissioning
stage of the Project, the Personnel should be fully aware of the installations, which are detailed out in
the Design Basis and other Project documents governed by Contract. Hence it is pointless to start
reinventing the wheel. This documents takes on from the Mechanical Completion of the Project and
details out systematic Procedures to transform the Project installations to a Safe Operating Terminal.
This document is written for providing overall guidance on the Pre-commissioning & Commissioning
Procedures and Startup & Operation of the Terminal. Towards this objective, the Manual is bifurcated
broadly into the following Chapters, the significance of each of which is as mentioned below.
Pre-commissioning
Pre-commissioning is the first step towards transforming the Installations at site from being a Project
to an Operating Plant or an Operating Terminal.
This chapter brings out the mandatory checks for each and every Installation of Equipment and
Systems of the Project to confirm that the Installations and Systems are ready to be commissioned in
service.
The Pre-commissioning steps are laid out as sequential Check list points, each of which carries its
significance to ensure the Safety of Plant & Personnel and Endurance of the installations on being
commissioned into Operational service. The Pre-commissioning Check & Test sheets may be
endorsed by the responsible Project / Operating personnel, to instill sanctity to the Checks and
ensure their completion as required.
The Check & Test sheets for all Disciplines and various categories of each Discipline are furnished.
Also the necessary Formats for maintaining records of important parameters of Pre-commissioning
Checks for future reference are furnished, wherever applicable. The Check & Test sheets for the
same category of Equipment of each Discipline may be filled in one for each Tag No. with mention of
Tag No. at the place mentioned in the Check & Test sheets, categorized as follows:
 Mechanical - Centrifugal Pumps, Gear Pumps, Floating roof Storage Tanks etc.
 Electrical - Transformers, Induction Motors etc.
 Instrumentation - Level Transmitters (Radar type), PLC Panels, SCADA etc.
 Systems & Packages – Thermic Fluid system, Chilled water system, Fire & Gas detection system
etc.
Commissioning
Once the individual Equipment and individual Systems are certified for Pre-commissioning
completion, the next step is to ensure that they are integrated in seamless union for the Safety of the
Terminal for the intended Operations. During this phase the Inter-disciplinary Interlocks associated
with all the Terminal Operations which impart Safety to the Personnel & Plant, are Functional Tested.
These tests are carried out prior to charging the Terminal with the Process fluids, so that the Terminal
is Safe to Store the fluids and Process them as required.
The Commissioning Procedures are elaborative with each Functional Test of the intended Operations
explained stepwise with Temporary installations, Safety precautions, if any required etc. The
Commissioning Procedures for each Unit Operation of the Terminal is furnished as ‘Operational Test
Procedure’ (OTP).
PCS Projects Consultancy Services

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Startup & Operations

Startup of the Terminal is the first step towards Commissioning the Terminal for regular
Operations.
This phase is detailed out stepwise covering all the segments of Operation in the Terminal as
mentioned below:
Receipt & Storage
 Unloading of Process Solvents / Products from the origin (Ship / Road Tanker)
 Receipt in their respective Storage Tanks
 Safe storage of the Solvents / Products received
Truck Loading (TLF)
 Loading of the Stored materials in Road Tankers
 All Interlocks associated with the Operation that have been tested during OTP intact to ensure
Safety of the Personnel & the Terminal
 Automation System installed for TLF is detailed stepwise
Drum Filling
 Filling of Solvents / Products in Drums as per requirement
 All Interlocks associated with the Operation that have been tested during OTP intact to ensure
Safety Personnel & the Terminal
 Manual operations of the process and precautions to be exercised are detailed out
Ship Loading
 Pumping the stored materials to the Manifold for onward Ship loading as per requirements
 Manual Operations involved at the Manifold and at the Jetty end are detailed out with
Precautions to be exercised
Blending
 Pumping the requisite materials from their Storage Tanks to the Blending Tank
 Manual Operations involved at the Manifold with Precautions to be exercised
Process Block
 The Process Block Pre-commissioning, Commissioning, Startup & Operations are detailed out as
a separate chapter.
 Interlocks associated between the Terminal and Process Block are fully detailed & tested as
part of Commissioning procedures to ensure Safety in Process Operations.

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TABLE OF CONTENTS
1. PRE-COMMISSIONING 8
1.1 Electrical Installations Pre-commissioning 8
Check & Test sheets Electrical - for all Systems & Equip 10-19
1.2 Instrumentation Pre-Commissioning 20
Check & Test sheets Instrumentation -for all Systems & Equip 22-31
1.3 Packages Pre-Commissioning 32

Check & Test sheets - for all Packages 34-49
1.4 Mechanical Installations Pre-Commissioning 52
Check & Test sheets Mechanical - for all Mechanical Installations 54-67
2. COMMISSIONING 68
2.1 HVAC Cooling water system 69
2.2 Process Cooling water system 69
2.3 HVAC Chilled water System 69
2.4 Process Chilled water System 70
2.5 Air Compressors 70
2.6 N2 & IA Package 70
2.7 Fire Water system 71
2.8 Fire & Gas system 71
2.9 Thermic Fluid system 71
2.10 Storage Tanks of Dike 1 72
2.11 Storage Tanks of Dike 2 (Except Bitumen Tanks) 72
2.12 Bitumen Storage Tanks Dike 2 72
2.13 Pig Launcher & Receiver PLR) 72
2.14 Terminal Automation System (TAS) 73
Commissioning -Operational Test Procedures - for all Systems 74-227
3. STARTUP & OPERATION OF SUPPORT SYSTEMS 230
3.1 Startup & Operation of HVAC Cooling water system CT-811-001 230
3.1.1 Preventive maintenance of HVAC CW system Equipment 231
3.1.2 Breakdown & Shutdown of HVAC Cooling water system 232
3.2 Startup & Operation of Process Cooling water system CT-M501 233
3.2.1 Preventive maintenance of Process CW system Equipment 234

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3.2.2 Breakdown & Shutdown of Process Cooling water system 235

3.3 Startup & Operation of HVAC Chilled water System & HVAC 236
3.3.1 Preventive maintenance of HVAC CHW Package Equipment 238
3.3.2 Preventive maintenance of CHW System & HVAC Equipment 240
3.3.3 Breakdown & Shutdown of HVAC Chilled water System 241
3.4 Startup & Operation of Process Chilled water System 243
3.4.1 Preventive maintenance of CHW Package Equipment 245
3.4.2 Preventive maintenance of CHW System 247
3.4.3 Breakdown & Shutdown of Process CHW System 248
3.5 Startup & Operation of Air Compressors 249
3.5.1 Preventive maintenance of Air Compressors 250
3.5.2 Breakdown & Shutdown of all the Air Compressors 250
3.6 Startup & Operation of N2 & IA Package 251
3.6.1 Preventive maintenance of N2 / IA Package 253
3.6.2 Breakdown & Shutdown of N2 / IA Package 256
3.7 Startup & Operation of Fire Water system 257
3.7.1 Preventive maintenance of Fire water system 258
3.7.2 Breakdown & Shutdown maintenance of Fire water system 259
3.8 Startup & Operation of Fire & Gas Detection System 260
3.8.1 Preventive maintenance of Fire & Gas Detection System 261
3.8.2 Breakdown & Shutdown maintenance of Fire & Gas Detection System 262
3.9 Startup & Operation of Thermic Fluid System 263
3.9.1 Preventive maintenance of Thermic Fluid system 263
3.9.2 Breakdown & Shutdown maintenance of Thermic Fluid System 265
3.10 Startup & Operation of SCADA / DCS 267
Preventive maintenance of SCADA / DCS 267
Breakdown & Shutdown maintenance SCADA / DCS 267
4. STARTUP & OPERATION - PRODUCTS INTAKE TO STORAGE TANKS 268
4.1 Unloading Products from the Ship (Ref. P&ID TCE 7410A-300-PI-8652) 271
4.1.1 Preventive maintenance during Unloading Products from the Ship 275
4.1.2 Breakdown maintenance during Unloading Products from the Ship 277
Marked up Drgs. & Procedures for Ship Unloading Operations 278-287

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4.2.1 Tanker Unloading to Storage Tanks 288

4.2.2 Tanker Unloading for Drum Filling 293
4.2.3 Preventive maintenance during Tanker Unloading 296
4.2.4 Breakdown maintenance during Unloading of Tanker 297
Marked up Drgs. & Procedures for Tanker Unloading Operations 298-315
4.3 Inter-Terminal Transfer of Products 316

4.3.1 Transfer from the McGraw Terminal to the New Terminal 316
4.3.2 Transfer from the New Terminal to the McGraw Terminal 317
4.3.3 Preventive maintenance during Inter Terminal Transfer of Products 317
4.3.4 Breakdown maintenance during Terminal Transfer of Products 317
4.4 Support Systems in Operation & Parameters for Specific Products 318
4.4.1 Thermic Fluid System for Bitumen Storage Tanks T-BTM-001 & 002 318
4.4.2 Electric Heater for Phenol Storage Tank T-PHL-001 319
4.4.3 Chilled Water System for Styrene & VAM Storage Tanks 319
4.4.4 N2 Blanketing of Storage Tank Products 320
5. TERMINAL OPERATIONS 322
5.1 Dispatch to Ship (Ref. P&ID TCE 7410A-300-PI-8682, PI-8652) 323
5.1.1 Preventive maintenance during Dispatch to Ship 331
5.1.2 Breakdown maintenance during Dispatch to Ship 333
Marked up Drgs. & Procedures for Dispatch to Ship Operations 336-346
5.2 Tanker Loading of Products 347
5.2.1 Preventive maintenance during Tanker Loading 351
5.2.2 Breakdown maintenance during Tanker Loading 352
Marked up Drgs. & Procedures for Tanker Loading Operations 353-356
5.3 Drum Filling of Products 357
5.3.1 Preventive maintenance - Drum Filling 362
5.3.2 Breakdown maintenance - Drum Filling 363
Marked up Drgs. & Procedures for Drum Filling Operations 364-367
5.4 Products Blending 368

5.4.1 Preventive maintenance during Dispatch for Blending 373
5.4.2 Breakdown maintenance during Dispatch for Blending 375
Marked up Drgs. & Procedures for Blending Operations 376-386

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5.5 Recirculation of Bitumen / Other Products in their Tanks 386

5.5.1 Recirculation of Bitumen in Tanks T-BTM-001 / T-BTM-002 386

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1. PRE-COMMISSIONING
Ideally, Pre-commissioning activities of each Discipline should be carried out with a marginal lag from
Mechanical completion, so that the activities are completed with the same marginal lag and the
Systems are ready for Commissioning. Normal convention is followed in this document for bifurcation
of activities between Mechanical Completion, Pre-commissioning, Commissioning and Start up &
Operations. Brief of bifurcation and scope for Pre-commissioning is also being furnished for each
Discipli ne for clarity.
Pre-commissioning activities with Check & Test sheets are being presented in this document with the
following criterion:
 Discipline wise sequence in which the Pre-commissioning activities should be done optimally
 Activities of each Discipline in the necessary / preferred sequence in which they should take
place.
 For Packages of the same Discipline that are independent of others, the sequence mentioned
in this document need not necessarily be followed.
1.1 Electrical Installations Pre-commissioning
Power is the prime requirement for all the activities to follow. Power from a Diesel Generator or a
temporary connections from an existing installation might have been us during the Construction
period up to Mechanical completion. However, ideally, permanent Power should be available for Pre-
commissioning and onward activities. Even if temporary Power has to be used for the initial activities
due prevailing reasons at site, the distribution of Power to the consumers should be routed through
their respective Switch Boards / MCC for the Controls and Interlocks to be effective. Since Pre-
commissioning activities of the other Disciplines involve Interlocks that need to be in place, Electrical
is the forerunner leading the Pack for the sequence of activities.
Since Power should be available to the consumers, Power distribution Installations need to be
commissioned in full. Hence the necessary Check & Test sheets for Commissioning the Power
distribution equipment are also being furnished in this chapter. The necessary Formats for
maintaining records of important parameters of Pre-commissioning & Commissioning activities for
future reference are also being furnished, wherever applicable.
Mechanical Completion of Electrical discipline is marked by the Certification of Completion of the
following activities:
 Installation of the Equipment as per drawings
 Foundation bolts tightened and grouted as applicable
 Cables initial IR values checked and Termination done to the Equipment
 Ready for Pre-commissioning certified for the Equipment
Pre-Commissioning of Electrical discipline should be as per the following sequence comprising of
activities mentioned below:
 HV Switch gear Pre-commissioning & to be certified ready for Commissioning
 Pre-comm. of HV Switch gear broadly cover the following major activities:
 Final IR value checks, Continuity checks
 Hi-Pot Test, Contact Resistance Test etc.
 HV Switch gear Commissioning & Certification

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 Commissioning of HV Switch gear broadly cover the following major activities:

 Final IR value checks of HV incomer cable and charging HV Power
 Check of all Protective Relays, Alarms etc.
 HV to LV Transformers Pre-commissioning & Certification

 HV to LV Transformers Pre-commissioning broadly cover the following major activities:
 Winding Resistance, Continuity checks & Final IR value checks
 Di-electric strength of Transformer oil check & filling
 Ratio test on Tap positions, Protective devices check, Vector group Test etc.
 HV to LV Transformers Commissioning & Certification

 Commissioning of HV to LV Transformers broadly cover the following major activities:
 Charge Power to the Transformer & Commissioning certification
 LV Switch gear Pre-commissioning & to be certified ready for Commissioning

 Pre-comm. of LV Switch gear broadly cover the following major activities:
 Final IR value checks, Continuity checks
 LV Test, Contact Resistance Test etc.
 LV Switch gear Commissioning & Certification

 Commissioning of HV Switch gear broadly cover the following major activities:
 Secondary & Primary injection Tests for CT
 Protective checks, Alarms checks & Functional Tests etc.
Once LV Power is available for distribution, the Pre-commissioning & Commissioning activities of
other Disciplines can commence. The balance Pre-commissioning & Commissioning of downstream
Electrical Equipment like Motors etc. can progress parallel to the activities of other Disciplines.

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HV SWITCHGEAR & MCC PRECOMMISSIONING
Tag No. Location From No. Subsystem No.
Sl.
Check List Items Remarks
No.
1 IR ckecks of the Bus Bars and Control circuit have been checked are OK
Continuity checks of Circuit Breakers wiring have been done and found in
2
order
3 IR checks of the Circuit Breakers verified and OK
*Contact Resistance Test eport to be

Contact Resistance Test on Circuit Breakers have been done, found
4 furnished in the enclosed Report
satisfactory and Recorded.
format.
5 Indications have been chekced and are OK
High Voltage Test been done by applying specified High Voltage (For HV *Hi Pot Test eport to be furnished in the
6
SWGR. and MCC ), Functional Tests carried out and are satisfcatory enclosed Report format.
7 Alarm checks have been carried out, found satisfactory
8 Punch List items cleared
9 The system is ready to be charged to be Commissioned in service
Remarks : Additional details / Comments, if any
Signatories Date Signature

Construction Contractor
EPC Contractor
Client (Optional)

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HIGH VOLTAGE TEST REPORT (FOR HIGH VOLTAGE SWGR / MCC) - HV SG & MCC PRECOMMISSIONING
Tag No/s. Location From No. Subsystem No.
INSULATION RESISTANCE: (TEST VOLTAGE: ……...KV)

Sl.
Phase Before HIPOT After HIPOT Phase Before HIPOT After HIPOT Remarks
No.
Mega Ohms Mega Ohms Mega Ohms Mega Ohms
1 R TO Y R TO G
2 R TO B Y TO G
3 Y TO B B TO G
HI POT TEST
Sl.
Step Time Test Voltage KV Leakage Current - Milli Amp
No.
R- Y- B-
Remarks
(YBG SHORTED (RBG SHORTED) (RYG SHORTED)
Step 1
Step 2
Step 3
Step 4
Step 5
15 Sec.
30 Sec.
45 Sec.
1 Mt.
2 Mts.
3 Mts.
4 Mts.
5 Mts.
6 Mts.
7 Mts.
8 Mts.
9 Mts.
10 Mts.
11 Mts.
12 Mts.
13 Mts.
14 Mts.
15 Mts.
HV SG tested satisfactorily with Hi Pot.

EPC Contractor
Client (Optional)

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TORQUE, CONTACT RESISTANCE INSPECTION (CIRCUIT BREAKERS) - SWITCHGEAR & MCC
PRECOMMISSIONING
Tag No/s.
Location From No. Subsystem No.
Panel Designation Resistance in Micro ohms Remarks
Sl.
Phase-R Phase-Y Phase-B
No.
1
10
Panels have been tested satisfactorily for Torque Contact Resistance Total SG / MCC Approved Nos…

EPC Contractor
Client (Optional)

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EQUIPMENT WINDING RESISTANCE OR CONTINUITY & IR TEST - PRECOMMISSIONING
WINDING RESISTANCE OR CONTINUITY
Sl. RESISTANCE RESISTANCE IN

WINDING (PRI) WINDING (SEC) Remarks
No. OHMS OHMS
INSULATION RESISTANCE TEST

ACCEPTABLE
Sl. MEASURED
INSPECTION ITEMS TEST VOLTAGE RESISTANCE Remarks
No. RESISTANCE
MEGA OHMS
1
The above results are Satisfactory. The Equipment and Items are cleared for Commissioning.

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Client (Optional)

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HV SWITCHGEAR COMMISSIONING
Sl.
No.
1 Protective relay characteristics have been tested and found in order
Operation checks on meters and remote metering on DMS have been

2
done
3 Indications are OK
4 Alarm checks have been done
5 Earth switch interlock operation has been checked
6 Remote operation from DMS has been checked
7 Secondary and primary injection tests for CT circuits have been done.
8 Busbars have been energized.
9 Circuit breaker inserted and energized by closing.
10 Functional checks for close/trip/protection trip completed
11 Downstream Transformer Mechanical Protection Alarm/Trip tested.
12 Switch gear is satisfactorily Commissioned to be kept in service

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Client (Optional)

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TRANSFORMERS PRECOMMISSIONING CHECKS
Sl.
No.
Grouting of Foundation of the Transformer done and Foundation bolts
1
tightened with a torque wrench.
2 Di-electric strength of the Oil checked & Oil level is correct.
3 No oil leaks visible.

*Results to be furnished as per the
4 IR Test has been done for the windings and found OK
enclosed format.
IR values of connections checked & terminations done on both the
5
Primary & Secondary sides of the Transformer.
6 Primary, secondary cable connections are correct
7 Ratio Test on all Tap positions done and found OK.
8 Vector Group Test has been performed and satisfctory
9 All Protective devices checked by simulation
10 Polarization Index Test (PI Test) has been done for the windings and OK
11 RCU / Emergency Stop P.B. Operations checked
Connection between the Transformer & Switchgear is satisfactory & Bus

12
Ducts are OK.
13 Surrounding area clean and Accessibility confirmed.
15 Transformer cleared for charging Power.

EPC Contractor
Client (Optional)

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LV SG & MCC PRECOMMISSIONING CHECKS
Sl.
No.
1 IR ckecks of the Bus Bars and Control circuit have been checked are OK
Continuity checks of Circuit Breakers wiring have been done and found in
2
order
3 IR checks of the Circuit Breakers verified and OK
*Contact Resistance Test eport to be

Contact Resistance Test on Circuit Breakers have been done, found
4 furnished in the enclosed Report
satisfactory and Recorded.
format.
5 Indications have been chekced and are OK
Voltage Test has been done by applying specified LV Voltage

6 (For LV SWGR. and MCC ), Functional Tests carried out and are
satisfactory
9 The system is ready to be charged to be Commissioned in service
EPC Contractor
Client (Optional)

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LV SWITCHGEAR COMMISSIONING
Sl.
No.
1 Functional checks for close / trip / protection trip completed
Auto / Manual change over between incomer and bus coupler circuit
2
breakers has been tested and are in order
Secondary and primary Injection Tests for CT and CT circuits have been
3
done.
4 CT polarity checks have been done
5 Protective relays have been tested and found in order
6 Operation checks on meters have been done and are OK.
8 Indications are OK.
9 Measurement of incomer voltages and Phase sequence have been done
10 Measurement of bus voltages, phase sequence have been done.
11 Currents after loading have been measured and are in order.
12 Operation check on meters have been carried out.

LV Switch gear and MCC are satisfactorily Commissioned to be
14
kept in service

EPC Contractor
Client (Optional)

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LV MOTORS PRECOMMISSIONING CHECKS
Sl. Check List Items Remarks

No.
Motor No Load run completed satisfactorily in Uncoupled conditions and
1
certified for Commissioning (Electrical) .
Motor coupled to Pump after reconfirming Final alignment * Data to be filled in the alignment
2
reading. sheet.
3 Coupling guards installed.
Lubrication - Lubrication of the Pump is ensured with the correct grade

4
of Lubricant.
Seal flushing fluid filled upto the correct level. N2 pre-charged, if

5
applicable for the flushing plan.
6 Temporary strainer has been installed on the suction line
Piping connected to the Pump have been completed, card board
7
blasted, flushed clean and reintsated
Vessels connected to the Pumps - Internal cleaning carried out and
8 cleared for boxing up. Man hole covers boxed up and tightened with
proper gaskets and hardwares.
Vessel has been flushed clean, if appropriate, cleaned
9
thoroughly with water and water drained
Vessel along with the connected piping has been Leak Tested
10
and approved for further progress
Vessel along with the connected piping has been inertized with
11 N2, a positive pressure of N2 has been maintained until it is
ready to receive the Process fuid.
All Instruments connected to the Pumps and the connected
12 lines are installed, Precommissioning of the Instruments
completed and taken in line
All the Loop checks and Logic Tests of all the Instrumentation
13 Loops connected to the Pump / System have been completed
and certified.
If the Pumps can be run with Water - Water filled in the Vessel
14 NA
connected to the Pump for Load Test of the Pumps.
15 All Punch List points cleared.
The equipment is ready to receive the Process fluid for
16
Commissioning
EPC Contractor
Client (Optional)

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ROTARY EQUIPMENT NO LOAD RUN CONDITION MONITORING REPORT

Tag No/s. Location Form No. Subsystem No.
Sl. Current drawn Temp. Noise Level

Time Volts Vibration HZ / mm/s RPM
No Amperes Deg. C DB
DE NDE
R Y B DE Bearing NDE Bearing DE NDE
Brg. Brg. Frame
Vert. Hor. Axi. Vert. Hor. Axi.

1
1 Mt.
15
2
Mts.
30
3
Mts.
4
1 Hr
1.5
5
Hrs
2
6
Hrs
Performance of the Equipment is satsifactory and cleared for Commissioning in service.
Remarks, if any:
*Maximum allowable limit for vibration is 5 mm/second and bearing temperatures 90 deg. C. Sound level should be less
than 80 DB at a distance of 1 m from the Equipment.
EPC Contractor
Client (Optional)

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1.2 Instrumentation Installations Pre-commissioning
Pre-commissioning activities of Components / Systems of Instrumentation and Mechanical

Disciplines involve Loop checks of Components of all the Systems and communication to the Control
Panel as a core function. Hence SCADA system / DCS needs to be Powered ON after the availability
of LV Power on priority. Pre-commissioning activities SCADA / DCS need to be completed first after
the availability of Power. Availability of SCADA after Pre-commissioning would pave the way for the
progress of Pre-commissioning activities of all the Components and Systems installed in the
Terminal.
Since the various packages installed in the Project need to be Pre-commissioned & Commissioned,
charging Power to their PLC Panels and their Pre-commissioning is the next priority on all the
following counts
 Pre-comm. of System / Package connected to the PLC
 Commissioning (OTP) of System
 Commissioning Process Operations (OTP) having Interlocks with the System
Mechanical Completion of Instrumentation discipline is marked by the Certification of
Completion of the following activities:
 Installation of the Component / Equipment / System as per drawings
 End connections of the Equipment / Component firmly fastened / fixed as per drawings with
correct hardware
 Cables Termination to the Equipment / Component / System completed as per drawings and
Continuity checks carried out
 Ready for Pre-commissioning certified
Pre-Commissioning of Instrumentation discipline should start with SCADA / DCS, followed by PLC
panels of Systems & Packages.
Among the Packages, only Fire & Gas Detection (F&G) system can be classified as purely
Instrumentation oriented. Commissioning of F&G system is also of priority considering that all the Unit
operations of the Terminal and associated equipment carry Interlocks to F&G system and hence
comes next in priority.
 SCADA / DCS & PLC Pre-commissioning & to be certified ready for Commissioning broadly
cover the following major activities:
 Loading of Software
 Functional Tests inherent to the system (SCADA / PLC)
 Communication tests and diagnostics
 Fire & Gas Detection System Pre-commissioning & to be certified ready for Commissioning
broadly cover the following major activities:
 Installation of Panel & Repeater Panel, Detectors, Hooters etc. as per drawings
 Power availability & Redundancy as per Specifications
 Loading of Software
 Communication tests and diagnostics
 Serial link (Ethernet) verification etc.
The Pre-commissioning & Commissioning activities of other Field Instrumentation and Systems shall
be as per Process & Mechanical Disciplines priorities and should follow the sequence of Pre-comm.
& Commissioning the Systems that are dealt with in the following section.

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The Pre-commissioning Check & Test sheets for all the applicable Instrumentation items in the
Terminal are however, furnished under this section.
Commissioning of the Instrumentation forming part of various systems in the Terminal are
accomplished as part of Commissioning procedures (OTP) detailed out in subsequent section under
Commissioning.

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PRECOMMISSIONING - DCS / SCADA (CONTROL SYSTEM) CABINETS

SYSTEM: PREOCESS CABINETS / SERVER CABINETS / OPERATING CONSOLES & PRINTERS
Sl.
No.
Instrument Type - Control System Cabinets (DCS)
1 Precommissioning - System Cecks
1.1 Software version is correct
1.2 Software load successful

1.3 Communication tests / diagnostics are complete
1.4 Manufacturer's specific Tests / Checks are complete
1.5 All modules installed as per the I/O layout drawing
1.6 All serial link connections are complete and verified
1.7 Internal drawings are available within the panels

1.8 Updated serial I/O list is available in the panel
1.9 Printer connections & Performance verified
3 DCS System Cleared for Commissioning

EPC Contractor
Client (Optional)

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PRECOMMISSIONING - PACKAGE PLC SYSTEM

SYSTEM: PREOCESS CABINETS / SERVER CABINETS
Sl.
No.
Instrument Type - Package PLC Cabinets
1 Precommissioning - System Cecks
1.1 Software version is correct
1.2 Software load successful
1.3 Communication tests / diagnostics are complete
1.4 Manufacturer's specific Tests / Checks are complete
1.5 All modules installed as per the I/O layout drawing
1.6 All serial link connections are complete and verified
1.7 Communication with DCS established
1.8 Internal drawings are available within the panels
1.9 Updated serial I/O list is available in the panel
3 PLC System Cleared for Commissioning

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Client (Optional)

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INSTALLATION & PRECOMM. - FIRE & GAS SYSTEM
Sl.
No.
Instrument Type -F & G System
1 Installation & Mounting
Installation of all Panels including the Repeater panel are in
1.1
correct locations as per design & drawings.
1.2 Equipment Cabinets / Panels mounting satisfactory.
1.3 Free access around cabinets is provided
1.4 All unused gland holes are plugged with proper caps
1.5 Access to internal equipment satisfactory
1.6 Suitable for environment
1.7 Door filters installed
1.8 Cable transits/glandplates complete
1.9 All associated cabling complete
1.10 Internal equipment/connections secure and complete
1.11 No external physical damage
1.12 No damage to internal equipment and connections
1.13 Elecrical systems and earth bonding complete
1.14 All Modules installed are identified with proper tags
2 Mains Power
2.1 Redundancy available
2.2 Safety provided
2.3 Distribution correct
3 System Power
3.1 Redundancy available
3.2 Safety provided
3.3 Distribution correct
4 Installation of Detectors & Alarms
All Fire, Smoke, H2 detectors, Gas detectors, Heat detctors and
4.1 Multi sensor detectors installed at their respective locations both
indoors and outdoors as per design & drawings.
Area classifications for all the installations confirmed to be
4.2
correct as per drawings.
5 Out door installations
Falme detectors, Point type Gas detectors, Open path Gas
5.1 detectors, Manual Call points, Hooters are installed as per
design and drawings.
Area classifications for Hooters and Manual Call points -
5.2 Outdoor Weather Proof or Outdoor Explosion Proof confirmed to
be correct as per drawings.
6 Indoor inststallations
Heat detectors, Multi sensor detectors, Smoke detectors, H2
Gas detectors (Battery room), Smoke detectors above false
6.1
ceilings & Response indicators, Hooters and Manual Call points
are installed as per design and drawings.
24
INSTALLATION & PRECOMM. -BEACONS AND SOUNDERS
Sl.
No.
Instrument Type -Beacons & Sounders
1 Instrument correctly tagged
2 Area Classification verified.
3 Installation
3.1 Instrument location verified and is suitable for service
3.2 Instrument securely fastened.
3.3 Free access provided for Operations & Maintenance
3.4 Instrument & accessories are free of damage
3.5 Instrument protected against environment
3.6 Instrument supports are properly fixed and painted
4 Electrical
4.1 Electrical cables installed, terminated and glanded
4.2 Earth bonding completed
4.3 Instrument enclosures fully closed
5 Precommissioning - Cables & Loop Cecks
5.1 Continuity test completed
5.2 Cables interconnections checked
5.3 Instrument loop checked
5.4 Loop number and descriptor verified
5.5 System displays verified
7 Instrument Cleared for Commissioning
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INSTALLATION & PRECOMM. - LEVEL TRANSMITTERS
(GUIDED WAVE RADAR TYPE - FOUNDATION FIELDBUS / HART )
Sl.
No.
3 Instrument calibrated
4 Certified plugs installed in all spare electrical entries
5 Size and end connections are correct
6 Installation
Vessel mounted Instruments are vertical & fastened with proper bolts &
6.2
gaskets and tightened.
6.7 Instrument lagging complete
7 Electrical
8.4 All alarms and Settings verified
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INSTALLATION & PRECOMM. - PRESSURE TRANSMITTERS
(FOUNDATION FIELDBUS / HART )
Sl.
No.
6 Installation
6.2 Instrument securely fastened with proper hardwares as per drawings.

6.4 Isolation & vent / drain valves provided
6.5 Impulse line(s) / knock-out pot(s) correctly installed
7 Impulse Lines
7.1 Impulse line pressure tested, no leakage verified & reinstated.

8 Electrical
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INSTALLATION & PRECOMM. - TEMPERATURE TRANSMITTERS (FOUNDATION FIELD BUS / HART)
Sl.
No.
Instrument Type - TTs (FOUNDATION Fieldbus / HART)

5 Installation
5.2 Instrument securely fastened as per drawings.
5.4 Thermowell correctly installed
6 Electrical
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INSTALLATION & PRECOMM. - ACTUATED VALVES / EMERGENCY SHUTDOWN VALVES
Sl.
No.
Instrument Type - Emergency SDV / BDV

Solenoid valve, limit switches, etc., complies with Hazardous Area
2
Classification
Instrument calibrated & Pre installation functional checks have been
3
completed.
5 Installation
5.1 Instrument location & and bypass arrangement are as per P&ID
5.3 Pneumatic line(s) correctly installed.
5.4 Solenoid, limit switches,etc. correctly installed
Flanges are provided with correct Gaskets & Hardware and tightened to
5.5
the requisite torque.
5.6 Installation position and direction of flow are correct
5.8 Instrument lagging correct
Air accumulators with accessories, if applicable, are installed, tubed and
5.9
supported
6 Electrical
6.3 Solenoid, limit switches, etc., enclosures fully closed
7 Precommissioning - Cables & Loop Checks
7.1 Cables Continuity test completed
Shutdown/blowdown valve loop checked (continuity & signal availability
7.3
check only)
7.4 Air failure position checked & OK.
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INSTALLATION & PRECOMM. -SAFETY RELIEF VALVES / PRVs / RUPTURE DISCS
Sl.
No.
Instrument Type - Safety Relief Valve, PRV & Rupture Discs

2 Adjustment mechanism is wired sealed.
5 Installation
5.1 Instrument location & and bypass arrangement are as per P&ID
5.3 Pneumatic line(s) correctly installed, If applicable
Flanges are provided with correct Gaskets & Hardware and tightened to
5.4
the requisite torque.
5.5 Installation position and direction of flow are correct
5.7 PG's/ Pressure switches installed in tell-tail hole of repture disc
6 Precommissioning
6.1 Setpoint is verified
6.2 Valve Control, Downstream or Upstream is confirmed.
Satisfactory Control / Regulation of Pressure verified by increasing the
6.3
Pressure up to the Set point / by Simulation - as applicable.
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INSTALLATION & PRECOMM. - EARTHING - FIELD INSTRUMENTATION & CONTROL ROOM
Sl.
No.
1 Earthing Field - Installation
1.1 Visual inspection of system for mechanical damage done & OK.
Enclosures of all local panels, Junction boxes, Supports, etc. are
1.2
connected to plant earth
1.3 All Instruments are connected to instrument earth system
1.4 Earthing conductors and fixings are properly installed
1.5 Earth wire connections are tight
1.6 Fixing bolts are tight and in accordance with the drawings
1.7 Washers are installed in accordance with the drawings

1.8 Earth boss shrouds are fitted to all terminations
2.0 Earthing Control Room/Auxiullary Room - Installation
IS earth system (ISE) is installed for intrinsically safe circuits using
2.1
passive barriers
2.2 Separate earthing points are provided for the intrinsically safe earthing
Clean earth system (SE) installed for non - IS circuits (Screens,

2.3
computer earth, signal earth)
2.4 Safety grounding (SGE) installed for panel/cabinets body earth
3 Precommissioning Checks
3.1 Continuity check completed on all earth connections
5 Earthing System Cleared for Commissioning
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1.3 Packages Pre-commissioning
Mechanical Completion of Packages are marked by the Certification of Completion of the following
activities:
 All Static equipment and components of the Package are installed with their internals as per
drawings
 Rotary equipment of the Package like Pumps, Compressors etc. installed along with their Drivers
(Motors)
 Cables termination completed for the Motors
 Piping connected to the Equipment completed, Flushed and lines reinstated
 Mechanical completion certified for the Package
Pre-commissioning & Commissioning of Packages should be carried out as per priorities and reasons
mentioned below.
 Cooling Water Systems - There are two Cooling water systems in the Terminal – one for HVAC
and the other for the Process. Their importance are as presented below:
 HVAC Cooling water system – SCADA / DCS and PLC panels are installed in the Control
room. These installations necessarily need to be in cool & controlled temperatures (20-25 deg.
C) on being Powered ON for onward Pre-commissioning and Commissioning. Hence HVAC
Cooling water system for HVAC is of prime priority, particularly considering the harsh site
environment where the atmospheric temperature may go up to 45 deg. C in summer.
 Process Cooling water system – Instrument Air is the prime requirement for Pre-
commissioning & Commissioning all the Instruments and hence all the Systems and Packages
of the Terminal. Instrument Air requires cooling water supplied by the Process Cooling water
system for the Aftercoolers, at the inlet of N2/IA Package. Hence Process Cooling water
system comes next in priority.
 Cooling water systems Pre-commissioning & to be certified ready for Commissioning broadly
cover the following major activities:
 Cooling Tower basin water intake & Level control
 ID fans run & confirm vibration within limits
 Motors of Cooling water circulation pumps No load run & certification
 Instrumentation Loop checks completion
 Air Compressor – is the source for Compressed Air supply to the N2 & IA package. Instrument
Air is the prime requirement for Pre-commissioning & Commissioning all the Instruments and
hence all the Systems and Packages of the Terminal. Hence Air Compressor is of priority.
 Air Compressor Pre-commissioning & to be certified ready for Commissioning broadly cover
the following major activities:
 Lubrication of Compressor and Coolant filling
 Direction of rotation verification and No load run of Compressor Motor
 Direction of rotation verification and run check of Air cooler and Oil cooler fans
 N2 & IA Package – Importance of Instrument Air for commencing the Commissioning activities of
the Terminal Systems and Packages is well known and mentioned above. Since N2 and
Instrument Air come as an integrated system, N2 & IA Package is the next in priority.

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 N2 & IA Package Pre-commissioning & to be certified ready for Commissioning broadly cover
the following major activities:
 Circulation of Cooling water through the After coolers verification
 Carbone Molecular sieves filling in PSA vessels
 Activated Alumina filling in IA Drier vessels
 Leak test of the Package
 HVAC Chilled water System – Carries Priority importance since without Chilled water, HVAC
cannot be commissioned and the importance of HVAC for the Control room is mentioned above.
 HVAC Chilled water System Pre-commissioning & to be certified ready for Commissioning
 Lubricating oil for the Compressor
 Direction of rotation check of the Compressor Motor & No load run of Motor
 Cooling water Supply & Return lines – confirm readiness
 Chilled water piping circuit - confirm readiness
 Chilled water Primary & Secondary Pumps Motors – Direction checks and No load runs etc.
The Pre-commissioning & Commissioning activities of the other Packages may be as per the
sequence in which Pre-commissioning Check & Test sheets are furnished. However the sequence of
Pre-commissioning these packages may be shuffled based on the sequence in which they are being
commissioned.
The Check & Test sheets for the Packages are specific for each Package and the Pre-commissioning
Check & Test sheets for all the applicable Packages in the Terminal are furnished under this section.
Commissioning of the Packages carry the same priority as Pre-commissioning of these Packages
and Commissioning of the priority Packages should be completed immediately following Pre-
commissioning. Commissioning Procedures (OTP) for all the Packages are detailed out in
subsequent section under Commissioning.

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COOLING WATER SYSTEM - PROCESS AND HVAC - PRECOMMISSIONING CHECKS
Tag No/s. : CT-M501, PM-5069A,B,C,D Subsystem
Location From No.
CT-811-001, CWP-811-03A,B, CWP-811-04 A,B No.
Sl.
No.
1 Cooling Tower Fans Precommissioning
Cables terminated to the Motor of CT Fans, IR values checked, direction

1.1
verified,coupling / Drive belts & guard installed.
Lubrication of the Drive assembly & Bearings of Fans have been done with
1.2 the right grade of lubricant / Correct lubricant charged in the Lubrication
system
All Instruments connected to the equipment and the connected lines are
1.3
installed.
Precommissioning of all Instruments connected to the CT Fans completed
1.4
and taken in line
All the Loop checks and Logic Tests of all the Instrumentation Loops
1.5
connected to the System have been completed and certified.
1.6 Fans Vibration switch functionality confirmed by manual activation.
1.7 CT Fans run for a sustained duration (min. 2 hours)
CT Fans Load Test Run data are satisfctory. Temperatures of Bearings *Results to be furnished as
1.8
& Vibration levels are within acceptable limits. per the enclosed format.
The fan blades run without the Blades touching the Planum and the
1.9
preformance is satisfactory.
1.10 All Punch List points cleared.
2 Cooling Water circulation Pumps Precommissioning

Motor No Load run completed satisfactorily in Uncoupled conditions and
2.1
certified for Commissioning (Electrical) .
* Data to be filled in the
2.2 Motors coupled to Pumps after reconfirming Final alignment reading.
alignment sheet.
2.3 Coupling guards installed.
Lubrication - Lubrication of the Pumps is ensured with the correct grade of
2.4
Lubricant.
2.5 Seal flushing lines are in position as per Flushing Plan.
2.6 Suction Strainers for the Pumps are clean and in position.
Piping connected to the Pump have been completed, card board blasted,
2.7
flushed clean and reintsated
Cooling Tower Sump - Internal cleaning carried out and Water filled to
2.8
sufficient level to start the Pump/s on recirculation.
Piping connected to the C.T. has been Flushed, Reinstated and approved for
2.9
further progress
All Instruments connected to the Pumps and the connected lines are
2.10
installed, Precommissioning of the Instruments completed and taken in line
34
COOLING WATER SYSTEM - PROCESS AND HVAC - PRECOMMISSIONING CHECKS
Tag No/s. : CT-M501, PM-5069A,B,C,D Subsystem
Location From No.
CT-811-001, CWP-811-03A,B, CWP-811-04 A,B No.
Sl.
No.
Cooling
All the Loop checks Tower
and Logic Fans
Tests Precommissioning
of all the Instrumentation Loops
2.11
connected to the Pump / System have been completed and certified.
Cooling Tower Level Control of the Basin has been tested & Control is OK.
Water intake valve (Ball Float) to the Basin Closes fully when the Cooling
2.12
Tower Basin is full ; Opens when the Level goes down, letting Intake of
water.
2.13 All Punch List points cleared.
3.0 The Cooling water system is ready for Commissioning
Notes: Please refer Operational Test Procedure (OTP) for Process and HVAC Cooling water Systems for Start
up checks, Load Run of Cooling water Recirculation Pumps & all associated ancillaries and Commissioning
of the Systems into Operational Service.
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AIR COMPRESSOR PRECOMMISSIONING CHECKS
No
1 Inlet Air Filter is installed and is clean
Coolant of the correct grade is filled upto the requisite level for bearing
2
lubrication
The Drive motor cables terminated, IR values of Motor Windings and
3
cables checked.
Direction of rotation of the Drive motor confirmed to be correct. This
should be done with Motor decoupled from the Compressor and
4 Tested in isolation. The Motor should be coupled back to the
Compressor without disturbing the Alignment and correct Terminal
connections .
No Load run of the Drive Motor has been completed with the Motor
5 decoupled from the Compressor and the parameters are acceptable
(Electrical).
Compressor drive Motor bearings lubricated with the correct grade of
6
lubricant
Air Cooler Motor (with coupling Fan assembly) cables terminated and IR
7
values checked.
Direction of rotation of the Air cooler Motor confirmed to be correct. May
8
done in-situ and corrected, if required.
Oil Cooler Motor (with coupling Fan assembly) cables terminated and IR
9
values checked.
Direction of rotation of the Oil cooler Motor confirmed to be correct. May
10
done in-situ and corrected, if required.
Starter & Controller Panel installed, Powered ON and the
11 Precommissioning checks as applicable for PLC panel completed
(Instruments )
12 Coolant Filer is confirmed to be in position
All other components of the Package have been checked as per Vendor
13
P&Id and are installed in order.
Confirmation obtained from the vendor that the entire circulation loop of
the Package - consisting of Equipment & Piping - has been Hydrotested,
14
precleaned, flushed and Leak tested at shop. All Instruments that are part
of the Package are calibrated at shop.
The Vibration Pads on which the Compressor Assembly is mounted as
15
Factory installed are undamaged and intact.
17 The Air Compressor is ready for Commissioning
Notes: Please refer Operational Test Procedure (OTP) for Air Compressor for Start up checks.

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NITROGEN GENERATION AND INSTRUMENT AIR PACKAGE PRECOMMISSIONING CHECKS

Sl.
No.
Common Installations for N2 and Instrument Air
After Coolers on Air Compressor discharge lines inlet to Air receiver
installed in position.
Air lines from Compressor upto upstream of the Coolers flushed clean
with Air with Coolers isolated. The lines boxed up to the Coolers after
flushing.
Coolig water - Supply and Return lines flushed with water with Coolers
isolated. The lines boxed up to the Coolers after flushing.
3 Filters upstream of the Air receiver - all 3 Filter elements are
confirmed installed.
Nitrogen Generation
Carbon Molecular Sieves have been filled in both the PSA vessels as
per vendor specs. and Covers boxed up with final gaskets and
hardwares.
Instrument Air Pot, Regeneration vent Silencer, N2 surge vessel, N2
storage tank and other static equipment of the Skid are installed in
position undisturbed.
All Feed and Regeneration Solenoid valves are in position and tested
for performance.
O2 Analyzer and Dew point meter - calibrations confirmed.
Panel for N2 generation and Instrument Air Powered ON and
Precommissioning checks applicable for PLC panels completed
(Instruments ).
The complete N2 generation package from the Inlet of Compressed Air
upto the outet of Surge vessel has been Leak tested and found
satisfactory as per the Check & Test sheet Leak Test.
IA Unit
Activated Alumina have been filled in both the Drier vessels as per
vendor specs. and Covers boxed up with final gaskets and hardwares.
Instrument Air Pot, Regeneration vent Silencer, Instrument Air receiver

and other static equipment of the Skid are installed in position
undisturbed.
IA Unit from the Compressed Air Air outlet line from the Air receiver
upto the Inlet of the IA receiver has been Leak tested and found
satisfactory as per the Check & Test sheet Leak Test.
15 The N2 Generation & IA Package are ready for Commissioning
Notes: Please refer Operational Test Procedure (OTP) for N2 Generation & IA package for Start up checks.

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CHILLED WATER SYSTEM (HVAC) PRECOMMISSIONING CHECKS
Subsystem
Location From No.
No.
Sl.
No.
Chiller Package
Correct grade of oil filled in the Compressor to prevent Dry run (without oil) of the
1.0
Screw Compressor
1.1 Oil separator level made upto the correclevel with the correct grade of oil
1.2 Refrigerant level made up in the Evaporator up to the correct level
The Drive motor cables terminated, IR values of Motor Windings and cables
1.3
checked (Electrical).
Direction of rotation of the Drive motor confirmed to be correct. This should be
done with Motor decoupled from the Compressor and Tested in isolation.
1.4
The Motor should be coupled back to the Compressor without disturbing
the Alignment and correct Terminal connections .
Compressor drive Motor bearings lubricated with the correct grade of lubricant
1.5
(Electrical ).
No Load run of the Drive Motor has been completed with the Motor decoupled
1.6
from the Compressor and the parameters are acceptable (Electrical).
All equipment, Piping Valves and Instruments of the Chiller Package skid
1.7
are in place and undisturbed
Confirmation obtained from the vendor that the entire circulation loop of the
Package - consisting of Equipment & Piping - has been Hydrotested, precleaned,
1.8
flushed and Leak tested at shop. All Instruments that are part of the Package are
calibrated at shop.
Cooling Water Inlet line from the Cooling water pumps discharge line up to the
Condenser and Return line from the Condenser to the Cooling Tower have been
1.9
flushed clean (after isolating the Inlet & Outlet of the Condenser ) and
Reinstated.
Package Panel installed, Powered ON and the Precommissioning checks as
1.10
applicable for PLC panel completed (Instruments ).
2.0 Chilled Water System - Receipt, Supply and Return of of CHW
CHWR line piping from the discharge of Primary Pumps (CHP-811-01 A/B) upto
the Inlet of the Chiller Package and CHWS line piping from the Chiller Package up
2.1 to the Seondary Pumps CHP-811-02 A/B have been flushed clean (after
isolating the Inlet & Outlet of the Evaporator ). Lines Reinstated and Leak
tested.
CHWS lines from the dishcrage of Secondary Pumps CHP-811-02 A/B up to the
Inlet points of individual HVAC users and their return CHWR lines have been
2.2
flushed clean (after isolating the Inlet & Outlet of the end users). Lines
Reinstated and Leak tested.
CHW Primary and Secondary pumps Motors cables Termination done, IR values *Data to be filled in Motor
checked and directions verified. Motors bearings Lubrication done with the correct No Load Run Condition
2.3
garde of Lubricant/s. Motors No load runs completed and parameters are Monitoring Report for all
acceptable (Electrical) the Motors.
Final Alignments of CHW Primary and Secondary Pumps to their resepective
motors completed, Motors coupled to pumps and coupling guards installed.
2.4 alignment sheets for all the
Suction strainers of all the pumps are installed. Correct grades of Lubricant/s filled
Pumps.
up to the correct level for all the Pumps.
38
CHILLED WATER SYSTEM (HVAC) PRECOMMISSIONING CHECKS
Subsystem
Location From No.
No.
Sl.
No.
Chiller
All Instruments - TG,PG etc. on the PupmsPackage
suction and discharge lines have been
2.5
calibrated and installed (Instruments).
CHW Primary and Secondary Pumps Run Test to be carried out during
2.6
Commissioning of CHW Package & System
3.0 The Chilled Water System (HVAC) is ready for Commissoning.

Notes: Please refer Operational Test Procedure (OTP) for Chilled water system of HVAC for Start up
checks.
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39
CHILLED WATER SYSTEM (PROCESS) PRECOMMISSIONING CHECKS
Subsystem
Location From No.
No.
Sl.
No.
Chiller Package
Correct grade of oil filled in the Compressor to prevent Dry run (without oil) of the
1.0
Screw Compressor
1.1 Oil separator level made upto the correclevel with the correct grade of oil
1.2 Refrigerant level made up in the Evaporator up to the correct level
The Drive motor cables terminated, IR values of Motor Windings and cables
1.3
checked (Electrical).
Direction of rotation of the Drive motor confirmed to be correct. This should be
done with Motor decoupled from the Compressor and Tested in isolation.
1.4
The Motor should be coupled back to the Compressor without disturbing
the Alignment and correct Terminal connections .
Compressor drive Motor bearings lubricated with the correct grade of lubricant
1.5
(Electrical ).
No Load run of the Drive Motor has been completed with the Motor decoupled
1.6
from the Compressor and the parameters are acceptable (Electrical).
All equipment, Piping Valves and Instruments of the Chiller Package skid
1.7
are in place and undisturbed
Confirmation obtained from the vendor that the entire circulation loop of the
Package - consisting of Equipment & Piping - has been Hydrotested, precleaned,
1.8
flushed and Leak tested at shop. All Instruments that are part of the Package are
calibrated at shop.
Cooling Water Inlet line from the Cooling water pumps discharge line up to the
Condenser and Return line from the Condenser to the Cooling Tower have been
1.9
flushed clean (after isolating the Inlet & Outlet of the Condenser ) and
Reinstated.
Package Panel installed, Powered ON and the Precommissioning checks as
1.10
applicable for PLC panel completed (Instruments ).
2.0 Chilled Water System - Receipt, Supply and Return of of CHW
Hot Well and Cold Well have been cleaned thoroughly from inside. The outlet
2.1 piping from Hotwell & Cold well upto the their Pumps suction, flushed clean,
CHWR line piping from the discharge of Hot Well Pumps (P-M5040 A/B) upto the
Inlet of the Chiller Package and CHWS line piping from the Chiller Package up to
2.2
the Cold Well have been flushed clean (after isolating the Inlet & Outlet of the
Evaporator ). Lines Reinstated and Leak tested.
CHWS lines from the dishcrage of Cold well Pumps P-M5045 A/B/C/D up to the
Inlet points of individual users - viz. VAM Chiller and Vent tank , Styrene Chiller
2.3 and Vent tank and Process Block - and their return CHWR lines have been
flushed clean (after isolating the Inlet & Outlet of the end users). Lines
Hot well and Cold well pumps Motors cables Termination done, IR values checked *Data to be filled in Motor
and directions verified. Motors bearings Lubrication done with the correct garde of No Load Run Condition
2.4
Lubricant/s. Motors No load runs completed and parameters are acceptable Monitoring Report for all
(Electrical) the Motors.
40
CHILLED WATER SYSTEM (PROCESS) PRECOMMISSIONING CHECKS
Subsystem
Location From No.
No.
Sl.
No.
Final Alignments of Hot well and Chiller
Cold wellPackage
Pumps to their resepective motors
completed, Motors coupled to pumps and coupling guards installed. Suction
2.5 alignment sheets for all the
strainers of all the pumps are installed. Correct grades of Lubricant/s filled up to
Pumps.
the correct level for all the Pumps.
All Instruments - TG,PG etc. on the Pupms suction and discharge lines have been
2.6
calibrated and installed (Instruments).
Water Run of the Cold Well and Hotwell Pumps with Recirculation of Water -
3.0
Stepwise Procedure:
3.1 Fill up water in both Hot well as well as Cold Well
Make temporary connections (with hoses) from the discharge headers of Hot well
and Cold well pumps to provide recycle back to the respective tanks. The extreme
3.2
ends of individual headers where blind flanges are provided are convenient points
to provide temporary connections for recycle back to the respective tanks.
Close the Isolation valves at the destination ends of the discharge of all the
3.3 Pumps so that the pumps can only discharge water to their respective
tanks through the temporary recycle connections made.
Cold well and Hot well pumps are ready for Water run. Water Run may be
3.4
carried out for One Cold well Pump and one Hot well pump at a time.
*Data to be filled in Rotary
Start 1 Hot Well pump (P-M5040 A) and 1 Cold well Pump (P-M5045 A) with Equipment Load Run
3.5
recirculation of water back to their tanks. Record the Operating parameters. Monitoring Reports for the
Pumps.
After a load run of around 2 hours, Close the discharge valves and stop the
3.6
Pumps.
3.7 Repeat the above and carry out Water runs for (P-M5040 B) and (P-M5045 B) "
Repeat the above for the other 2 Cold well pumps (P-M5045 C) and (P-M5045D),
3.8
1 pump at a time each for a duration of around 2 hours. "
After successful Water Runs of all the Pumps, remove the temporary recycle line
3.9 connection and reinstate the lines to Operating positions. Clean the Suction
strainers of all the Pumps and reinstall them.
3.10 The Cold well and Hot well pumps are ready to be Commissioned in Service.
4.0 The Chilled Water Package (Process) is ready for Commissoning

Notes: Please refer Operational Test Procedure (OTP) for Chilled water system for Start up checks.

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JOCKEY FIRE WATER PUMPS PRECOMMISSIONING CHECKS
Subsystem
Tag No/s. : 617-JP-01, 02 Location From No.
No.
Sl.
No.
*Data to be filled in Motor No
Motor No load Run completed satisfactorily with Jockey pump decoupled and
1 Load Run Condition
certified.
Monitoring Report.
Motor to Pump Final Alignment done and Motor coupled to the Pump. * Data to be filled in the
2
Coupling guard installed. alignment sheet.
Lubrication of Pump - Lubrication of the Pump is ensured with the correct
3
grade of Lubricant.
4
Fire Water tank Mechancal completion certified; Level and other instruments
5 on the tank are kept in operating position; Internal cleaning done, Man hole
cover boxed up and Water filled in the Fire Water tank.
7
Water Run of the Jockey Pump with Recirculation of Water - Stepwise
8
Procedure:
Keep the isolation valves of all the pumps connecting to the discharge
header Closed - All 300 NB valves of Diesel pumps and 80 NB valves of
8.1
Jockey pumps to be kept Closed including of the Jockey pump that is
to be tested with Water Run.
Keep Only for the Jockey pump that is to be tested with Water Run -
the discharge isolation valve connecting the Test header Open (80 NB
valve for Jockey pump Open) . Keep all the Other isolation valves
8.2
connecting to the Test header Closed - 250 NB isolation valves and 80
NB isolation valves of Other pumps connecting to the Test header to
be kept closed.
Open one of the Outlet valves of the Tank and open the drain valve (50NB)
on the suction header of Pumps. Check if water comes with sufficient
8.3 pressure (proportionate to the head in the Tank) and qunatity to ensure that
the Tank outlet valve and the line do not have blind gasket / obstruction.
Close the Tank outlet valve and drain the suction header.
Reppeat the same after opening the other Tank outlet valve to confirm that
8.4 there is no blind gasket or obstruction through the other valve also. The
above would confirm that the Suction header to the Pumps is clear.
Keep both the Tank outlet valves Open. Open the Suction isolation valve of
8.5 the pump to be tested. Keep the discharge valve of the pump free enough to
be opened quickly on starting the pump.
8.6 Open the test header retcycle valve to the Tank.
42
JOCKEY FIRE WATER PUMPS PRECOMMISSIONING CHECKS
Subsystem
Tag No/s. : 617-JP-01, 02 Location From No.
No.
Sl.
No.
*Data to be filled in Motor No
Start
MotortheNo Jockey
load RunPump to be satisfactorily
completed tested, Openwith
theJockey
discharge
pumpvalve of theand
decoupled
Load Run Condition
pump enough to maintain the Operating Pressure of the header in
certified.
*Data to be Report.
Monitoring filled in Rotary
service at 11.5 Kg / cm2 (170 PSI) with reciculation of water back to the
8.7 Equipment Load Run
FW Tank. Record the Flow meter reading on the recycle line and
Monitoring Report.
Record Operating parameters. The flow should be not less than 240
gpm (54 m3 / hr) at the above pressure.
After a load run of around 2 hours, Close the discharge valve and stop the
8.8
Pump.
Close the Suction isolation of the Pump that has been tested, Clean the
8.9 Suction strainer and reinstall and keep the Pump to be ready for
service.
8.10 Repeat the above steps for test run of other Jockey pump.
Make necessary corrections for anamolies observed during the Test run of
8.11 the individual pumps and attend to leakages etc., if any observed dring the
Test.
If both the Jockey pumps are satisfactorily tested, the Run Test of the
8.12
Jockey Fire Water pumps are completed satisfacotrily.
After the Test run of the Jockey Pumps and all the Diesel engine driven FW
pumps are completed, keep all the Tank outlet valves, Suction and
8.13 discharge valves of all the Pumps Open with all the Instruments on the Fire
water circuit taken in line ready for tests on the Fire water distribution as per
logic.
The Diesel Engine driven Fire Water pumps are ready to be

9
Commissioned in Service.
EPC Contractor
Client (Optional)

[email protected]
43
MAIN DIESEL ENGINE DRIVEN FIRE WATER PUMPS PRECOMMISSIONING CHECKS
Subsystem
Tag No/s. : 617-FP-01, 02, 03, 04 Location From No.
No.
Sl.
No.
1 Diesel Engine (driver) Mechanical completion certified.
2 Disesel tank cleaned dry and Diesel filled

Lubrications of the Diesel Engine- Lubrication of the bearings done.
3 Lubrication system of the Diesel engine commissioned as per vendor
documents and recommendations.
No load run of the Diesel Engine completed satisfactorily with the pump *Data to be filled in Rotary
4 decoupled. Vibration and Temperature parameters are within limits and Equipment Load Run
certified. Condition Monitoring Report.
Diesel Engine to Pump Final Alignment done and Engine coupled to the * Data to be filled in the
5
Pump. Coupling guard installed. alignment sheet.
Lubrication of Pump - Lubrication of the Pump bearings is ensured with the
6
correct grade of Lubricant.
7
Fire Water tank Mechancal completion certified; Level and other instruments
8 on the tank are kept in operating position; Internal cleaning done, Man hole
cover boxed up and Water filled in the Fire Water tank.
10
Water Run of the Diesel Pump with Recirculation of Water - Stepwise
11
Procedure:
Keep the isolation valves of all the pumps connecting to the discharge
header Closed - All 300 NB valves of Diesel pumps and 80 NB valves of
11.1
Jockey pumps to be kept Closed including of the pump that is to be
tested with Water Run.
Keep Only for the pump that is to be tested with Water Run - the
discharge isolation valve connecting the Test header Open (250 NB
valve for Diesel engine driven pump Open) . Keep all the Other
11.2
isolation valves connecting to the Test header Closed - 250 NB
isolation valves and 80 NB isolation valves of Other pumps connecting
to the Test header to be kept closed.
Open one of the Outlet valves of the Tank and open the drain valve (50NB)
on the suction header of Pumps. Check if water comes with sufficient
11.3 pressure (proportionate to the head in the Tank) and qunatity to ensure that
the Tank outlet valve and the line do not have blind gasket / obstruction.
Close the Tank outlet valve and drain the suction header.
Reppeat the same after opening the other Tank outlet valve to confirm that
11.4 there is no blind gasket or obstruction through the other valve also. The
above would confirm that the Suction header to the Pumps is clear.
44
MAIN DIESEL ENGINE DRIVEN FIRE WATER PUMPS PRECOMMISSIONING CHECKS
Subsystem
Tag No/s. : 617-FP-01, 02, 03, 04 Location From No.
No.
Sl.
No.
Diesel Engine
Keep both the (driver) Mechanical
Tank outlet completion
valves Open. Opencertified.
the Suction isolation valve of
11.5 the pump to be tested. Keep the discharge valve of the pump free enough to
be opened quickly on starting the pump.
11.6 Open the test header retcycle valve to the Tank.

Start the Diesel engine FW pump to be tested, Open the discharge
valve of the pump enough to maintain the Operating Pressure of the
*Data to be filled in Rotary
header in service at 11.5 Kg / cm2 (170 PSI) with reciculation of water
11.7 Equipment Load Run
back to the FW Tank. Record the Flow meter reading on the recycle line
Monitoring Report.
and Record Operating parameters. The flow should be not less than
400 gpm (91 m3 / hr) at the above pressure.
After a load run of around 2 hours, Close the discharge valve and stop the
11.8
Pump.
Close the Suction isolation of the Pump that has been tested, Clean the
11.9 Suction strainer and reinstall and keep the Pump to be ready for
service.
Repeat the above steps for test run of other Diesel Engine driven
11.10
pumps, one after another.
Make necessary corrections for anamolies observed during the Test run of
11.11 the individual pumps and attend to leakages etc., if any observed dring the
Test.
If all the Diesel driven pumps are satisfactorily tested, the Run Test of
11.12 the Diesel Engine driven Fire Water pumps are completed
satisfacotrily.
After the Test run of all the Diesel Engine driven FW pumps and both the
Jockey Pumps are completed, keep all the Tank outlet valves, Suction and
11.13 discharge valves of all the Pumps Open with all the Instruments on the Fire
water circuit taken in line ready for tests on the Fire water distribution as per
logic.
The Diesel Engine driven Fire Water pumps are ready to be

12
Commissioned in Service.
EPC Contractor
Client (Optional)

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45
THERMIC FLUID SYSTEM (TERMINAL) PRECOMMISSIONING CHECKS
Subsystem
Tag No/s. : HRT-06 (HSD) Location From No.
No.
Sl.
No.
1 TF storage & Supply
1.1 TF Storage Dump vessel T-TF-004 thoroughly cleaned dry from inside
TF-charging pump PTF-002 and Motor M-TF-003 installed and Final
1.2
alignment done.
M-TF-003, cables terminated, IR values checked, Motor No Load run
*Results to be furnished as
1.3 completed satisfactorily in Uncoupled conditions and certified for
per the enclosed format.
Commissioning (Electrical) .
1.4 Motor coupled to pump and coupling guard installed.
TF De-Aeration cum Expansion tank T-TF-001 thouroughly cleaned dry from
1.5
inside
The piping connected to the system - TF charging line to Expansion tank,
Outlet line of Expansion tank feeding the suction of TF circulation pumps P-
TF-006 A &B, Discharge lines of circulation pumps to the Common header
1.6 and the individual lines from the header to the inlet to the Coils of Fired
Heaters E-TF-008 A & B - Flushed clean, leak tested and all Instruments,
Vales, Strainers etc. installed on the lines as per P&ID and Piping insulation
done as per specs.
TF-Circulation pumps PTF-006 A/B and their Motors M-TF-005 A/B installed *Results to be furnished as
1.7
and Final alignments done. per the enclosed format.
M-TF-005 A/B, cables terminated, IR values checked, Motors No Load runs
1.8 completed satisfactorily in Uncoupled conditions and certified for
Commissioning (Electrical) .
2.0 Fire Heaters
Fire Heaters E-TF-008A / B are installed with their Burners Br-HSD-007 A / B
2.1
and Insulation done as specs.
Heating coil of Thermic fluid - Hydrotest done (at vendor's shop) and
2.2
certified. The coil flushed clean and dry after Hydrotest.
Control Panel for the Package installed, cables terminated and Pre-
2.3
commissioning checks carried out as applicable for PLC panels.
Burner Management System (BMS) for the burners of E-TF-008A / B
2.4
have been Functional tested and certified (Instruments).
Common Flue gas Chimney for both the Fired Heaters C-EG-011 installed
2.5 and Verticality checked with plumb line. The rain hood is installed on top of
the Chimney.
Foundation bolts of the Chimney tightened with a torque wrench up to the
2.6
requisite torque.
Flue gas dampers on the Flue gas lines of both the Fired heaters E-TF-008A
2.7 / B are installed with their limit switches. The dampers shaft end bearings
have been greased and dampers operate freely.
3 Fuel Oil storage & Supply to Burners
3.1 Fuel oil Service Tank T-HSD-012 roughly cleaned dry from inside
The piping connected to the system - Feed Fuel lines to the Burners of E-TF-
008A / B (includinng the Return lines from the Burners) - Flushed clean, leak
3.2
tested and all Instruments, Vales, Strainers etc. installed on the lines as per
P&ID.
46
Subsystem
No.
Sl.
No.
4.0 Thermic Fluid
TFlines to Process
storage & Return lines
& Supply
Thermic Fluid Piping from the Outlet of the Coils of both the Heaters up to
the Terminal End users - T-BTM-001 & 2 and Return lines from them -
4.1
Flushed clean, leak tested and all Instruments, Vales etc. installed on the
lines as per P&ID and Piping insulation done as per specs.
5.0
connected to the System have been completed and certified (Instruments ).
Stepwise procedure - TF Charging, Pump Test Run & Interlocks

5.0
(Pl. Refer Marked up drawing)
The above checks / tests have been concluded and Thermic Fluid can be
5.1
charged into the system.
Confirm that all nterlocks of the circuit are healthy and in line. Keep the
5.2 Charging Pump P-TF-002 and TF circulation Pumps P-TF-006 A & B
Electrically Energized.
5.3 Confirm that the drain valve of Dump vessel T-TF-004 is fully closed.
Keep the Outlet valve of the De-Aeration cum Expansion Tank T-TF-001
feeding the TF circulation pumps P-TF-006 A &B, Closed. Also keep the
5.4
Drain valve of the Expansion Tank T-TF-001 drining to the Dump vessel T-
TF-004 Closed.
Connect the charging hose to the TF - Therminal-55- Barrel and open the
5.5
globe valve connecting the TF barrel.
keep the Barrel at a slightly elevated position from the Dump vessel and
open the Inlet Globe valve to the Dump vessel. Let the Thermic fluid fill by
5.6 gravity into the Dump vessel. Keep a watch on the level of the Dump
vessel LI-1351-03 and close the inlet valve to the Dump vessel at high
level before it sarts overflowing.
At around 50% Level of the Expansion vessel T-TF-001 Close the Inlet valve
5.7
to the Storage vessel T-TF-004 and stop intake from the Barrel.
Confirm that the Suction of TF Charging pum PTF-002 is flooded, open its
discharge valve and start the Charging Pump P-TF-002. Keep monitoring
5.8
of the Level Indicator LI-1351-02 of the Expansion cum De-Aerator
vessel T-TF-001.
Monitor the performance of the Pump PTF-002 for Vibrations of &

5.9
Temperatures of Pump & Motor and the Current drawn.
At around 20-25% Level of the Expansion vessel - Just above the Low
level trip of TF circulation Pumps of the Expansion vessel - Stop the
5.10
TF Charging Pump P-TF-002 . Open the Outlet of the vessel and Suction
valves of TF circulation pump P-TF-006 A / B.
47
Subsystem
No.
Sl.
No.
Keep the following isolation TF valves
storageClosed:
& Supplyi) Inlet to the coils of both
the Fired Heaters E-TF-008A (80 NB & 25 NB bypass valve in parallel) ii)
Inlet to the coils of both the Fired Heaters E-TF-008B (80 NB & 25 NB
5.11
bypass valve in parallel) iii) Battery limit isolation valve feeding the End
users T-BTM-01 & 02 iv) Battery limit isolation valve of the Return line
from the End users T-BTM-01 & 02.
Make a temporary connection (hose) preferably from downstream of

the Flow meter FM-TF-016 to the De-Aeration cum Expansion Tank T-
TF-001. If it is difficult to give the temporary connection downstream of
FM-TF-016, the temporary connection may be made from the blind
5.12 flange of the Common header on the discharge of circulation pumps P-
TF-006 A/B. If the connection is made from the common header, the
discharge flow from the circulation pumps cannot be measured or
monitored. If temporary connection is through hose, ensure that the
hose is firmly tied and secured in position.
Start one of the pumps (P-TF-006 A) and open its discharge valve. Monitor if
5.13
there is circulation of TF back to the Expansion vessel.
At low level of the Expansion vesel, confirm that there is Alarm and at
5.14 very low level, the circulation pump (P-TF-006 A) trips due to activation
of Level switches LS-1351-05 and 06.
If the Low level Alarm of Expansion vessel or trip of the Circulation

pump does not occur, probably due to the higher level in the
Expansion vessel than the Set point, crack open the drain valve of the
5.15
Expansion vessel to drain some TF back to the Storage / Dump vessel (T-TF-
004). Confirm Alarm and at very low level, the circulation pump (P-TF-
006 A) trips due to activation of Level switches LS-1351-05 and 06.
If the above Interlocks are healthy, open the Inlet valve to the Storage vessel
5.16 T-TF-004 and restart intake of TF from the Barrel to the TF Storage / Dump
vessel until the level is around 65-70% in the Storage vessel.
Restart the TF Charging Pump P-TF-002 and fill the De-Aeration / Expansion
5.17
vessel, with vigilant monitoring of the Expansion tank level.
At High level of the De-Aerator cum Expansion vessel T-TF-001,

5.18 confirm that the Charging Pump trips by activation of the High level
Limit Switch of T-TF-001.
Close the isolation valve inlet to the Storage / Dump vessel. Stop taking TF
into the Storage / Dump vessel
Restart the circulation pump (P-TF-006 A) with circulation back to the

5.19
Expansion vessel through the tempory connection.
Monitor the performance of the circulation pump (P-TF-006 A) for Vibrations
of & Temperatures of Pump & Motor and the Current drawn and keep the *Results to be furnished as
5.20
recirculation going for around 2 hours. Confirm that the Pump running per the enclosed format.
parameters are are within acceptable limits.
48
Subsystem
No.
Sl.
No.
If temporary connection is made downstream
TF storage of the Flow meter, FM-TF-016,
& Supply
adjust the discharge valve opening to regulate a Flow of 45 m3/hr (rated
5.21
capacity of Pump) and Record the corresponding discharge pressure on PI-
1351-05.
After the sustained run of P-TF-006 A, repeat the same for P-TF-006 B for
5.22 around 2 hours to monitor and Record the performance. Confirm that the
Pump running parameters are are within acceptable limits.
6.0 Temporary connections to be maintained till OTP is completed
After the successful completion of the above Checks / Tests and Test run of
the TF-charging pump and circulation pumps, Keep the temporary
connection from the circulation pump discharge to the De-Aerator /
Expansion vessel as it is till the OTP for the system is completed.
7.0 All Punch list points cleared

Precommissioning of Thermic Fluid system completed Completed and
8.0
cleared for Opertional Test Procedure.
Notes: Please refer Operational Test Procedure (OTP) for Thermic Fluid system for Start up checks.

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49
Closed
Either one Temporary
connection Firmly tied
& Fixed
Closed
Common lines for Test
I ) TF Charging Pump Test Run Runs of P-TF -006A & B
50
Closed
II) P-TF -006A Circulation Pump Test Run
III) P-TF -006B Circulation Pump Test Run
51
1.4 Mechanical Installations Pre-commissioning
Mechanical Discipline carries the following three subcategories:

 Static Equipment
 Rotary Equipment
 Piping
Among the three major Disciplines that are involved in the commissioning of the Project viz.
Mechanical, Electrical and Instrumentation, Piping is invariably the first to Start and the last to Finish
in any Project. Even in a Project with limited piping scope, any change in any discipline including
Process, due to last minute Revisions or Punch list points connected to them, might result in Piping
modifications, thus making Piping the ultimate winner. Knowing the sensitivity connected to piping, it
is a recommended practice to keep focus on piping completion - not just overall focus but with the
recommended prioritized focus, which for this Project is - the sequence in which the Pre-
commissioning and Commissioning activities are presented herein and also explained above with
reasons.
 Piping Mechanical Completion is marked by the Certification of Completion of the following
activities:
 Fabrication, Erection, Supports installation and NDT complete
 Hydro test, Flushing of lines dry and Reinstatement of Piping complete
 All Piping Instruments are calibrated and Installed on the Piping
 Piping Pre-commissioning & to be certified ready for Commissioning broadly cover the
following major activities:
 Leak Test of the Piping loops
 Inertization of the Piping loops
 The Check & Test sheets for the above Pre-commissioning activities are furnished.
 The Check & Test sheets furnished are self-explanatory with record of parameters to be
maintained.
Next in priority are the Rotary Equipment, because Rotary Equipment namely the Pumps (excluding
the Rotary equipment of Packages) are shared by Solvents in this Project and hence each pump
might be an essential part of more than one Unit Operation of the Terminal in Commissioning the
Project, dealt with in the Operational Test Procedures (OTP).
 Rotary Equipment (Pumps) Mechanical Completion is marked by the Certification of
Completion of the following activities:
 Installation complete with all accessories like Flushing plans, Minimum flow recycle & Thrust
balancing lines where applicable, all instruments.
 Final alignment completed - Motor & Pump (for centrifugal pumps);
Motor & G.B and G.B. & Pump (for Gear pumps)
 Foundation bolts of Pump & Motor are grouted as per specifications
 Piping connected to the Pump is complete and hooked up to the Pump
 Rotary Equipment (Pumps) Pre-commissioning & to be certified ready for Commissioning

 Direction check and No load run of Motor
 Final alignment checks, installation of couplings & guards
 Lubrication of Pumps and Filling of Seal flushing / Barrier fluid, as per requirement

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52
 The Check & Test sheets for the Pre-commissioning activities are furnished both for Centrifugal
and Gear Pumps.
 The parameters record sheets for Motor No Load runs and the Pumps Load run during Start
up and Operations are also furnished for maintaining records.
Last but not the least in Priority are the Static Equipment mainly the Storage tanks of the Terminal,
which are the nerve centers of the Terminal around which all the Unit Operations are made. There
are two types of Storage Tanks namely Floating roof and Fixed roof tanks for storing Solvents /
Products depending on their characteristics.
 Storage Tanks Mechanical Completion is marked by the Certification of Completion of the
following activities:
 Site Fabrication of Storage Tanks complete in all respects – NDT, Hydro test & Reinstatement.
 Floating roof Tanks – Floating roof installation along with accessories specific to Floating roof
like Sealing ring, Seal etc.
 All the Firefighting accessories around the tank like Medium Velocity Water Spray (MVWS),
Deluge, Foam distribution piping etc. are complete in all respects including NDT, Hydro test
etc. as applicable
 All instruments connected to the system are calibrated and installed
 Storage Tank Pre-commissioning & to be certified ready for Commissioning broadly cover the
following major activities:
 Finer Installation checks like internal cleaning, Installation of Flame arrestor etc. specific to the
Tank.
 Floating roof Tanks - Confirm unobstructed movement of Floating roof
 Confirmation of all F&G accessories around the Tank/s like Detectors, Manual call points etc.
as per Drawings.
 Loop checks of Instrumentation around the Tank
 Final alignments confirmation, Direction check and No load run of the Motors for Transfer
pumps connected to the Tank, followed by coupling & installation of guards.
 The Check & Test sheets for the Pre-commissioning activities are furnished for both Floating roof
and Fixed roof Tanks of Dike 1 and Dike 2, with specific checks for installations specific to some
tanks like Bitumen Tanks, VAM Storage Tanks, Styrene Storage Tanks etc.

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53
Form No. SYSTEM : Subsystem No.
Card board / Plastic sheet -blasting / Flushing
Line Nos. All Instruments and Equipment PID Nos.
Equipment Isolated during independantly flushed
Lines flushing Tag Nos.
Yes / No
(* Please refer Notes
below).
Medium Air No. of Times Blasted with Air / N2 Mositure / Water fully Cleared for Reinstatement Done Permanent Gasketss and
/ N2 / Water removed from Lines & reintatement Yes / No Hardwares provided after
Equipment Yes Yes / No Reinstatement
/ No Yes / No
Notes: 1) All the Instruments in the lines should be isolated and Control valves should dropped and spool pieces provided in their place during Lines flushing.
2) Equipment should be isolated during Flushing of Pipe lines to prevent the foreign materials from Pipes to be carried over to vessesl.
3) Unless air is prohibitive for the system, the lines should be blasted with Card bard or prefeably with multilayed Plastic sheets by the following procedure. The area
around the Pipe line being flushed should be cardoned off. One end of the line or a few lines joined together should be blinded and at the other end Card board /
multilayered Plastic (Polyethylene) sheets should be sandwitched between the Flange at the open end and a matching flange tightly fastened to the end of the pipe
with erection fasters. Process Air / Plant Air should be used to pressurize the line up to around 6 Kg / cm2 until the Card board / Plastic sheet ruptures spewing out
water, dust, rust, weld spatter and other foreign materials in the pipe line. This should be repeated minimum 3 times or until the pipe line is free of Water and foreing
materials. 4) Equipment should be flushed independantly by water (if not prohbitive for the system) from top to bottom with the drain valve removed / open. All the
water sholuld be drained and flushed dry with Air / N2 and the vessel should be boxed up. 5) Water lines may be flushed with water free of all foreign materials and
finally flushed with air to clear the pipe of water.
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54
Form No. SYSTEM: Subsystem No.
Leak Test Report

Line Nos. Equipment included Oper. Pressure PID Nos.
Tag Nos. PSI / Kg/ cm2
Test Medium Air Test Duration Intial Presssure (P1) Final Pressure (P2) Pr. Drop during test % Pr. Drop Note:
/ N2 Hrs. / Mts. PSI / Kg/ cm2 PSI / Kg/cm2 DP = (P1-P2) Kg/cm2 DP / P1 * 100 P1 should be min.6 K g /
cm2 or Operating
Pressure, whichever is
higher.
Acceptance Test Result Remarks:
Criterion: Accepted / Rejected
Max. Pressure drop
0.1%/hr of Test
Pressure / Hr.
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Form No. SYSTEM: Subsystem No.
Inerting the System

Line Nos. All Instruments and All Equipment in the PID Nos.
Equipment Reinstated to system taken in line
normal position during (except pumps /
inerting the System. Blowers / Fans etc.
Yes / No which can be a source
(* Please refer Notes of leakage). Tag Nos.
below). of Equipment taken in
line
Inerting Medium Final O2 content at the exit % All the external connections N2 Pressure Cleared for Commissioning and charging
N2 O2 removed, all the valves maintained in the Process fluid
closed and system boxed system Yes / No
up with N2 Pressure
Yes / No
Notes: 1) All the Piping, Instruments and Equipment should have been fully reinstated and boxed up before commencing Inertization of the system. 2) O2 content at
the exit should be less than 2% before N2 is bottled up in the system (all the valves closed) and external connections are removed. 3) A positive pressure of N2
should be maintained in the system until the system is taken up for Commissioning and to be charged with the Process fluid.

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56
CENTRIFUGAL PUMPS PRECOMMISSIONING CHECKS

Sl.
No.
Motor No Load run completed satisfactorily in Uncoupled conditions
1
and certified for Commissioning (Electrical) .
Motor coupled to Pump after reconfirming Final alignment * Data to be filled in the alignment
2
reading. sheet.
3 Coupling guards installed.
Lubrication - Lubrication of the Pump bearings is ensured with the

4
correct grade of Lubricant.
Seal flushing fluid filled upto the correct level. N2 pre-charged, if
5
applicable for the flushing plan.
7
9
10
All Instruments connected to the Pumps and the connected lines
12 are installed, Precommissioning of the Instruments completed
and taken in line
and certified.
If the Pumps can be run with Water - Water filled in the Vessel
14 NA
connected to the Pump for Load Test of the Pumps.
16
Commissioning
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57
GEAR PUMPS PRECOMMISSIONING CHECKS

Sl.
No.
Motor No Load run completed satisfactorily in Uncoupled conditions
1
and certified for Commissioning (Electrical) .
Motor to Gear box and Gear box to Pump Final alignments * Data to be filled in the alignment
2
checked and readings are within acceptable limits. sheet.
Lubricant filled in the Gear box with the right grade of lubricant
3
upto correct level.
Motor to Gear Box coupling installed and coupling guard fitted in
4
position - Gear box to Pump remaining decoupled .
Motor run only with Gear box coupled (Pup decoupled) for a
sustained period period of around 2 hours. Vibrations and
*Data to be filled in the monitoring
5 Temperatures of Gear box bearings, Gear box body and also
shee.
that of the Motor monitored and readings are within acceptable
limits.
Motor stopped, electriclly isolated and coupling installed on Gear
6
box to Pump shafts. Coupling guard installed.
8
10
11
All Instruments connected to the Pumps and the connected lines
13 are installed, Precommissioning of the Instruments completed
and taken in line
and certified.
16
Commissioning
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58
Form No. Rotary Equipment Alignment Sheet Subsystem No.
Driven Equipment Pump / Compressor / Blower / Fan Tag No.
Driver Equipment Motor / Turbine Tag No.
Coupling Type Size
Alignment Results
Sl. Recorded Values ( from driver end)
No.
1 Angle 0 90 180 270
2 Runout
R1
3 Concentric
R2
4 Parallel A1
R1
DRIVEN 0°
DRIVER
A1
270° 90°
R2
GAUGES POSIT I ONS 180°
ORI ENT AT ION FROM VIEWER
Remarks:
Constr. Contractor
EPC Contractor
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59
ROTARY EQUIPMENT NO LOAD RUN CONDITION MONITORING REPORT
Sl. Current drawn Temp. Noise Level

Time Volts Vibration HZ / mm/s RPM
No Amperes Deg. C DB
DE NDE
Brg. Brg. Frame

1
1 Mt.
15
2 Mts.
30
3 Mts.
4 1 Hr
1.5
5
Hrs
2
6
Hrs

Remarks, if any:
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ROTARY EQUIPMENT LOAD RUN & CONDITION MONITORING REPORT
Sl. Pr.
Volt Current drawn Temp. Noise Level Flow
No Time Vibration HZ / mm/s RPM Kg/
s Amperes Deg. C DB m3/hr
. cm2g
DE NDE
Brg. Brg. Frame
1 1 Mt.
15
2
Mts.
30
3
Mts.
4 1 Hr
1.5
5
Hrs
2
6
Hrs
Remarks, if any:
Date Signature
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FLOATING ROOF TANKS PRECOMMISSIONING CHECKS
Tag Nos. T-GSL-001, T-GSL-002, T-TOL-001, T-
WSP-001, T-POL-001, T-ETA-001, T-C09-001, Subsystem
Location (Dike No. 1) From No.
T-C09-002, T-C10-001, T-MTL-001, T-MTL-002, No.
T-DEG-001, T-ETL-001
No
Mechanical Completion including Hydro test of the Tank is satisfactory and has been
1
Approved for further progress.
Flame Arrestor installation, Earthing and Cathodic Protection have been checked and
2
cleared.
Internal Floating Deck installation Approved, its movement is unobstructed & free and
3
checked. Primary Seal gap width and Area checked to be as per Specs.
Tank Internal cleaning carried out and cleared for boxing up. Man hole covers boxed
4
up and tightened with proper gaskets and hardwares.
Piping connected to the Tank have been completed, card board blasted, flushed clean
5
and reintsated
6 Tank along with the connected piping has been approved for further progress
All the Loop checks and Logic Tests of all the Instrumentation Loops connected to the
7 Tank - LT, LI, XVs, FS, Tank Gauging System have been completed and certified.
Alarms & Trips have been logic Tested against their set points.(Instrumentation)
All Instruments connected to the Tank, connected Systems and connected piping
8
have been taken in line
9 Foam System has been tested and OK (Not Applicable for DEG Tank)
Water Spray ring of the Tank has been tested practically and water spray is uniform
10
and good
F & G detection, Manual call points and Hooters in the vicinity of the Tank, Common
11 installations in the pumps ares and other Common areas are installed as per
Drawings & Specs., Functional tested and Approved (Instrumentation)
Motors for Transfer pumps connected to the tank have been installed, cables
12
terminated and Direction of rotation verified (Electrical)
No load run of the Motors, have been completed in uncoupled condition (Electrical),
13
Pumps coupled after No load runs and protective guards installed.
Transfer pumps lubricated with the correct grade of lubricant, Seal flushing fluid filled
14 & N2 pre-charged, if applicable as per the flushing plan of the pump, and kept ready
for start up
The Tank and connected Piping kept inertised with N2 ready to receive the Process
15
fluid.
The Tank along wth connected Equipment & Systems is ready to be
17
Commissioned in regular service.
EPC Contractor
Client (Optional)

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PHENOL (FIXED ROOF) TANKS PRECOMMISSIONING CHECKS
Location
Tag No/s. T-PHL-001 From No. Subsystem No.
(Dike No. 1)
Sl.
No.
Mechanical Completion including Hydro test of the Tank is satisfactory
1
and has been Approved for further progress.
Electrical Heating coil is installed in the Tank and cable terminated. The
2 Electrical Heater has been subjected to Pre-Comm. Checks as per
Check and Test sheet for Electrical Heaters (Electrical)
3 Vent is installed with Flame arrestor and Wire mesh.
Tank Internal cleaning carried out and cleared for boxing up. Man hole
4
covers boxed up and tightened with proper gaskets and hardwares.
Piping connected to the Tank have been completed, card board
5
Tank along with the connected piping has been approved for further
6
progress
connected to the Tank - LT, LI, TT,TI, XVs, FS, Tank Gauging System
7
have been completed and certified. Alarms & Trips have been logic
Tested against their set points. (Instrumentation)
All Instruments connected to the Tank, connected Systems and
8
connected piping have been taken in line
Water Spray ring of the Tank has been tested practically and water
9
spray is uniform and good
F & G detection, Manual call points and Hooters in the vicinity of the
Tank, Common installations in the pumps ares and other Common
10
areas are installed as per Drawings & Specs., Functional tested and
Approved (Instrumentation)
Motors for Transfer pumps connected to the tank have been installed,
11
cables terminated and Direction of rotation verified (Electrical)
No load run of the Motors, have been completed in uncoupled condition

12 (Electrical), Pumps coupled after No load runs and protective guards
installed.
Transfer pumps lubricated with the correct grade of lubricant and kept
13
ready for start up
The Tank and connected Piping kept inertised with N2 ready to receive
14
the Process fluid.
The Tank along wth connected Equipment & Systems is ready to
16
be Commissioned in regular service.
EPC Contractor
Client (Optional)

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BASE OIL, BLENING (FIXED ROOF) TANKS PRECOMMISSIONING CHECKS
Tag Nos. T-BOL-001, T-BOL-002, T-BOL-003, Location
From No. Subsystem No.
T-BOL-004, T-BLD-001 (Dike No. 1)
Sl.
No.
1
2 Base Oil and Blending Tanks
Vent is installed with Wire mesh. (BLD installed with Flame arrestor
2.1
also.
3

4
5
progress
connected to the Tank - LT, LI, TT,TI, XVs, PS (BOL), FS (BLD), Tank
6
Gauging System have been completed and certified. Alarms & Trips
have been logic Tested against their set points. (Instrumentation)
7
8
9
10

installed.
12
ready for start up
13
the Process fluid.
15
EPC Contractor
Client (Optional)

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STYRENE AND VAM (FIXED ROOF) TANKS PRECOMMISSIONING CHECKS
Tag No/s. T-STY-001, T-VAM-001 Location (Dike ..) From No. Subsystem No.
Sl.
No.
Mechanical Completion including Hydro test of the Tank is satisfactory and has
1
been Approved for further progress.
Chilled water Heat Exchanger for cooling circulated Styrene by CHW has been
hydrotested. The Styrene recirculation loop along with the recirculation pump
2
has been checked for Precomm. Completion as per Check & Test sheets for
Centrifugal pump, Heat Exchnager and piping
Vent fitted with coil is connected to CHWS & CHWR. The vent is installed with
3
Wire mesh (D/S OF PVRV)
Polymer. inhibibitor dozing system has been checked for Precomm. Completion
4
as per Check & Test sheet for Dozing package.
Tank Internal cleaning carried out and cleared for boxing up. Man hole covers
5
boxed up and tightened with proper gaskets and hardwares.
Piping connected to the Tank have been completed, card board blasted, flushed
6
clean and reintsated
All the Loop checks and Logic Tests of all the Instrumentation Loops connected
to the Tank - LT, LI, TT,TI, XVs, FS, Tank Gauging System have been
8
completed and certified. Alarms & Trips have been logic Tested against their set
points. (Instrumentation)
All Instruments connected to the Tank, connected Systems and connected
9
piping have been taken in line
10 Foam System has been tested and OK
Water Spray ring of the Tank has been tested practically and water spray is
11
uniform and good
F & G detection, Manual call points and Hooters in the vicinity of the Tank,
12 Common installations in the pumps ares and other Common areas are installed
as per Drawings & Specs., Functional tested and Approved (Instrumentation)
Motors for Transfer pumps connected to the tank have been installed, cables
13
terminated and Direction of rotation verified (Electrical)

14
(Electrical), Pumps coupled after No load runs and protective guards installed.
Transfer pumps lubricated with the correct grade of lubricant and kept ready for
15
start up
The Tank and connected Piping kept inertised with N2 ready to receive the
16
Process fluid.
18
EPC Contractor
Client (Optional)

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FLOATING ROOF TANKS PRECOMMISSIONING CHECKS
Tag Nos. T-NPT-001, T-NPT-002, T-NPT-003, T- Location (Dike
From No. Subsystem No.
MEG-001, T-BAT-001, T-XYL-001 No. 2 )
No
Mechanical Completion including Hydro test of the Tank is satisfactory and
1
has been Approved for further progress.
Flame Arrestor installation (and PVRV for MEG), Earthing and Cathodic
2
Protection have been checked and cleared.
Internal Floating Deck installation Approved, its movement is unobstructed &
3 free and checked. Primary Seal gap width and Area checked to be as per
Specs.
Tank Internal cleaning carried out and cleared for boxing up. Man hole covers
4
boxed up and tightened with proper gaskets and hardwares.
Piping connected to the Tank have been completed, card board blasted,
5
connected to the Tank - LT, LI, XVs, FS, Tank Gauging System have been
7
completed and certified. Alarms & Trips have been logic Tested against their
set points.(Instrumentation)
All Instruments connected to the Tank, connected Systems and connected
8
piping have been taken in line
9 Foam System has been tested and OK (Not Applicable for MEG Tank)
Water Spray ring of the Tank has been tested practically and water spray is
10
uniform and good
F & G detection, Manual call points and Hooters in the vicinity of the Tank,
Common installations in the pumps ares and other Common areas are
11
installed as per Drawings & Specs., Functional tested and Approved
(Instrumentation)
installed.
Transfer Pumps coupled to their Motors after No load run and the protective
13
guards are installed
Transfer pumps lubricated with the correct grade of lubricant, Seal flushing
14 fluid filled & N2 pre-charged, if applicable as per the flushing plan of the pump,
and kept ready for start up
The Tank and connected Piping kept inertised with N2 ready to receive the
15
Process fluid.
17
EPC Contractor
Client (Optional)

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BITUMEN (FIXED ROOF) TANKS PRECOMMISSIONING CHECKS
Location
Tag Nos. From No. Subsystem No.
(Dike No. 2)
Sl.
No.
1
Heating coil of the Tank has been hydrotested satsifctorily including -
from the source, Tank internal Coil and Return line and Approved. All
2
blinds have been removed after Hydrotest and the system reinstated.
The Hot oil loop Leak tested and cleared.
3 Vent is installed with Wire mesh
4

5
6
progress
connected to the Tank - LT, LI, TT,TI, XVs, PS, Tank Gauging System
7
have been completed and certified. Alarms & Trips have been logic
Tested against their set points. (Instrumentation)
8
9
10
11
installed.
13
ready for start up
14
the Process fluid.
16
EPC Contractor
Client (Optional)

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2. COMMISSIONING
This is the final step of Project completion, before charging the Process fluids in to the system, to
commence Startup & Operations which transforms the Project to an Operating Terminal.
The Loop Checks of individual Components of Systems have been completed as part of Pre-
commissioning. However an integrated overall Functional Test of each Total System and the
Response of each System to the demands of the Unit Operations it is functionally connected to, is
critical, to ensure that neither the Functional requirements nor the Safety aspects are compromised.
During Commissioning the following critical aspects are ensured, prior to charging Process fluids into
the System, some of which are highly inflammable:
 Components and Systems are linked by correct Functional requirements and Logics
 Serial / Ethernet links of various field Instruments with SCADA / DCS are in order
 SCADA / DCS Software is correct as per Logics proposed by Design and Engineering
 The Integrated Systems conform to the requirements with all Safety aspects functional
 Confirm the safe operational capabilities of individual Systems
 Confirm proper functioning of safeguards in the integrated Network - Alarms and Trips – to
ensure the Safety of Personnel in Terminal Operations.
The Commissioning Procedures are elaborative with each Functional Test of the intended Operations
explained stepwise with Temporary installations, Safety precautions, if any required etc. The
Commissioning Procedures for each Unit Operation is furnished as ‘Operational Test Procedure’
(OTP).
Commissioning Procedures (OTPs) are carried out by Simulation of parameters and confirming the
Responses thus confirming that Cause & Effect Logics as per Design and Engineering are confirmed
and established. After the Commissioning procedures are complete, the Terminal Equipment should
be ready to receive the Process fluids to commence Operations.
Total Commissioning of the Terminal is accomplished in two stages as follow:
 Commissioning (OTP) of individual Systems / Packages to establish that each System by
itself carries the necessary Interlocks to ensure its internal Safety and Sustainability in
Operations.
 Commissioning (OTP) of Unit Operations of the Terminal with all the Systems that support the
Unit Operation to ensure the Overall Safety of the Terminal and Sustainability in Operations.
 SCADA & PLC Panels – Completion of OTP of all the Packages and Systems by themselves
complete the OTP of the above Control Panels
 Since all the Controls for the Unit Operations are through SCADA, demonstration of all the
Controls & Interlocks establish the performance of SCADA
 Since all the Controls for the Package to which the PLC Panels are attached are routed
through PLC Panel, demonstration of all the Controls & Interlocks attached to the Package
establish the performance of the Performance of the PLC Panel forming part of it.
The Operational Test Procedures furnished beginning with Packages first, followed by the Storage
Tanks around which all the Unit Operations in the Terminal are made.

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The Operational Test Procedures of various Systems are presented in the recommended sequence
to optimize the Startup & Operations Schedule of the Terminal. The following is the sequence of
OTPs and salient features:
2.1 HVAC Cooling Water system
Since the Control room where the SCADA Units and the PLC panels are located need to be kept cool
to dissipate the heat generated by them and keep them Operational, Startup of HVAC of the Control
Room is of paramount priority. The coolant for the HVAC units of the Buildings is Chilled water and
Chilled water Package (HVAC) requires cooling water for Startup. Hence HVAC Cooling water
system is No. 1 in priority for Startup.
 During OTP of the Cooling water system, the following are established:
 All Trips and Interlocks associated with the system
 CT Fans and Circulation pumps performances established with Load run parameters.
 Corrective actions if any required may be taken up immediately, to ensure sustained
performance of the system.
 Flexibility of Process Cooling water system to supply Cooling water selectively to the HVAC
Chilled water Package and HVAC cooling water system to the Process Chilled water package is
also established.
 This is a backup arrangement to keep both the Chilled water packages in operation, even if
either of the Cooling water systems is shut down due to contingencies.
 This Flexibility is very critical – since the Chilled water packages of HVAC and Process are
critical for their respective duties – HVAC because of criticality of Control room and Process
because of the criticality of the stored materials VAM / Styrene which might polymerize if not
kept cool.
2.2 Process Cooling water system
Power and Instrument Air are the most important Utilities for Process Operation and Controls. Power
supply has already been established by commissioning the Electrical Installations on priority. The
next vital utility required for Process controls is Instrument Air. Instrument Air is generated through
the Air Drier units installed as a part of N2 Package. Compressed Air from the Air compressors need
to be cooled in the Aftercoolers prior to IA Driers. The Cooling water for the Aftercoolers is supplied
by the Process Cooling water system and hence its priority.
 During OTP of the Cooling water system, the same functional characteristics as above for the
HVAC Cooling water system are established:
 CT Fans and Circulation pumps performances established with Load run parameters.
 Corrective actions if any required may be taken up immediately, to ensure sustained
performance of the system.
 Flexibility of the Process Cooling water system to supply Cooling water to the HVAC Chiller
package is also established considering the criticalities mentioned above.
2.3 HVAC Chilled water System

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Chilled water is the coolant for HVAC of Buildings. Control Room necessarily needs to be kept cool
because of SCADA and other Panels installed in the Control room and hence HVAC Chilled Water
system is of high priority.
 During OTP of the HVAC Chilled water system, the following are established:
 Actual Load run and Performance of the System is established and hence the System can be
pressed into service immediately after the Sustained run and corrective actions if any required.
2.4 Process Chilled water System
Process Chilled water system assumes importance before the intake of VAM and Styrene into their
respective tanks. Since HVAC Chilled water system has to be commissioned on priority and Process
Chilled water package is identical to HVAC Chilled water package, its OTP is mentioned immediately
after HVAC.
However, if there is constraint for resources to take up Process Chilled water package immediately
after HVAC package, there is room to adjust its Commissioning to be taken up later, but in any case
well before the arrival of first cargo of VAM or Styrene to be unloaded to its storage tank.
 During OTP of the Process Chilled water system, the same parameters as above for HVAC are
established:
 Actual Load run and Performance of the System is established and hence the System can be
pressed into service immediately after the Sustained run and corrective actions if any required.
 To carry out the Load run of this Unit, some temporary hose connections are required as
detailed in the OTP
2.5 Air Compressors
Air Compressors commissioning is of high priority since they are source of feed for generating
Instrument Air.
 During OTP Air Compressors, its built in Logics are established before the Load Run
 Loading & Unloading of the Air Compressors are established by simulation
 Actual Load run and Performance of the Compressors are carried out and their running
parameters monitored to confirm their suitability for sustained Run
2.6 N2 & IA Package
After the preceding enablers, comes the utilities of high priority namely Instrument Air and N2. N2 is a
utility of high priority for all seasons by virtue of its applications for Utility stations and as Blanket
VAM, MEG and Styrene Storage Tanks. Instrument Air is crucial for Instrumentation which forms the
backbone of all Functional Tests in the Operating Test Procedures for the Process Block. Hence N2
& IA package comes next in line.
 During OTP of the Package, its built in Alarms for Temperatures and Pressures are confirmed by
Simulation before the Sustained Run of the Package on Load
 During the Run Test the capacity of the Package to deliver N2 and Instrument Air as per
Specifications are confirmed

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 O2 Content & Dew Point of Product N2 are verified to conform to Specs

 Changeover of running PSA to the Standby PSA unit as per Logic is established
 Instrument Air Quality (Dew Point) verified by Lab analysis
 Changeover of running Air Drier Unit (ADU) to the Standby ADU unit as per Logic is
established
2.7 Fire Water system
Safety is paramount in any Operating Chemical Complex. Focus on Safety installations and their
functionalities is many times more in a Chemical Terminal handling multiple Solvents, some of which
are highly inflammable. Hence Fire Water & Foam system (FW system) and Fire & Gas (F&G)
detection systems are of very high importance. F&G systems play active roles when the Solvents /
Products are stored in Tanks for onward startup of Terminal Operations. However FW system might
have a role to play even during the Project stage before the Solvents are taken into the Storage
tanks. Hence FW system takes precedent over F&G in sequential order of Commissioning.
 During OTP of the FW system, the following aspects are established, which are crucial to combat
Fire if it occurs:
 Auto Start of Jockey pumps and Diesel Engine Fire water pumps to maintain Hydrant pressure
at all times.
 Auto start of Diesel engine driven pumps in case of Fire Alarm in any segment of Unit
operation protected by FW system
 Automatic Water spray system for Tanks
 Sprinkler system for Buildings
 Performance check of Foam system
 Check of MVWS system, Hydrants and Monitors to confirm their Performance
2.8 Fire & Gas system
The importance of F&G system for an Operating complex is well known as mentioned above and
never overemphasized. F&G System comes next in line to get the Terminal Safe for Operations.
 During OTP of the F&G system, the following aspects are established, which are crucial for Alert
and Actions to follow in case of Fire detection in the Terminal:
 All the detectors – Point type and Open path type in the Terminal are tested for performance
by simulation
 All the Manual Call points are tested
 All the F&G detection installations in the Buildings are tested for performance viz. Heat
detection, Smoke detection, H2 detection (Battery room), Multi sensor detection and Manual
Call points
2.9 Thermic Fluid system
Next in line is the Thermic Fluid system, which is crucial for Bitumen Storage tanks.
 During OTP of the Thermic Fluid system, the following aspects are established to ensure its
dependability:
 Built in Interlocks of the System with respect to levels of Diesel tank and Expansion tank
 Burner Management system (BMS) of the Heaters

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 Interlocks associated with the Heaters viz. Flame failure, High Flue gas temperature, Flue Gas
discharge damper, High DP across the Heater, Flame cut off in case of high Thermic Fluid
inlet temperature etc.
2.10 Storage Tanks of Dike 1
Once the support systems to ensure their Safety are ensured come the Royal Family of Storage
Tanks around which all the Terminal Operations are made. The Operations around the tanks are
similar for all the Storage tanks, with some additional installations / parameters / safeguards added
for specific Solvents / Products based on their characteristics.
The Operational Test Procedures (OTP) for the Storage Tanks of Dike 1 and Dike 2 are furnished
separately not only to maintain their identities with respect to the Dike to which they belong, but also
considering the uniqueness of some of the Tanks.
 During OTP of the Storage Tanks, the following aspects are established, which control all the Unit
operations of the Terminal:
 All the Logics & Interlocks associated with the Tanks viz. Tank Gauging system, High & Low
levels, F& G detection etc.
 Interlocks associated with various Operations centered around the Tanks are fully tested to
ensure Safety of the Operation, Personnel and the Plant.
 The Safe Operational capabilities tested include - Ship Unloading of Solvents / Products to
their respective Tanks, Truck Loading by pumping from the Tank to the TLF, Drum filling of
material Stored in the Tank, Ship Loading of the material in the Tank for Export, Tanker
Unloading of materials to their respective storage Tanks, Blending of materials in the Tanks in
the Blending Tank for making different compositions
 Exclusions and Additional Tests required for materials stored Specific Storage tanks are also
brought out
2.11 Storage Tanks of Dike 2 (Except Bitumen Tanks)
All Tests mentioned as above for Dike 1 Storage Tanks. The Tests are separately detailed out for
Dike 2 Tanks not only considering their Dike identities but also because some of them are connected
to the Process Block Operations.
2.12 Bitumen Storage Tanks Dike 2
Bitumen Tanks Operational Tests are detailed separately considering its uniqueness of nature,
Pumps handling Bitumen (Gear Pumps) etc. as mentioned next.
 The nature of Tests carryout are similar for Bitumen Tanks. Since Bitumen Tanks also involve
heating coils for Thermic fluid circulation, Gear Pumps for transportation etc. some of the
parameters simulated for Tests are different.
2.13 Pig Launcher & Receiver (PLR)
The Unit Operations of the Terminal might be able to commence only after Unloading of the cargo of
material to the Storage Tank. Hence this might be the first System to be commissioned with Process
Fluid.

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 The Operation of the PLR is Functional Tested with water so that its performance is established.
2.14 Terminal Automation System (TAS)
The Terminal Automation System covers the Automation of the Truck Loading Facility in the
Terminal. From the arrival of the Truck for loading up to its Exit from the Gate with the loaded
materials, all the activities are captured and Automated by the Software to ensure the following:
 Correct material is loaded in the correct Truck

 Correct Quantity is loaded
 All Safety precautions associated with the Process are adhered to
 Security system is streamlined to ensure that there is no foul play
 All the Documents are in order and available for retrieval
 All the Logics and Interlocks associated with the Automation System are tested during the OTP
so that the System can be lined up for Terminal Operations on Start of the unit

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OPERATIONAL TEST PROCEDURE

HVAC COOLING WATER SYSTEM – CT-811-001
Ref: P&ID TCE-7410A-811-PI-1008
(P&ID 7410A-613-PI-1002)

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Table of Contents
1. Test Summary
1.1. Aim of Operational Test

1.2. Test Description
1.3. Temporary Installation
1.4. Special Precautions
2.0 Planning and Manpower
2.1 Resource Requirements

2.2 Vendor Assistance
2.3 Estimated duration of Test
3.0 Test Requirements
4.0 Test Preparation
5.0 Tests & Procedures
5.1 Cooling Tower Basin Level maintenance

5.2 Pre-start Interlocks Check – Vibration switches of Fans
5.3 Pre-start Interlocks Check– CW Options for Process CHW Pkg. CHP-M501/502
5.4 Startup of Recirculation Pumps and Interlocks Check–Trip on Basin Low level
5.5 HVAC Cooling Water System Sustained Run & Parameters
5.6 Reinstatement of the System
6.0 Ready for Commissioning Terminal Systems and Operations

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Step Task Description Remarks, if any &

Signature
1 Test Summary
1.1 Aim of Operational Test
The aim of operational test is to demonstrate the following:
 Confirm the safe operational capabilities of the HVAC Cooling Water System.
 Ensure proper distribution of Cooling Water to the users
 Confirm proper functioning of safeguards - Alarms and Trips – to ensure the Safety
of Personnel and the System.
1.2 Test Description
The Tests cover the following
 Running of the Cooling Tower system consisting of Cooling Tower, Cooling water
supply pumps and Fans along with the ancillaries
 Onward distribution of Cooling Water (CWS) to the users
 Cooling Water Return (CWR) from the users and distribution from the top through
the Cooling Tower
 Confirm the cooling capacity of the Cooling Tower

 Confirm the Wet and Dry Bulb temperatures of Cooling Water conform to
Guarantees and Requirements
 Confirm the function of Automatic Pneumatic Butterfly valves in the Process

Cooling water system - if Cooling water Supply and Return for the Process
Chilled water Package is diverted through HVAC Cooling water system
The Loop Checks of individual Components should have been completed as part of
Instrumentation procedure. However an integrated overall Functional Test is important to
ensure that the Integrated Cooling Water system conforms to the Process requirements
with all Safety aspects functional.
On successful completion of OTP, Report shall be prepared, which may be signed by the
authorized representatives of TPL and HIF. The Report would form part of the
Commissioning Dossier.
On successful conclusion of the Operational Tests, the Cooling Water system is ready to
be pressed into regular Operational Service.
1.3 Temporary Installations
Nil
1.4 Special Precautions
None
2.0 Planning and Man Power
Commissioning Engineer 1
Commissioning Operator 1

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Mechanical Technicians 3 (Need based)
Instrument Engineer 1 (Need based)
Communication sets 3
Tools & tackles 1 set
Not envisaged
1 day
 Pre-commissioning activities have been completed

 Ready for Commissioning (RFC) has been signed
 Safety compliance - Permit to Work, if required, should be obtained
 Utilities requirement – Power (LV), Lubricants for the rotary equipment, Dozing
chemicals and Instrument air
 Cooling water Supply and Return lines of the users should have been completed,
Lines flushed clean and reinstated
 Cooling water users are ready to receive Supply and Return cooling water, to
enable start of Cooling tower Recirculation pumps
4.0 Test Preparations
 Keep the Cooling water circulation Pumps and Fans Electrically Energized
 Ensure proper Lubrication of all the rotary Equipments of Cooling water system are
lubricated with the correct grades of lubricants viz.
 Circulation pumps
 Fans – Drive gear box, if applicable; Fans bearings
 Motors bearings - Circulation pumps and Fans
 Ensure that all the Interlocks of cooling water system are in place.
 Cooling Tower Basin should be filled with water

 Cooling Tower should have been dozed with the correct corrosion inhibiting
chemicals as per specifications and dozing chemicals should be readily available.
 Keep the Control room informed
5.0 Tests & Procedure
 Keep the Makeup water Intake valve fully Open

 When the Cooling Tower Basin is full, the inlet valve (Float valve) should shut off
water intake
 If the Intake valve passes water even when the Basin is full, take corrective
actions to ensure that there is no wastage of water
 If the above parameters are Normal, proceed to the next step.

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 Start the Cooling Tower Fans and keep them running and confirm that their
performances are normal
 Activate the Vibration switches of Fans one after another
 Confirm that the Fans trip
 Reset and Restart the Fans and keep them running
 If the above parameters are Normal proceed to the next step.
 Option is provided for the Process Chilled water Package CHP-M501/502 to

Operate with Cooling water Either from the Process Cooling water system
OR HVAC Cooling water system
 In case of an Emergency or Shut down of Process Cooling water
system, Cooling water can be supplied from HVAC Cooling
R1
water system to Process Chilled water Package CHP-M501/502
1
 This would ensure uninterrupted (or minimum interrupted)
Operation of CHP-M501/502 and hence Chilled water supply for Process
users viz. VAM and Styrene Storage & their cooling systems to maintain
the requisite temperature to prevent their Polymerization
Test of Flexibility for CW Supply & Return
Option 1 – Process Cooling water system CW to CHP-M501/502
 HVAC Cooling water system (CT-811-001) - Close the ON/OF valves XV 0203
and XV0204 on the Cooling water Return and Supply lines respectively of the
system
 Process Cooling water system (CT –M501) – Confirm that Automatic Butterfly
valves (pneumatic) XV-0201 and XV0202 Open Automatically
 With this option, the Process CHW package CHP-M501/502 would be
working on CW Supply From and CWR Return to the Process Cooling
water system CT-M501
Option 2 – HVAC Cooling water system CW to CHP-M501/502
 HVAC Cooling water system (CT-811-001) - Open the ON/OF valves XV 0203
system
valves (pneumatic) XV-0201 and XV0202 Close Automatically
 If the above option is chosen, the Process CHW package CHP-M501/502
would be working on CW Supply From and CWR Return to the HVAC
Cooling water system CT-811-001
 If the above parameters are Normal proceed to the next step with settings as
per Option 2
 Keep ON/OF valves XV 0203 and XV0204 Open and hence XV-0201 and
XV0202 Closed i.e CW Supply From and Return to the HVAC Cooling water
system.
5.4 Startup of Recirculation Pumps and Interlocks Check–Trip on Basin Low level
 Keep the Supply and Return lines of Users Open
 The User viz. HVAC Chilled water Package WCP-811-001 A&B, should be fully
ready to receive Supply and Return cooling water, for the Recirculation pumps to
be Run and their performance assessed.
 The Optional User - Process Chilled water Package CHP M501 & M502,
should also be ready to receive Supply and Return cooling water, for the

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Recirculation pumps (for Process Water Chiller) to be Run and their

performance assessed
 Open the Cooling Tower Basin Outlet valve

 Check for leakages and take corrective actions, if any required
 Open the Suction isolation valves of the CW Recirculation Pumps CWP-811-03

A/B for HVAC Chilled Water Package
 Kick start (On & Off immediately) one of the Pumps (CWP-811-03 A)
 Confirm that the Direction of rotation is correct and there is no abnormality
observed
 If there is no abnormality observed, keep the pump running and crack open the
discharge valve (around 20-25% Open)
 Confirm water flow through the discharge piping
 If the conditions are normal, keep the pump running
 Repeat the above steps for the second CW Pump (CWP-811-03 B) and if the
conditions are normal, keep it running with the discharge valve 20-25% open
 Open the Suction isolation valves of the Recirculation Pumps CWP-811-04 A/B for
Process Chilled Water Package
 Kick start (On & Off immediately) one of the Pumps (CWP-811-04 A)
observed
 Repeat the above steps for the second CW Pump (CWP-811-04 B) and if the
conditions are normal, keep it running with the discharge valve 20-25% open
 The above four pumps may be kept running with throttled discharge for a
short period to check the Interlock against Low basin level for all the Pumps
simultaneously
 Simulate Low Low Level in the Basin / Activate the Level Switch LS
 Confirm that all the four Pumps trip due to Low Low Level activation
 If the above actions are as mentioned above, one of the Recirculation pumps for
HVAC Chilled Water Package (CWP-811-03 A) one of the Recirculation pumps for
Process Chilled Water Package (CWP-811-4 A) may be restarted one after
another as explained above, for Sustained Run Test Cooling Water system.
 Check for leakages in the CW circuit and take corrective actions, if any
required
5.5 HVAC Cooling Water System Sustained Run & Parameters
 Keep One Recirculation pump for HVAC Chilled water system and One
Recirculation pump for Process Chilled water system in Operation at a time
 Adjust the discharge valve openings to maintain a discharge pressures as follows:

 CWP-811-03 A/B of 2.5 Kg/cm2 indicated by PG on the discharge line of
Pump
 CWP-811-04 A/B of 3.5 Kg/cm2 indicated by PG on the discharge line of
Pump
 Confirm that Cooling water is available to the Users at the requisite pressure

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 If required, throttle the isolation valves on the Cooling water Return

header on top of the Cooling Tower to maintain the requisite back
pressure
 With the above conditions keep the Cooling water system on Sustained Run for
minimum 4 hours and Monitor the following parameters
 *Cooling Tower parameters

 Water dispersion in different sections (Visual)
 Louvers installation & their function OK – No spillage of water (Visual) *Data of Running
 CWS and CWR Temperatures - Performance of the Cooling Tower can parameters to be
be gauged only when both the Users are running on Load
filled in Rotary
 Dry Bulb and Wet Bulb temperatures of Cooling water (Analysis)
Equipment Load
 *Recirculation Pumps & Motors parameters Run Monitoring
 Suction & Discharge Pressures Reports.
 Current drawn
 Bearings & Body Temperatures and Vibrations
 *Fans parameters
 Current drawn
 Motor Bearings & Body Temperatures and Vibrations
 Drive assembly (Gear box, if applicable) Temperatures and Vibrations
 Cooling Tower Plenum vibrations
 If performance parameters are normal for the 1 pump each in operation, the
Standby pumps CWP-811-03 B and CWP-811-04 B may be started and kept
running to monitor their performance and the running established pumps (
CWP-811-03 A and CWP-811-04 A) may be stopped.
 None
 If the above Tests are satisfactory, the HVAC Cooling water system is ready
for service for onward Commissioning & Operation of Terminal Systems.

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PROCESS COOLING WATER SYSTEM – CTM-501
Ref: P&ID 7410A-613-PI-1002,
(P&ID TCE-7410A-811-PI-1008)

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Table of Contents
1. Test Summary



5.4 Start up of Recirculation Pumps and Interlocks Check–Trip on Basin Low level
5.5 Process Cooling Water System Sustained Run & Parameters

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Signature
1 Test Summary
 Confirm the safe operational capabilities of the Process Cooling Water System.
 Ensure proper distribution of Chilled Water to the users
 Running of the Cooling Tower system consisting of Cooling Tower, Cooling water
supply pumps and Fans along with the ancillaries
 Onward distribution of Cooling Water (CWS) to the users
 Cooling Water Return (CWR) from the users and distribution from the top through
the Cooling Tower
 Confirm the cooling capacity of the Cooling Tower

 Confirm the Wet and Dry Bulb temperatures of Cooling Water conform to
Guarantees and Requirements
 Confirm the function of Automatic Pneumatic Butterfly valves in the Process

Cooling water system - if Cooling water Supply and Return for the Process
Chilled water Package is diverted through HVAC Cooling water system
ensure that the Integrated Cooling Water system conforms to the Process requirements
On successful conclusion of the Operational Tests, the Cooling Water system is ready to
Nil
None

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Not envisaged
1 day

 Utilities requirement – Power (LV), Lubricants for the rotary equipment, Dozing
chemicals and Instrument air
 Cooling water Supply and Return lines of the users should have been completed,
Lines flushed clean and reinstated
 Cooling water users are ready to receive Supply and Return cooling water, to
enable start of Cooling tower Recirculation pumps
 Keep the Cooling water circulation Pumps and Fans Electrically Energized
 Ensure proper Lubrication of all the rotary Equipments of Cooling water system are
lubricated with the correct grades of lubricants viz.
 Circulation pumps
 Fans – Drive gear box, if applicable; Fans bearings
 Motors bearings - Circulation pumps and Fans
 Ensure that all the Interlocks of cooling water system are in place.
 Cooling Tower Basin should be filled with water

 Cooling Tower should have been dozed with the correct corrosion inhibiting
chemicals as per specifications and dozing chemicals should be readily available.
 Keep the Makeup water Intake valve fully Open

 When the Cooling Tower Basin is full, the inlet valve (Float valve) should shut off
water intake
 If the Intake valve passes water even when the Basin is full, take corrective
actions to ensure that there is no wastage of water

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 Start the Cooling Tower Fans and keep them running and confirm that their
performances are normal
 Activate the Vibration switches of Fans one after another
 Confirm that the Fans trip
 Reset and Restart the Fans and keep them running
 If the above parameters are Normal proceed to the next step.
 Option is provided for the Process Chilled water Package CHP-M501/502 to

Operate with Cooling water Either from the Process Cooling water system
OR HVAC Cooling water system
 In case of an Emergency or Shut down of Process Cooling water
system, Cooling water can be supplied from HVAC Cooling
water system to Process Chilled water Package CHP-M501/502 R1
 This would ensure uninterrupted (or minimum interrupted) 1
Operation of CHP-M501/502 and hence Chilled water supply for Process
users viz. VAM and Styrene Storage & their cooling systems to maintain
the requisite temperature to prevent their Polymerization
Test of Flexibility for CW Supply & Return
Option 1 – Process Cooling water system CW to CHP-M501/502
 HVAC Cooling water system (CT-811-001) - Close the ON/OF valves XV 0203
system
valves (pneumatic) XV-0201 and XV0202 Open Automatically
 With this option, the Process CHW package CHP-M501/502 would be
working on CW Supply From and CWR Return to the Process Cooling
water system CT-M501
Option 2 – HVAC Cooling water system CW to CHP-M501/502
 HVAC Cooling water system (CT-811-001) - Open the ON/OF valves XV 0203
system
valves (pneumatic) XV-0201 and XV0202 Close Automatically
 If the above option is chosen, the Process CHW package CHP-M501/502
would be working on CW Supply From and CWR Return to the HVAC
Cooling water system CT-811-001
 If the above parameters are Normal proceed to the next step with settings as
per Option 1
 Keep ON/OF valves XV 0203 and XV0204 Closed and hence XV-0201 and
XV0202 Open i.e CW Supply From and Return to the Process Cooling water
system.
5.4 Start up of Recirculation Pumps and Interlocks Check–Trip on Basin Low level
 Keep the Supply and Return lines of Users Open

 If work is in progress on the Supply or Return lines of any of the Users
within their Battery limits, keep the Cooling water Supply and Return
isolation valves of that particular User Closed. Provide positive isolation
with Blinds on the CW Supply & Return lines of the User to ensure that
there no accident takes place due to water flow while work is in

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progress on the lines.
 At least one, preferably a few or All the Users, should be fully ready to receive
Supply and Return cooling water, for the Recirculation pumps to be Run and their
performance assessed.
 Open the Cooling Tower Basin Outlet valves (on the two ends of the Basin)
 Check for leakages and take corrective actions, if any required
 Open the Suction isolation valves of all the Recirculation Pumps
 Kick start (On & Off immediately) one of the Pumps (PM-5069 A)
observed
 Repeat the above steps for the second Pump (PM-5069 B) and if the conditions
are normal, keep it running with the discharge valve 20-25% open
 . Repeat the above steps for the third Pump (PM-5069 C)
 . Repeat the above steps for the fourth Pump (PM-5069 D)
 All the four pumps may be kept running with throttled discharge for a short
period to check the Interlock against Low basin level for all the Pumps
simultaneously
 Simulate Low Low Level in the Basin / Activate the Level Switch LS 0203
 Confirm that all the four Pumps trip due to Low Low Level activation
 If the above actions are as mentioned above, 3 pumps may be restarted one after
another as explained above, for Sustained Run Test Cooling Water system.
 Check for leakages in the CW circuit and take corrective actions, if any
required

5.5 Process Cooling Water System Sustained Run & Parameters
 Keep 3 Recirculation pumps in Operation at a time

 Adjust the discharge valve openings to maintain a discharge pressure of 5 Kg/cm2
indicated by PGs on the discharge line of Pumps viz. PG 02-05/06/07/08
 Confirm that Cooling water is available to All the Users at the requisite pressure
 If required, throttle the isolation valves on the Cooling water Return
header on top of the Cooling Tower to maintain the requisite back
pressure
 With the above conditions keep the Cooling water system on Sustained Run for
minimum 4 hours and Monitor the following parameters
 *Cooling Tower parameters

 Water dispersion in different sections (Visual)
 Louvers installation & their function OK – No spillage of water (Visual) *Data of Running
 CWS and CWR Temperatures - Performance of the Cooling Tower can parameters to be
be gauged only when all the Users are running on Load filled in Rotary
 Dry Bulb and Wet Bulb temperatures of Cooling water (Analysis) Equipment Load
Run Monitoring
Reports.
 *Recirculation Pumps & Motors parameters

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 Suction & Discharge Pressures

 Current drawn
 Bearings & Body Temperatures and Vibrations
 *Fans parameters
 Current drawn
 Motor Bearings & Body Temperatures and Vibrations
 Drive assembly (Gear box, if applicable) Temperatures and Vibrations
 Cooling Tower Plenum vibrations
 If performance parameters are normal for the 3 pumps in operation, the

Standby pump PM-5069 D may be started and kept running to monitor its
performance and one of the running established pumps (e.g. PM-5069 A)
may be stopped.
 None
 If the above Tests are satisfactory, the Process Cooling water system is
ready for service for onward Commissioning & Operation of Terminal
Systems.

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CHILLED WATER SYSTEM (HVAC) – WCP-811-01 A & B & CHW DISTRIBUTION
Ref: P&ID 7410A-811-PI-1007

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Table of Contents
1. Test Summary


5.1 Chilled water Sec. & Prim. Pumps – Interlocks against Low Suction Pr. & ‘0’ DP
5.2 Chiller Package Pre-start Interlocks Check-Chilled water flow- WCP 811-01A
5.3 Chiller Package Pre-start Interlocks Check–Compressor Load/Unload – WCP 811-01A
5.4 Chiller Package Pre-start Interlocks Check–Compressor Trips – WCP 811-01A
5.5 Chilled Water circuit Start up preparation
5.6 Chiller Package Start up Checks – WCP-811-01A
5.7 Chiller Package WCP-811-01A Sustained Run & Parameters
5.8 Chilled Water System Sustained Run & Parameters
5.9 OTP for other Chilled Water Package WCP-811-01B
5.10 HVAC package Monitoring

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Signature
1 Test Summary
 Confirm the safe operational capabilities of the HVAC Chilled Water System.
 Confirm the Operational capabilities of HVAC system as per specifications
 The Production of Chilled Water (Vendor Package)

 Onward distribution of Chilled Water (CHWS) to the users (HVAC) through
Secondary pumps CHP-811-02 A/B
 Return of Chilled Water Return (CHWR) from the users (HVAC)
 Pressurization of Return CHW through Dual Pump pressurization unit, if required
 Recirculation of CHWR by Chilled water Primary pumps CHP-811-01 A/B
through the Chilled Water Production package to re-chill CHWR (along with
makeup water if required to be added) to be suitable for HVAC requirements as
CHWS
 Receipt of Chilled water at HVAC system, adjustment of AHU parameters,

adjustment of dampers on the Air ducts etc. and monitor the HVAC Parameters
and Performance of the HVAC system
ensure that the Integrated Chilled Water system conforms to the requirements with all
Safety aspects functional.
The Chilled water Package for HVAC is identical to the package for Process; there are
some changes only in Chilled water Distribution and Return. Hence for this HVAC
Chilled water Package, the logic tests described below bear the same Tag Nos.
(Highlighted in yellow) for individual Instruments / Equipment of the Package as in
the Process Package. The Tag Nos. may be verified from the actual delivered Chilled
Water package for HVAC.
For Chilled water Distribution and Return, however, the Tag Nos. as per the Ref. P&ID
7410A-811-PI-1007 are mentioned.
On successful conclusion of the Operational Tests, the Chilled Water systems are ready to
Nil

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Since there are no storage tanks (Hot well and Cold well as in the case of Process
Chilled water package), the Primary and Secondary Pumps shall be Run on Load
and Tested with actual circulation of CHW To and From the HVAC users.
None
Instrument Engineer 1
Instrument Technician 1
Vendor assistance may be availed to keep the Warranty obligations intact.
1 day
 Pre-commissioning activities of the vendor package have been completed

 Pre-commissioning Checks of the Chilled water system Pumps have been done
 HVAC system of Users is ready after Pre-commissioning with all the Chilled
water Supply & Return lines of the users ready to receive Chilled Water
 Utilities requirement – Power (LV), Oil Lubricant for the Compressor, Lubricant for
the Pumps, Refrigerant filled in the Evaporator and top up quantity, if required.
 Keep the Chiller Compressors Electrically Energized

 Keep the Starter / Controller Panel switched ON
 Ensure that the Compressor is lubricated and Oil is filled in the Oil Separator
up to the correct level
 Ensure Compressor Motor bearings lubrication is done
 Confirm that Refrigerant is filled in the Evaporator up to the correct level
 Ensure that correct grade of Lubricant is filled for Primary CHW Pumps,
Secondary CHW Pumps and Dual Pumps Pressurization unit Pumps
 Ensure that cooling (Tower) water pumps are running and isolation valves
for Cooling Water Supply and Return from the Condenser are open and
cooling water circulation is established through the Condenser.
 Ensure that all the Interlocks of Chilled Water Production package and
Process Chilled water system are in place.

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 The Chilled water production Package panel should be Powered ON after

Pre-commissioning checks as applicable for PLC panels
 Keep the Chilled Water Primary Pumps P-811-01 A and B and Secondary Pumps
P-811-02 A and B Electrically Energized and ready to start
 Keep the AHU of the HVAC package running. The Sustained Run of the
HVAC package to demonstrate the parameters may be concurrent to the
Sustained Run of the Chilled water package.
5.1 Chilled water Sec. & Prim. Pumps – Interlocks against Low Suction Pr. & ‘0’ DP
 Keep the Primary Pumps P-811-01 A/B, Secondary Pumps P-811-02 A/B and
the Dual Pump Pressurization unit Pumps in ‘Electrical Test Position’ with all
Interlcoks in place.
 Try to kick start the Sec. Pumps P-811-02 A/B with No flow of CHW to
consumers. The Pumps should not take start, due to ‘0’ Differential between
Supply & Return pressure of Consumers
 Try to kick start the Primary Pumps P-811-01 A/B.
 The Pumps should not take start, since the Suction pressure to the Pumps is
below Set pressure (circulation of CHW not established)
 Simulate a a healthy Pressure on the discharge of Dual Pump Pressurization unit

Pumps / Activate the two PS
 Try to kick start the Primary Pumps P-811-01 A/B. The Pumps should take start.
 Try to start the Sec. Pumps P-811-02 A/B Simulate a DP of around 1 Kg / cm2 /
Activate on both PS.
 The Pumps should take start.
 Increase the simulated DP in both the PS. Monitor and confirm that the
Speed of the Pump increases.
 Gradually Decrease the simulated DP in both the PS.
 Monitor and confirm that the Speed of the Pump Decreases.
5.2 Chiller Package Pre-start Interlocks Check - Chilled water flow- WCP 811-01A
 Confirm that the Motorized valve outlet of the Chiller Package feeding the
Secondary Pumps is closed by Interlock, since the Package is not started yet.
 Keep the Compressor in ‘Electrical Test Position’

 Start the Compressor and wait for 30 seconds
 The Compressor should not take start, because there is no flow of Water In &
Out of the Chiller Package and Interlock for No flow trip coming into play
 Simulate Flow / Activate the Flow Switch FS 0101 on the Chilled Water outlet
line of the Evaporator to Flow conditions

 The Compressor should take start
If the above parameters are Normal proceed to the next step.

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5.3 Chiller Package Pre-start Interlocks Check–Compressor Load/Unload –

WCP 811-01A
Step 1
 Simulate the following parameters to defeat the Interlocks and the

Compressor to ‘Test run’ on Start up.
 Simulate Flow / Activate the Flow Switch FS 0101 on the Chilled Water outlet
 Discharge Pressure PT-02 below the High Pr. Set pt. of Equipment
 Oil Pr. PT 03 above the Low oil Pr. Set pt. of Equipment
 Make a Set Point of 20 deg C for Chilled Water temperature (LWT), which
should be below the atmospheric temperature at site
Step 2
 Simulate the Suction pressure PT-01 (on the Evaporator) to atmospheric
pressure (14.7 psi g / 1 Kg/cm2 g)
 Start Compressor and wait for 30 seconds

 Compressor should start Loading and Load up to 100%
Step 3
 Slowly and Gradually reduce the Simulated Suction pressure PT-01
 The Compressor should start unloading below the Low Suction Unload Set Point
 Record the Simulated pressure at which the Compressor starts unloading
Step 4
 Gradually increase the Simulated Suction pressure PT-01 from the previous step
until the Compressor is 100% loaded in ‘Electrical Test Position’ of the
Compressor
 Simulate a Discharge Pressure on the discharge of the Compressor PT-02 to
atmospheric pressure
 Slowly and Gradually increase the simulated Pressure on the discharge of

the Compressor PT-02
 The Compressor should start unloading above the High Discharge Set Point
 Record the Simulated pressure at which the Compressor starts
unloading
Step 5
 Gradually decrease the Simulated Discharge pressure PT-02 from the previous
step until the Compressor is 100% loaded in ‘Electrical Test Position’ of the
Compressor
 Simulate a Current Consumption (Amperes) for the Motor less than the
Normal value on 100% load (Electrical)
 Slowly and Gradually increase the Simulated Current Consumption

(Amperes)
 The Compressor should start unloading above the High Motor Current Unload Set
Point
 Record the Simulated Current at which the Compressor starts unloading

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Step 6
 Gradually increase the simulated Current Consumption from the previous step
Compressor
 Simulate Actual Evaporator Temperature (TE-05) to be equal to Atmospheric
Temperature
 Slowly and Gradually reduce the simulated Temperature of (TE-05)
 The Compressor should start unloading below the Low Temperature (LWT) Set
Point
 Record the simulated Evaporator temperature (TE-05) at which the
Compressor starts unloading
Step 7
 Gradually increase the simulated Evaporator temperature (TE-05) from the
previous step until the Compressor is 100% loaded in ‘Electrical Test Position’ of
the Compressor
 Slowly and Gradually simulate and increase the discharge Temperature of

Compressor (TE-06)
 The Compressor should start unloading above the High Temperature Unload Set
Point
 Record the simulated Compressor discharge temperature (TE-06) at
which the Compressor starts unloading
5.4 Chiller Package Pre-start Interlocks Check–Compressor Trips – WCP 811-01A
Step 1
Step 2

Step 3
 The Compressor should start Unloading and finally Trip at Low Suction Trip Set
Point
 Record the Simulated pressure at which the Compressor Trips
Step 4
 Simulate the Suction pressure PT-01 back to atmospheric pressure (14.7 psi g / 1
Kg/cm2 g)
 Reset the Trip and restart the Compressor again in ‘Electrical Test Position’

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 The Compressor should start Unloading and finally Trip above the High Discharge
Pressure Trip Set Point
Step 5
 Simulate discharge pressure PT-02 back to below the High Pr. Set pt. of
Equipment for keeping the Compressor on Load
 Slowly and Gradually reduce simulated Pressure of Oil feed Pressure of the
Compressor PT-03.
 The Compressor should Trip below the Low Oil Pressure Trip Set Point
 Record the Simulated pressure of PT-03 at which the Compressor Trips
Step 6
 Simulate Oil Feed pressure PT-03 back above the Low oil Pr. Set pt. of Equipment
for keeping the Compressor running on load
 Slowly and Gradually reduce simulated Temperature of Chilled Water outlet

of the Evaporator TE-02
 The Compressor should Trip below the Antifreeze Trip Set Point
 Record the Simulated Temperature of TE-02 at which the Compressor
Trips
5.5 Chilled Water circuit Start up preparation *Data of Pumps

Running
 Confirm that all simulations are removed and all Interlocks are in place parameters to be
filled in Rotary
 Confirm that all the CHW Supply and Return lines of HVAC users are Equipment Load
complete in all respects and the lines can be charged. Run Monitoring
Reports for the
 Keep the Chilled Water Inlet (CWHS) and outlet (CWHR) isolation valves of
Pumps.
the users of HVAC Open.
 Open the suction isolation valves of the CHW Primary Pumps CHP-8110-01 A/B
 Open Make up water to Dual Pump pressurization unit

 Kick start (ON & OFF) the pumps to reconfirm the Direction of rotation and to
ensure that there is nothing abnormal.
 If there is no abnormality observed, start one of the pumps of the Dual Pump
pressurization unit and open the discharge valve.
 Kick start (ON & OFF) the Primary pumps (CHP-8110-01 A/B) to reconfirm the
Direction of rotation and to ensure that there is nothing abnormal.
 If there is no abnormality observed, start one of the pumps CHP-8110-01 A and
crack open (around 20-25%) the discharge valve, enough to maintain flow.
 The water flows from the Primary pump through the Evaporator of the CHW
package to the Secondary Pumps CHP-8110-02 A/B

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 When flooded suction for the Secondary pumps is established, kick start (ON &
OFF) the Primary pumps (CHP-8110-02 A/B) to reconfirm the Direction of rotation
and to ensure that there is nothing abnormal.
 If there is no abnormality observed, start one of the pumps CHP-8110-02 A and
crack open (around 20-25%) the discharge valve, enough to balance the flow.
 *Monitor the performance of Dual Pump pressurization unit Pump,

Primary Pump and the Secondary Pump.
5.6 Chiller Package Start up Checks – WCP-811-01A
 Confirm that all simulations are removed and all Interlocks are in place
 Keep an Operator posted near the Compressor Drive Motor to note and confirm
the correct Direction of rotation of the Motor
 Confirm that there is no Active alarm for trip of Compressor. If there is any, take
corrective actions and Reset.
 Make a Set point for LWT (Low Water Temperature) of 20 deg. C
(this should be lower than the atmospheric temperature at site). R1
 Start the Compressor from the Control Panel by turning the ‘Run / 1
Stop’ Selector Switch to ‘Run’ position and wait for 30 seconds for
the Loading Vanes to Close. R1
 Turn the System ‘Run / Stop’ Selector Switch to ‘Run’ position 1
 Confirm that the Motor operated valve on the Chilled water outlet line
Opens within 30 seconds
 Confirm that the Compressor starts after 30 seconds
 Confirm that the Direction rotation is correct and there is no abnormality

observed on start of the Compressor.
 If any abnormality is observed, Stop the Compressor immediately from
the Control Panel and take corrective actions
 If no abnormality is observed Monitor the parameters of the Package and proceed

to the next step.
 If the Package had to be stopped for any abnormality, wait for around 5 minutes
after the last start before repeating the Steps mentioned above.
5.7 Chiller Package WCP-811-01A Sustained Run & Parameters
 If there is no abnormality in the Compressor as mentioned in paragraph 7.0 keep

the package in Operation for a sustained duration of around 4 hours.
 The Water should keep circulating in the following circuit:
 i) Makeup water of Dual Pump pressurization unit
 ii) Primary Pump CHP-8110 - A
 iii) Evaporator of the CHW package
 iv) Secondary Pump
 v) Users of HVAC
 vi) CWHR Returned back to the Primary Pump CHP-8110 A.
 When the CWHR pressure is above the Set pressure, Monitor and Confirm
that the Dual Pump pressurization unit pump stops.
 There should be no further addition of Makeup water and the circulation
of water should be self sustained.
 The Dual Pump pressurization unit pump and Makeup water should Auto
start if the CWHR pressure falls below the Set point (due to leakage of
Chilled water etc.)
 Monitor the following important parameters of the Chilled water Package

during the Sustained Run of the Package.

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 Compressor –
 Current consumed (Amperes)
 Vibrations
 Suction Pressure PT-01
 Discharge Pressure PT-02
 Oil Feed Pressure PT-03
 Compressor discharge temperature TE-06
 Oil Separator –
 Level
 Condenser –
 Cooling water Inlet and Outlet temperatures
 Level of the Condenser
 Expansion valve -
 Opening and Closing to maintain the Suction pressure of Compressor
and hence indirectly the Performance (Capacity) of the Package against
Set points
 Evaporator -
 Chilled Water (CHW) Inlet and Outlet temperatures
 Pressure (PT-01), which is the Suction pressure to the Compressor
 Level of Evaporator
 Monitor the following important parameters of the Chilled water System

during the Sustained Run.
 Temperature of CHWS being delivered by the Package

(TG0101)
 Temperature of CHWR being returned back to the Package for chilling

(TG01012).
 Secondary Pump CHP-811-02A –

 Normal running parameters of Pump– Current drawn, Temperature of
Bearings and Vibrations
 The running pump may be changed over during the Run, after starting
the Standby pump (CHP-811-02B), to check performance of both the
Secondary pumps.
 Primary Pump CHP-811-01A –

 Normal running parameters of Pump – Current drawn, Temperature of
Bearings and Vibrations
 The running pump may be changed over during the Run, after starting
the Standby pump (CHP-811-01B), to check performance both the
Primary pumps.
5.9 OTP for other Chilled Water Package WCP-811-01B
 Repeat the above Test Procedure for the Chilled water Package
WCP-811-01B.
5.10 HVAC package Monitoring
 Monitor all parameters of the HVAC package as per HVAC vendor procedure

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 The set point of CHWS may be adjusted as per test requirements of

HVAC package.
 Variation in set point of CWHS would also demonstrate the capabilities
of Chilled water package to cater to demand requirements.
 After successful completion of Operational Tests for both the packages, Stop the
packages and the Chilled water system as follows:
 Stop the Compressor from the Control Panel by turning the ‘Run / R1
1
Stop’ Selector Switch to ‘Stop’ position.
 Turn the System ‘Run / Stop’ Selector Switch to ‘Stop’ position R1
 Confirm that the Motor Operated valve (MOV) on the Chilled 1
water outlet line Closes within 30 seconds
 If the above Tests are satisfactory, the Chilled water packages and Chilled
water System are ready to be pressed into service for sustained operation of
HVAC system.

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CHILLED WATER SYSTEM (PROCESS) – CHP M501, CHP M502 & CHW DISTRIBUTION
Ref: P&ID 7410A-622-PI-1001,
Vendor (Kirloskar Chillers) P&ID 7410A-81J-KCP-ME-PI-1502

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Table of Contents
1. Test Summary


5.1 Hot well and Cold Well Pumps Interlocks against Tank Levels
5.2 Chiller Package Pre-start Interlocks Check - Chilled water flow- CHP M501
5.3 Chiller Package Pre-start Interlocks Check – Compressor Load / Unload – CHP M501
5.4 Chiller Package Pre-start Interlocks Check – Compressor Trips – CHP M501
5.6 Chiller Package Start up Checks - CHP M501
5.7 Chiller Package Sustained Run & Parameters
5.9 OTP for other Chilled Water Package CHP-M502

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Signature
1 Test Summary
 Confirm the safe operational capabilities of the Process Chilled Water System.
 The Production of Chilled Water (Vendor Package)

 Onward distribution of Chilled Water (CHWS) to the users
 Collection of Chilled Water Return (CHWR) from the users
 Recirculation of CHWR through the Chilled Water Production package to re-chill
CHWR (along with makeup water if required to be added) to be suitable for
Process requirements as CHWS
ensure that the Integrated Chilled Water system conforms to the Process requirements
Temporary connection (Hose connection) from the Cold well pumps (P-M5045 A/B/C/D)
discharge header to the Hot well tank. The extreme end of Cold well Pumps discharge
header where blind flange is provided is a convenient point to provide temporary
connection from the header to Hot well tank. If hose connection is made, ensure that
the hose is securely tied so that it will not get dislodged and start flying around
while discharging water to the Hot well tank.
None

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1 day

 Utilities requirement – Power (LV), Oil Lubricant for the Compressor, Refrigerant
filled in the Evaporator and top up quantity, if required.
 Keep the Chiller Compressors Electrically Energized

 Ensure that the Compressor is lubricated and Oil is filled in the Oil Separator
up to the correct level
 Ensure Compressor Motor bearings lubrication is done
 Confirm that Refrigerant is filled in the Evaporator up to the correct level
 Ensure that cooling (Tower) water pumps are running and isolation valves
for Cooling Water Supply and Return from the Condenser are open and
cooling water circulation is established through the Condenser.
 Ensure that all the Interlocks of Chilled Water Production package and
Process Chilled water system are in place.
 The Chilled water production Package panel should be Powered ON after
Pre-commissioning checks
 Keep the Hot well and Cold well circulation pumps Electrically Energized and
ready to start
 Keep Hot well and Cold Well drained and empty and ready
5.1 Hot well and Cold Well Pumps Interlocks against Tank Levels
 Try to kick start the Hot well (Primary) Pumps PM5040 A/B with 0 level in the Hot
well. The Pumps should not take start, due to low level in the Hot well.
 Try to kick start the Cold well Pumps PM5045 A/B/C/D with 0 level in the Cold well.
The Pumps should not take start, due to low level in the Cold well.
 Fill up water in the Hot well (ST-M 521A) and confirm that the Float valve closes
100% when the Tank is full.
 Kick start (ON & OFF immediately) the Hot well (Primary) Pumps PM5040 A/B.
The Pumps should take start; confirm the Direction of Rotation.

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 Fill up water in Cold well (ST-M 521B)

 Kick start (ON & OFF immediately) the Cold well (Secondary) Pumps PM5045
A/B/C/D. The Pumps should take start; confirm the Direction of Rotation.
5.2 Chiller Package Pre-start Interlocks Check - Chilled water flow- CHP M501
 Confirm On-Off Valve XV 0101 outlet of the Chiller Package feeding the Cold well
remains Closed by Interlock, since the Package is not started yet.

 The Compressor should not take start, because there is no flow of Water In &
Out of the Chiller Package and Interlock for No flow trip coming into play
 Simulate Flow / Activate the Flow Switch FS 0101 on the Chilled Water outlet

If the above parameters are Normal proceed to the next step.
5.3 Chiller Package Pre-start Interlocks Check – Compressor Load / Unload –

CHP M501
Step 1

Step 2

Step 3
 The Compressor should start unloading below the Low Suction Unload Set Point
unloading
Step 4

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 Gradually increase the Simulated Suction pressure PT-01 from the previous step
Compressor

 The Compressor should start unloading above the High Discharge Set Point
unloading
Step 5
 Gradually decrease the Simulated Discharge pressure PT-02 from the previous
step until the Compressor is 100% loaded in ‘Electrical Test Position’ of the
Compressor
 Simulate a Current Consumption (Amperes) for the Motor less than the
Normal value on 100% load (Electrical)
 Slowly and Gradually increase the Simulated Current Consumption

(Amperes)
 The Compressor should start unloading above the High Motor Current Unload Set
Point
 Record the Simulated Current at which the Compressor starts unloading
Step 6
 Gradually increase the simulated Current Consumption from the previous step
Compressor
 Simulate Actual Evaporator Temperature (TE-05) to be equal to Atmospheric
Temperature
 Slowly and Gradually reduce the simulated Temperature of (TE-05)
 The Compressor should start unloading below the Low Temperature (LWT) Set
Point
 Record the simulated Evaporator temperature (TE-05) at which the
Compressor starts unloading
Step 7
 Gradually increase the simulated Evaporator temperature (TE-05) from the
previous step until the Compressor is 100% loaded in ‘Electrical Test Position’ of
the Compressor
 Slowly and Gradually simulate and increase the discharge Temperature of

Compressor (TE-06)
 The Compressor should start unloading above the High Temperature Unload Set
Point
 Record the simulated Compressor discharge temperature (TE-06) at
which the Compressor starts unloading
5.4 Chiller Package Pre-start Interlocks Check – Compressor Trips – CHP M501
Step 1

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Step 2

Step 3
 The Compressor should start Unloading and finally Trip at Low Suction Trip Set
Point
Step 4
 Simulate the Suction pressure PT-01 back to atmospheric pressure (14.7 psi g / 1
Kg/cm2 g)


 The Compressor should start Unloading and finally Trip above the High Discharge
Pressure Trip Set Point
Step 5
 Simulate discharge pressure PT-02 back to below the High Pr. Set pt. of
Equipment for keeping the Compressor on Load
 Slowly and Gradually reduce simulated Pressure of Oil feed Pressure of the
Compressor PT-03.
 The Compressor should Trip below the Low Oil Pressure Trip Set Point
 Record the Simulated pressure of PT-03 at which the Compressor Trips
Step 6
 Simulate Oil Feed pressure PT-03 back above the Low oil Pr. Set pt. of Equipment
for keeping the Compressor running on load
 Slowly and Gradually reduce simulated Temperature of Chilled Water outlet

of the Evaporator TE-02
 The Compressor should Trip below the Antifreeze Trip Set Point

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 Record the Simulated Temperature of TE-02 at which the Compressor

Trips
 Keep the Chilled Water Inlet (CHWHS) and outlet (CHWR) isolation valves of
all the users Closed. The users for which the CHWS and CHWR isolation valves
to be kept Closed are VAM chiller and Vent tank, Styrene chiller and Vent tank and
the Process Block - E 002 (Steam Condenser for C -001) and E 005 (Steam
Condenser for C -002)
 Make a temporary connection from the discharge header of Cold well (Secondary)
pumps to the Hot well tank as explained under paragraph 1.3 Temporary
Installations.
 Open the Hot well tank ST-M 521A (filled with water) outlet valve and the suction
isolation valves of the Hot well (Primary) Pumps PM5040 A/B.
 Kick start (ON & OFF) one of the pumps (PM5040 A) to reconfirm the Direction of
rotation and to ensure that there is nothing abnormal.
 If there is no abnormality observed start the pump PM5040 A and crack open
(around 20-25%) the discharge valve, enough to maintain flow.
5.6 Chiller Package Start up Checks - CHP M501
 Confirm that there is no Active alarm for trip of Compressor. If there is any, take
corrective actions and Reset.
 Make a Set point for LWT (Low Water Temperature) of 20 deg. C
(this should be lower than the atmospheric temperature at site).
R1
 Start the Compressor from the Control Panel by turning the ‘Run / 1
Stop’ Selector Switch to ‘Run’ position and wait for 30 seconds for
the Loading Vanes to Close. R1
 Turn the System ‘Run / Stop’ Selector Switch to ‘Run’ position 1
 Confirm that the Shutdown valve on the Chilled water outlet line XV0101
Opens within 30 seconds
 Confirm that the Direction rotation is correct and there is no abnormality

observed on start of the Compressor.
 If any abnormality is observed, Stop the Compressor immediately from
the Control Panel and take corrective actions
 If no abnormality is observed Monitor the parameters of the Package and proceed

to the next step.
 If the Package had to be stopped for any abnormality, wait for around 5 minutes
after the last start before repeating the Steps mentioned above.
5.7 Chiller Package Sustained Run & Parameters
 If there is no abnormality in the Compressor as mentioned in paragraph 7.0 keep

the package in Operation for a sustained duration of around 4 hours.
 The Water should keep circulating from the Hot well (Primary) Pump (PM5040 A)
discharge (CHWR) through the Evaporator and flow to the Cold Well.
 Open the outlet valve of the Cold well and the suction isolation valves of the Cold
well pumps.

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 Start one of the Cold well (Secondary) pumps (PM5045 A) and crack open the
discharge valve.
 The Cold well (Secondary) pump (PM5045 A) should discharge water to the Hot
well through the temporary connection (Ref. paragraphs 1.3 and 6)
 Balance the levels in Hot well and Cold well by throttling the discharge valves of
Hot well (Primary) Pump (PM5040 A) and Cold well (Secondary) Pump (PM5045
A) as required
 Start an additional Cold well (Secondary) pump (PM5045 B), if required to
balance the levels of Hot well and Cold well Tanks.
 If some water overflows from Hot well or Cold well during initial adjustment of
levels and valves openings of the discharge valves of pumps, there is no
harm, as the initial overflow water would be diverted to drain through the
Overflow lines of the tanks.
 Ensure that there is always enough level in both Cold well and Hot well
so that the pumps are not starved of suction and do not trip due to low
level in the tanks during Sustained Run.
 Monitor the following important parameters of the Chilled water Package

during the Sustained Run of the Package.
 Compressor –
 Current consumed (Amperes)
 Vibrations
 Suction Pressure PT-01
 Discharge Pressure PT-02
 Oil Feed Pressure PT-03
 Compressor discharge temperature TE-06
 Oil Separator –
 Level
 Condenser –
 Cooling water Inlet and Outlet temperatures
 Level of the Condenser
 Expansion valve -
 Opening and Closing to maintain the Suction pressure of Compressor
and hence indirectly the Performance (Capacity) of the Package against
Set points
 Evaporator -
 Chilled Water (CHW) Inlet and Outlet temperatures
 Pressure (PT-01), which is the Suction pressure to the Compressor
 Level of Evaporator
 During the Sustained Run of the Chilled water Package, the Chilled Water system
consisting of – Hot well, Cold well and their respective pumps for distribution
should be necessarily in line with temporary installations as mentioned in
paragraphs 6 and 8.
 Monitor the following important parameters of the Chilled water System
during the Sustained Run.
 Cold Well –
 Temperature of CHWS being delivered by the Package to Cold well
(TG0101)
 If the Chilled water temperature approaches the Set point on the
Package (20 deg. C) add some make up water to the Hot well to increase
the temperature of Inlet water to the Package to keep the Package
loaded during the Sustained Run.

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 Ensure level in the Tank by adjusting (throttling) the discharge opening

of the Cold well pump so that the running pump does not trip on Low
level of tank
 Hot well –
 Temperature of CHWR being returned back to the Package for chilling
(TG01012).
 As mentioned under Cold well, if the Chilled water temperature to Cold
well approaches the Set point on the Package (20 deg. C) add some
make up water to the Hot well to increase the temperature of Inlet water
to the Package to keep the Package loaded during the Sustained Run.
 The temperature of CHWR (TG01012)may be maintained at around 25
deg. C (around 5 deg. C higher than the Package set point of 20 deg. C)
to ensure that the package is 100% loaded
 Ensure level in the Tank, the makeup water valve is Open
 Cold Well (Secondary) Pump –

 Normal running parameters of Pump (as done during OTP) – Current
drawn, Temperature of Bearings and Vibrations
 The running pump may be changed over during the Run, if desired, after
starting the Standby pump (PM5045 B), to check performance of both
the Cold well pumps.
 Hot Well (Primary)Pump –

 Normal running parameters of Pump (as done during OTP) – Current
drawn, Temperature of Bearings and Vibrations
 The running pump/s may be changed over during the Run, if desired,
after starting the Standby pump (PM5040 C/D), to check performance of
all the Hot well (Secondary) pumps.
5.9 OTP for other Chilled Water Package CHP-M502
 Repeat the above Test Procedure for the Chilled water Package CHP-M502.
 After successful completion of Operational Tests for both the packages, Stop the
packages and the Chilled water system as follows:
 Stop the Compressor from the Control Panel by turning the ‘Run / R1
1
Stop’ Selector Switch to ‘Stop’ position.
 Turn the System ‘Run / Stop’ Selector Switch to ‘Stop’ position R1
 Confirm that the Shutdown valve on the Chilled water outlet 1
line XV0101 Closes within 30 seconds
 Remove the Temporary Installations mentioned in paragraph 1.3 and Reinstate the
discharge line of Cold well pump to normal Operating position.
 If the above Tests are satisfactory, the Chilled water packages and Chilled
water System are ready to be pressed into service for onward
Commissioning of Terminal Systems.

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AIR COMPRESSORS

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Table of Contents
1. Test Summary


5.1 Kick Start & Confirm the readiness of Compressor 1

5.2 Online & Offline Pressure set points and Run of Compressor 1
5.3 Compressor Loading & Unloading
5.4 Loading the Compressor to 100% Capacity
5.5 Volumetric Capacity confirmation of Compressor 1
5.6 OTP for other Air Compressors – 2, 3 and 4
5.7 Reinstatement of the Compressor discharge line to Operating positions

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Signature
1 Test Summary

The aim of operational test is to demonstrate and confirm the safe operational capabilities
and Guaranteed Capacity of the Air Compressors.
 Start up of the Compressor as per Vendor recommended Procedure, with venting

of air at a convenient location downstream of the Compressor e.g. upstream of the
N2 generation Package.
 Monitor the Operating parameters of the Compressor to confirm suitability for
regular service.
 Modulate different Set discharge Pressures and confirm Stop / Auto Restart
capacity of the Compressor.
 Confirm the Guaranteed Capacity of the Compressor (M3 / hr)
If the Procedure recommended by the Vendor / Vendor’s Commissioning representative’s,

if any, and different from the Procedure mentioned herein, then the Vendor’s /
Commissioning representative’s procedure shall override and take precedence over the
procedure outlined in this document.
On successful conclusion of the Operational Tests, the Air Compressor is ready to be

pressed into regular Operational Service.
Compressed Air discharge line should be opened at a convenient position from Flanged
joint upstream of the N2 Generation package to vent compressed Air. This would not only
serve to Test the parameters of the Compressor but also carry out flushing of the line.
Keep the valve upstream of the vent point throttled & vary the opening as required to
maintain Test pressures as required and detailed below.
If sound pollution is raised as an objection to venting of Air, then a temporary chute with a
silencer may be provided for venting the Air.
R1
Since there is no flow measurement element on the Compressed Air 1
discharge, an Orifice Plate calibrated for 1000 - 4000 m3/hr range for an upstream
pressure of 10 – 11 bar g may be installed at a convenient location upstream of the
vent point, if the Capacity of the Compressor for the rated discharge pressure is to
be established and confirmed.
None

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Mechanical Technicians 3
2 days (for all 4 Compressors)

 Utilities requirement – Power (LV), Coolant and Lubricants for the Compressor.
 Electrically Energize the Compressor

 Set The Controller for the desired Unit of Measure viz. Temp. deg. C and
Pressure Kg / cm2
5.1 Kick Start & Confirm readiness of Compressor 1
 Kick start the Compressor (ON and OFF immediately) from the Compressor
Control Panel
 Confirm that there is no abnormality observed on Kick start of the Compressor
 Confirm that the Compressor drive, Air cooler and Oil cooler fans started
simultaneously
 Confirm the correct Direction of rotation of the Compressor drive motor
 Confirm the correct Direction rotation of the two Fans viz.
 Air cooler Fan
 Oil cooler Fan
 Wait for around 5 minutes before restarting the Compressor for the next step
5.2 Online & Offline Pressure set points and Run of Compressor 1
 Keep a low set point for Online pressure of around 6 Kg / cm2 - above the
minimum Online Pressure of 4.5 Kg / cm2 (65 PSI) - on the Control Panel
 Keep an Offline set point of around 7 Kg / cm2g cm2 - above the minimum
Offline Pressure of 5.1 Kg / cm2 (75 PSI) - on the Control Panel
R1
 Set ‘Enable Auto Restart’ on the Controller Panel 1
 Start the Compressor from the Control Panel in Local position

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 Load the Compressor by pressing the Load Push Button until the Package
discharge pressure is stable below the Offline discharge pressure
 Adjust the isolation valve upstream of the vent point, if required, to
maintain the pressure as above
 Note the following display on the Control Panel
Set values
 Online Pressure Set Point R1
 Offline Pressure Set Point 1
Actual Operating values

 Package discharge Pressure
 Sump Pressure
 Air end discharge Temperature
 Inject Coolant Temperature
 After cool discharge Pressure
 Separator Pressure drop
 Maintain the above condition for about 15 minutes

 Monitor, Record and Confirm that all parameters are within limits
 Temperatures and Vibrations of the DE, NDE and Body of the Compressor
 Temperatures and Vibrations of the DE, NDE and Body of the Drive Motor
 Temperature Transmitter on the discharge of the Compressor (2ATT)
 Differential Pressure (SCPT Out - In) across the Oil Filter (OF) - (should be
<0.3 Kg / cm2)
 Injected coolant Temperature (2CTT)
 Vacuum at suction of the Compressor (1AVPT)
 Confirm that the Filter Breather (BR) is unobstructed and functions normally

 Take corrective actions, if any required based on the above parameters
5.3 Compressor Loading & Unloading
 Carry out the following steps at an Interval of around 5 minutes or more to

confirm the capability of the Compressor to maintain the sequence mentioned
below:
 Loading of Compressor when the discharge Pressure is equal to or just

below the Online set pressure.
 Unloading / Stop of the Compressor when the discharge pressure is
equal to or just above the Offline set point
Step 1
Maintain the same Offline and Online set points as the previous step i.e. Online set
point of 6 Kg/cm2 g and Offline set point of 7 Kg/cm2 g
 Slowly increase the valve opening upstream of the temporary vent so that the
discharge Pressure on discharge line of the Compressor (4APT) is slightly below
the Online set pressure of around 6 Kg / cm2 g (to around 5.8 Kg / cm2g)
 Confirm that the Compressor is Loaded when the discharge pressure is
below the Online set Pressure of 6 Kg/cm2 g
Step 2
 Slowly Decrease (Close) valve opening upstream of the temporary vent so that the
discharge Pressure on discharge line of the Compressor (4APT) is
equal to or slightly above the Offline set point of 7 Kg/cm2 g
 Observe and confirm that the Compressor Unloads / Stops.

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 Observe that when the discharge Pressure falls below the Online Set point of
6 Kg/cm2 g, the Compressor Restarts because of setting in the Control
Panel ‘Auto Restart’
 Monitor, Record and Confirm that all parameters during the above Steps are
within limits as carried out in the previous step (5.2).

 Take corrective actions, if any required based on the above parameters
5.4 Loading the Compressor to 100% Capacity
 Run the Compressor on Load with an Offline set point equal to 7 Kg / cm2g
(4APT) and Online set point to 6 Kg/cm2g
 Slowly increase the Offline set point in steps e.g. increase of 1 Kg/cm2 g per 5
minutes.
 Simultaneous to increase of Offline set point increase the Online set point to
maintain a lag of around 1 Kg / cm2g from the Offline set point i.e. if the Offline set
point is 8 Kg/cm2g, the Online set point should be around 7 Kg/cm2g
 Check to confirm if the opening for Air venting from the Open end is
adequate to discharge all the Compressed Air to atmosphere and just
enough to maintain the Offline set pressure
 Gradually Load the Compressor up to a an Offline set point of 10.2 Kg / cm2 g and
an Online set point of 9.7 Kg / cm2 g
 Maintain the above conditions and Monitor all the above parameters
mentioned under paragraph 5.2 for around 4 hours with readings noted at an
interval of 15 minutes
 Additionally carry out the following checks:
 Moisture separator functions properly and Condensate drain valve (9SV)
drains the Condensate.
 Collect a sample of Air from the discharge of the Compressor at a
convenient location and analyze the Air to confirm that there is no
carryover of Coolant with the discharged Air
 Check all the Flanges in the Compressed Air line for leakage with soap
solution.
 Attend to leakages observed
5.5 Volumetric Capacity confirmation of Compressor 1
 Check and Record the Volume discharged from the Compressor under
Sustained Run with an Offline set point of 11 Kg / cm2 g and an Online set
point of 10 Kg / cm2 g through the Orifice flow meter mentioned under
Temporary installations in paragraph 1.3
 The Volume discharged should be not less than 745 cfm = 1266 m3/hr
(for 1 Compressor)
5.6 OTP for other Air Compressors – 2, 3 and 4
 Repeat the above Test Procedure for the other 3 Compressors – 2,3 and 4
5.7 Reinstatement of the Compressor discharge line to Operating positions
 After successful completion of Operational Tests for all the 4 Compressors, Stop
the Compressors, Remove the Temporary Installations mentioned in paragraph
1.3 and Reinstate the discharge line and the System to Operating positions.
 Restart the Compressors (one at a time) and keep them in line as per
requirements - Maximum 3 Compressors running at a time and 1 Standby.

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 If there is any leakage from the Reinstated position, the same should be attended
to.
 If the above Tests are satisfactory, the Air Compressors are ready to be
pressed into service for onward Commissioning of Terminal Systems

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NITROGEN & INSTRUMENT AIR GENERTATION PACKAGE
Vendor (Sam Gas Projects P Ltd.) P&ID 7410A-81B-SAM-CN-PI-1001

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Table of Contents
1. Test Summary


5.1 Air Receiver Low Pressure Alarm

5.2 Air Receiver High Temperature Alarm
5.3 N2 Surge Vessel Low & High Pressure Alarms
5.4 O2 Analyzer Functional Test
5.5 PSA Cycle & Changeover of PSA Units R1
1
5.6 IA Receiver Low & High Pressure Alarms
5.7 IA Receiver High Temperature Alarm R1
1
5.7 IA Cycle Changeover of IA Drier Units R1
5.8 Run Test of N2 / IA Package 1
5.9 Monitoring IA output & Quality

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Signature
1 Test Summary
 Confirm the safe operational capabilities of the Nitrogen & Instrument Air
Generation Package.
 Confirm that the Package delivers N2 and IA as per specifications
 Confirm proper functioning of safeguards - Alarms and Trips – to ensure the
Safety of Personnel and the System.
 Generation of N2 by PSA through Carbon Molecular Sieves from Compressed Air

 Generation of IA from Compressed Air
ensure that the Integrated Chilled Water system conforms to the Process requirements
On successful conclusion of the Operational Tests, the N2 & Instrument Air Package is
ready to be pressed into regular Operational Service.
 Open any spool piece downstream of the Tie-in points for N2 outlet and Instrument
Air outlet from the Package and make temporary vent provisions for venting N2
and Instrument Air during the initial Load Run of the Package
None

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1 day

 Utilities requirement – Compressed air from Air Compressor, Power (LV), Cooling
water
 Keep the Control Panel Energized and ON

 Keep all the Instruments in line
 Keep all the isolation valves of the Package in Operating positions
 All the Auto Drain traps should be open and in Operating positions
 Confirm that all the Equipment and vessels of the Package – Air receiver, N2
Surge vessel, N2 Storage tank, IA Receiver etc. are in Operating positions
 Confirm that the internals of all the 4 stage filters are installed to protect
the PSA Molecular sieves from poisoning R1
1
 Keep the Process Cooling Tower CT – M501 in Operation with Cooling water
circulation pumps running
 Open the Inlet and Outlet Cooling water isolation valves of the After coolers and
keep Cooling water circulation going through the After coolers
 Maintain a Cooling water pressure of around 4 Kg / cm2 g R1
 Keep the Control room informed 1
5.0 Tests & Procedure – Dry Interlocks checks by Simulation
 Switch on the Control Panel of the N2 / IA Package in ‘Test Mode’ and

Proceed with the following Simulated Tests
5.1 Air Receiver Low Pressure Alarm
 Confirm that Low Pressure Alarm is initially displayed in the Control Panel
 Try to Start the PLC of PSA units
R1
 It should not Start below the Set point Pressure (8.5 Kg / cm2 g)
1
 Simulate Pressure in the Receiver / Activate the Pressure Switch PS 0102 a

healthy Pressure of 10 bar g
 Confirm that the Low Pressure Alarm goes off
 Confirm that PLC of PSA units can be started on pressing the Start
button
 Record the Pressure at which Low Pressure Alarm goes off
 Lower the Simulated Pressure / Release the PS

 Confirm Low Pressure Alarm
 Confirm Trip of the PLC Panel
 Record the Pressure at which the PLC Panel trips and Low Pressure Alarm is
displayed
 I If the above parameters are Normal, Simulate Pressure in the Receiver /

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Activate the Pressure Switch PS 0102 to a healthy Pressure of 10 bar g and

Proceed to the next step
5.2 Air Receiver High Temperature Alarm
 Simulate the Air Receiver Temperature through TIC 0101.

 Slowly Increase the Temperature until the High Temperature set point is reached
 Confirm High Temperature in the Receiver Alarm
 Record the Temperature at which High Temperature Alarm is displayed
 If the above parameters are Normal, remove the High Temperature Simulation and
proceed to the next step.
5.3 N2 Surge Vessel Low & High Pressure Alarms
 Confirm that Low N2 Pressure Alarm is initially displayed in the Control Panel
 Simulate the Pressure in the N2 Surge Vessel / Activate the Pressure Switch (PS
2103) to a healthy pressure of 8.5 bar g.
 Confirm that the Low N2 Pressure Alarm goes off
 Record the Pressure at which Low Pressure Alarm is displayed
 Slowly increase the Simulated Pressure / Activate the Pressure Switch (PS 2103)
above the Set point
 Confirm N2 High Pressure Alarm is displayed
 Record the Pressure at which High Pressure Alarm is displayed
 If the above parameters are Normal, keep the Simulated Pressure / Pressure
Switch (PS 2103) activated to a healthy of 8.5 bar g in the Surge Vessel and
5.4 O2 Analyzer Functional Test
 Initial reading of the O2 Analyzer should be high corresponding to Atmospheric Air

(21%)
 Confirm High O2 Alarm in the Control Panel
 Confirm that the 3 way vent valve upstream of the N2 storage Tank is Open
to vent
 Close the 3 way vent valve from the Control Panel
 Confirm that the 3 way vent valve Closes & Opens again
to vent, because the O2 content is high R1
1
 Confirm that the N2 / IA Package is running on ‘Test Mode’
 Simulate the O2 Analyzer (OAA 0101) and gradually reduce the O2 level around
0.5%.
 Confirm that the High O2 Alarm goes Off
 Record the O2 % at which the High Level Alarm goes Off
 Close the 3 way vent valve from the Control panel
 3 way vent valve should close
 With the above simulation of O2 content within limits (<0.5%), simulate the
Pressure of N2 storage tank and gradually increase the simulated pressure to
more than 8.5 bar G
 Confirm that the 3 way vent valve Opens (to vent) due high N2 Pressure in
the N2 storage tank
 Record the simulated pressure at which the 3 way vent valve
Opens (to vent) R1
1
 Then Slowly increase the simulated value of O2 %
 Confirm High O2 Level Alarm in the Control Panel R1
 Record the O2 % at which the High Level Alarm appears 1

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 Confirm that the 3 way vent valve Opens again to vent

 Record the O2 % at which the 3 way vent valve Opens to vent
 If the above parameters are Normal, keep the Simulated Pressure / Pressure
Switch (PS 2103) activated to a healthy of 8.5 bar g in the Surge Vessel and
PSA vessel T-PSA-008 in line on ‘Test Mode’ and proceed to the next step.
5.5 PSA Cycle & Changeover of PSA Units R1

1
 Observe and confirm the PSAs alternatively come in line and go on Regeneration
every 1 minute viz.
 PSA (1) online time of 1 minute, Pressure Equalization, PSA Unit (2) comes
in line and PSA (1) goes on Regeneration
 After 1 minute Pressure Equalization, PSA (1) comes in line and PSA (2)
goes on Regeneration
 This process of Online period of PSA, Pressure Equalization, Changeover of PSA,

Regeneration of spent PSA and Regenerated PSA coming in line again should
continue after 1 minute interval of time
 The position of Solenoid vales for online period, Pressure Equalization

period and Regeneration period should be as follows:
 Confirm Operation of Solenoid valves by hissing sound & heat
PSA T-PSA-007 in line & PSA T-PSA-008 under Regeneration

(57.5 Seconds)
Position of Sol. Valves PSA T-PSA-007 Position of Sol. Valves PSA T-PSA-008
 S0l01 A & B (Inlet valves) Open S0l02 A & B (Inlet valves) Closed
 S0l03 A & B (Vent valves) Closed S0l04 A & B (Vent valves) Open
 S0l07 A & B (Outlet valves) Open S0l08 A & B (Outlet valves)
Closed
Position of Sol. Valves Common to PSA T-PSA-007& PSA T-PSA-008

 S0l06 (Common outlet to N2 Surge Vessel) Open
 S0l05 A & B (Vent valves to Silencer) Open
Pressure Equalization before Change over from PSA T-PSA-007 to PSA T-PSA-008
(1.5 Seconds)
 S0l01 A & B (Inlet valves) Closed S0l02 A & B (Inlet valves) Closed
 S0l03 A & B (Vent valves) Open S0l04 A & B (Vent valves) Open
 S0l07 A & B (Outlet valves) Open S0l08 A & B (Outlet valves) Open

 S0l06 (Common outlet to N2 Surge Vessel) Closed
 S0l05 A & B (Vent valves to Silencer) Closed
PSA T-PSA-008 comes in line & PSA T-PSA-007 goes into Regeneration
(1 Second)
 S0l01 A & B (Inlet valves) Closed S0l02 A & B (Inlet valves) Open
 S0l03 A & B (Vent valves) Open S0l04 A & B (Vent valves) Closed
 S0l07 A & B (Outlet valves) Closed S0l08 A & B (Outlet valves) Open

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 S0l06 (Common outlet to N2 Surge Vessel) Open
 S0l05 A & B (Vent valves to Silencer) Open
5.6 IA Receiver Low & High Pressure Alarms
 Confirm that Low IA Pressure Alarm is initially displayed in the Control Panel
 Simulate the Pressure in the IA Receiver / Activate the Pressure Switch (PS 0106)
to a healthy pressure of 8.5 bar g.
 Confirm that the Low IA Pressure Alarm goes off
 Record the Pressure at which Low Pressure Alarm goes off
 Slowly increase the Simulated Pressure / Activate the Pressure Switch (PS 2103)
above the Set point
 Confirm N2 High Pressure Alarm is displayed
 Record the Pressure at which High Pressure Alarm is displayed
 Bring the Simulated Pressure back to a healthy pressure of 8.5 bar g

 Confirm that there is No Pressure Alarm for IA
 If the above parameters are Normal, maintain the above simulations and proceed
to the next step.
5.6 IA Receiver High Temperature Alarm R1

1
 Confirm that initially there is no Temperature Alarm
 Simulate the Temperature on TIC 0102 on the Instrument Air Receiver and
gradually increase the simulated Temperature
 Confirm High Temperature Alarm
 Record the Temperature at which High Temperature Alarm is displayed
 If the above parameters are Normal, Remove the Temperature simulation and
proceed to the next step
5.7 IA Cycle Changeover of IA Drier Units R1
1
 Observe and confirm the IA Drier units alternatively come in line and go on
Regeneration every 5 minutes viz.
 IA Drier (1) online time of 5 minutes, IA Unit (2) comes in line and IA (1) goes
on Regeneration
 After 5 minutes, PSA (1) comes in line and PSA (2) goes on Regeneration
 This process of Online period of IA unit, Changeover of IA unit, Regeneration of

spent IA unit and Regenerated IA unit coming in line again should continue after 5
minutes interval of time
 The position of Solenoid vales for online period and Regeneration period
should be as follows:
 Confirm Operation of Solenoid valves by hissing sound & heat
T-ADU-11 in line & T-ADU-12 under Regeneration

(5 minutes)
Position of Sol. Valves T-ADU-11 Position of Sol. Valves T-ADU-12
 S0l01 (Inlet valve) Open S0l02 (Inlet valves) Closed

 S0l03 B (Vent valve) Closed S0l04 (Vent valve) Open
T-ADU-12 comes in line & T-ADU-11 goes into Regeneration

(5 minutes)

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Position of Sol. Valves T-ADU-11 Position of Sol. Valves T-ADU-12
 S0l01 (Inlet valve) Closed S0l02 (Inlet valves) Open

 S0l03 B (Vent valve) Open S0l04 (Vent valve) Closed
 The above completes the Simulated Checks for the Package

 Remove all Simulations and get the System ready for Run Test of the
Package
5.8 Run Test of N2 / IA Package
 Confirm that the following are as set before:

 Control Panel Energized and ON
 All the Instruments in line
 All the isolation valves of the Package in Operating positions
 All the Auto Drain traps should be open and in Operating positions
 Inlet and Outlet Cooling water isolation valves of the After coolers are Open
and Cooling water circulation is going through all the After coolers
 Start the Air Compressors (3 Nos.) and keep them running with all Interlocks
in place
 Vent some air initially by keeping Open some drain valves the
Compressed Air Network prior to Feeding the N2 / IA Package to flush
out the lines free of water and dirt
 When the lines are Clean, Close all the valves in the Compressed Air
distribution Network and Open the Feed to the N2 / IA Package
 Maintain the Compressed Air Pressure Inlet to the N2 Package at 10 bar g.

 Maintain Air pressure inlet to the PSA units at 9.5-10 Kg / cm2 g by
adjusting the Globe valve at the inlet of PSA module
 When the Inlet Compressed Air Pressure is stable, Start the N2 Package from the
Control Panel
 Rest are taken care by the Package – from the feed of Compressed Air to PSA
and outlet N2 from the N2 Storage Tank T-ST-010
 Regulate the Outlet valve T-ST-010 to maintain a Pressure of 8.5 bar g in the
N2 Storage Tank T-ST-010
 Confirm N2 being vented from the temporary vent downstream of N2 Storage

Tank T-ST-010
 Maintain the above conditions and monitor the parameters:
 Air Pressure and Temperature in the Air Receiver
 Cooling water Temperatures Inlet & Outlet of After coolers
 Drain traps for draining of trapped moisture
 No leaks in the circuit etc.
 Check the O2 content in the Oxygen Analyzer
 If the Oxygen content is less than 0.5% Close the 3 way vent valve from
the Control panel and stop venting upstream of N2 storage vessel
 When steady state is established Regulate the Regulate the Outlet valve T-ST-010 **There is No FT
to maintain a flow 700 Nm3 / hr. as indicated on the FT provided on the outlet of on the Comr. Air
N2 surge vessel and a Pressure of 8.5 bar g in the N2 Storage Tank T-ST-010 line. Temporary
provision may
 **Maintain the flow of Compressed Air at 3200 Nm3 /hr. inlet to the Air be made to
receiver to confirm the Capacities of both N2 Generation and IA Generation confirm Capacity
of the Package of the IA Unit
 When the parameters are steady for a sustained duration of around an hour,
check the following on the installed meters in the Package and also confirm
through Lab Analysis:
 O2 content in the N2 (< 0.5%)

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 Dew point of Product N2 (-40 deg. C)

 N2 Purity (> 99.5%) (Lab Analysis)
 Confirm PSA Cycle & Changeover of PSA Units every 1 minute as detailed in
paragraph 5.5
 Monitor & Confirm that just after Pressure equalization, the N2 pressure
drops by 0.2 to 0.3 bar G, which is a healthy sign
5.9 Monitoring IA output & Quality
 Confirm IA being vented from the temporary vent downstream of Instrument Air
Receiver T-IAR-013
 Regulate the Outlet valve to maintain a Pressure of 8.5 bar g in the IA
Receiver
 When the parameters are steady for a sustained duration of around an hour,
check the following through Lab Analysis:
 Dew point of Product Instrument Air (-40 deg. C)
 If the above results are satisfactory continue to run the Unit with Monitoring of
parameters.
 Confirm Auto Changeover of ADU and Regeneration cycle being initiated for
the spent ADU as per Logic once in 5 minutes as detailed in paragraph 5.7, ** There is no FT
during the sustained run of the Package installed for IA
 **Maximum Capacity of IA output with 700 Nm3 / hr. of N2 output as flow
mentioned above.
 After successful completion of the Run Test, Remove the Temporary Installations
mentioned in paragraph 1.3 and Reinstate the outlet lines of N2 and IA to normal
Operating positions
 If the above Tests are satisfactory, the N2 / IA package is ready to be

pressed into service for onward Commissioning of Terminal Systems.

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FIRE PROTECTION SYSTEM
(FW PUMPS AND FOAM & MVWS SYSTEMS)
(Ref. P&IDs: TCE.7410A-300-PI-1004, TCE.7410A-300-PI-1005
Fire Fighting System Design Philosophy: 7410A-81P-CME-OT-BD-1851)

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Table of Contents
1. Test Summary


5.1 Fire Water Tank Level Tests

5.2 Pumps & Drivers basic checks
5.3 Auto Change Over of Jockey Pumps
5.4 Auto start of Diesel Pump (Diesel Engine driven Pump) on Power failure
5.5 Diesel Pumps Auto Start on Fire Alarm – Automatic Water spray system for Loading
Gantry
5.6 Diesel Pumps Auto Start on Fire Alarm – Automatic Water spray system for Product
Pump houses for Dike I & Dike II
5.7 Diesel Auto Start on Fire Alarm– Automatic Water spray system for Tanks
5.8 Sprinkler System for Buildings
5.9 Performance checks of MVWS
5.10 Performance Checks of Foam system
5.11 Performance Checks of Fire Hydrants and Monitors

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Signature
1 Test Summary
The aim of operational test is to demonstrate the safe operational capabilities of the Fire
fighting systems consisting of the following:
 Fire Water Jockey Pumps

 Diesel Engine operated main FW pumps
 Medium Velocity Water Spray (MVWS) System
 Foam System
The systems under this Test cover the following Equipments
 Fire Water Storage Tank T-FRW-001

 Jockey Pumps 617-JP-001 and 002
 Diesel Engine operated FW pumps 617-FP-001,002,003 and 004
 Foam system consisting of Foam Concentrate tanks (2 Nos.), Foam Admixing
Unit with Diesel Engine driven Foam pump, Motor driven Foam pump, Foam
proportioning and distribution to Foam network on demand.
The Loop Checks of individual Equipment and Systems should have been completed as
part of Instrumentation procedure. However an integrated overall Functional Test is
important to confirm and ensure that the integrated system is equipped to handle
contingencies arising out of Fire for the Safety of installations.
On successful conclusion of the Operational Tests, the systems are ready to support the
regular Operation functions of the Terminal.
Nil
The Operational Tests would be carried out by simulation to avoid flooding of the
areas with Fire Water and hence all the Fire Water pumps including the Jockey
pumps should be decoupled from their Drivers viz. Diesel Engines / Motors.
The foam pumps drivers of Foam Admixing unit viz. Diesel Engine and Motor
should also be decoupled from their pumps for the Test.
After the Tests are concluded satisfactorily, the pumps may be coupled to the
drivers. It is desirable to carry out actual Spray of Fire Water and Foam distribution
in selected identified areas to confirm that the coverage of Spray water and Foam
distribution are as per design and adequate to handle contingencies, in case
required.

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MVWS System Design & Supply vendor and Diesel Engines Vendor are desirable.
2 days
 The system under Test is isolated process wise

 Functional Tests of the system have been completed
 Utilities requirement – Power (LV), Instrument air, Foam tank filled and Water
level in the Fire Water Tank (for actual confirmation of requisite flow patterns in
identified areas)
 Consumables – Lubricants for the pumps, Diesel, Foam Concentrate and Water
in the Fire Water Tank.
 All Pumps are decoupled from motors.

 Direction rotation of motors are confirmed in de-coupled condition
 Jumper list if any – Nil
 Blind List - Nil
 Isolate the all the MVWS systems by closing the individual isolation valves, in
preparation for actual demonstration at identified areas after successful
conclusion of Tests.
5.1 Fire Water Tank Level Tests
 Simulate High Level of the FW Tank; Since the Tank is provided with a ball float
valve, hold the Float in full ‘Close’ Confirm that the Inlet valve closes fully.
 Simulate Low Level of FW Tank on the Differential Pressure transmitter (LT

126-1).
 Confirm that the Inlet Float valve is 100% Open and Low Level Alarm is
displayed and sounded in the Fire Alarm Panel (Terminal Automation
System (TAS) Control Panel) in the Control room

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5.2 Pumps & Drivers basic checks
 Start one Jockey Pump Motor at a time in Test position (Pump decoupled), from
the Controller
 Confirm Direction of Rotation and the running indication of the same Pump in
the Control room.
 Start one Diesel Engine of the FW Pumps at a time in Test position (Pump
decoupled) from Local Push Button.
 Confirm Direction of Rotation and the running indication of the same Pump in
the Control room.
5.3 Auto Change Over of Jockey Pumps
 Keep both Jockey Pumps in Auto mode.

 Simulate a healthy Fire Water pressure of more than 12 Bar g in the Hydrant
Network by Simulating the PT / PS on the Pump Controllers of Jockey pumps
(617-JP-001) and 617-JP-002).
 Try to start Jockey pump (617-JP-001).
 The Pump (Motor) should not start since the simulated pressure is more
than the Cut off (Stop) pressure of 12 Bar g for Jockey pumps.
 Slowly lower the simulated value of Pressure below the Set Point to 10 Bar g (or
slightly lower) on the Controllers of both (617-JP-001) and 617-JP-002).
 Confirm that Jockey Pump 617-JP-001 (Motor) starts on Auto. Note Cut off
pressure at which 617-JP-001 Auto starts (It should be 10 Bar g).
 Maintain the above set point of 10 Bar g (or slightly lower)

 Stop the Jockey Pump 617-JP-001 and keep the Stop push button locked in Stop
position.
 Confirm Auto start of Jockey Pump (Motor) 617-JP-002.
 Confirm Alarm of the Jockey Pump Auto Change over in the Control Room.
 If the above test is satisfactorily concluded, restore the system to Normal state.
5.4 Auto start of Diesel Pump (Diesel Engine driven Pump) on Power failure
 Simulate a healthy Fire Water pressure 11 Bar g in the Hydrant Network by

Simulating the PT / PS on the Pump Controllers of both the Jockey pumps (617-
JP-001 and 617-JP-002) and all the Diesel driven FW Pumps.
 Keep one of the Jockey Pumps (Motor) (617-JP-001) running on Auto mode and
the Other Jockey pump (Motor) (617-JP-002) electrically isolated.
 Stop the running Jockey pump (617-JP-001) and keep the Stop push button
locked in Stop position. The other Jockey Pump cannot start due to Electrical
isolation.
 Slowly lower the simulated value of Pressure on the Controllers of Diesel driven
Pumps to slightly below the Cutoff point of 9 Bar g.
 Confirm that Diesel Engine for Pump 1 Auto starts as per sequential
priority allotted to maintain the Fire Water pressure. Note the Pressure at
which the Pump (Engine) Auto starts
Pumps to slightly below 8 Bar g.
 Confirm that Diesel Engine for Pump 2 Auto starts with Diesel Engine
for Pump 1 still running.
 Note the Pressure at which the Pump 2 (Engine) kicks in and Auto starts

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 Confirm that Diesel Engine for Pump 3 Auto starts with Diesel Engines
for Pumps 1 and 2 still running. Note the Pressure at which the Pump 3
(Engine) kicks in and Auto starts.
 Confirm that Diesel Engine for Pump 4 Auto starts with Diesel Engines
for Pumps 1, 2 and 3 and still running. Note the Pressure at which the
Pump 4 (Engine) kicks in and Auto starts.
 If the above tests are satisfactory, stop the simulations and manually stop the
Diesel Engines and restore the system to Normal state.
5.5 Diesel Pumps Auto Start on Fire Alarm – Automatic Water spray system for
Loading Gantry
 Keep the Control room and the main security gate informed of the Test of
the FW system and not to panic on getting Fire Alarms.
 Keep both the Jockey Pumps and all four Diesel Pumps in Auto mode.
 Start one Jockey pump (decoupled) Motor running
 Keep all the PS on the individual headers FW Network catering to Water
Spray viz. – Tanks Farm, Loading Gantry and Pump houses for Dikes I and II
- simulated to a healthy level of 11 Bar g.
 Shatter a few Quartzoid bulbs (in different bays) of the Loading gantry.
 Ensure Alarm is sounded in the Control room-Fire Alarm Panel
 Simulate a Pressure to slightly below 9 Bar g on the Loading Gantry

Network and PT of all the FW Pumps Controllers.
 Confirm Auto start of Diesel Engine 1.
 Confirm that the Deluge valve to the Loading Gantry opens 100%.
 Gradually reduce the Simulated pressure to 8 Bar g on the Loading Gantry

Network and all the FW Pumps Controllers
 Confirm that Engine for FW main Pump 2 Auto starts.
 Gradually reduce the simulated pressure to 6 Bar g.

 Confirm Auto start of Engine for FW main Pumps 3 and 4 at 7 and 6 Bar g
respectively.
 If the occurrences in the field are as mentioned above, the Tests are
satisfactorily concluded and the MVWS system in the circuit is healthy.
 Stop the Diesel Pump (Engines) manually, Replace the broken Quartzoid bulbs
and Restore the system to normal state.
5.6 Diesel Pumps Auto Start on Fire Alarm – Automatic Water spray system for Product
Pump houses for Dike I & Dike II
 Repeat the above steps for the Product Pump houses for Dikes I & II, by
activating the respective components – Quartzoid bulbs, PS in the circuit of the
Pump houses circuit and PT all the FW Pumps Controllers.

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 If the occurrences are identical as mentioned above for the Loading gantry,
the Tests are satisfactorily concluded and the MVWS system in the circuit is
healthy.
 Replace the broken Quartzoid bulbs and Restore the system to normal state.
5.7 Diesel Auto Start on Fire Alarm–Automatic Water spray system for Tanks
 Repeat the above steps for the Storage Tanks of Dike I & Dike II, by activating the
respective components – Quartzoid bulbs, PS in the circuit for Water Spray for
Tanks and PT all the FW Pumps Controllers.
 If the occurrences are identical as mentioned above, the MVWS system in

the circuit is healthy.
 Replace the broken Quartzoid bulbs and Restore the system to normal state.
5.8 Sprinkler System for Buildings
 The Buildings covered under Sprinkler system are the Administration Building,
Security Cabin, Utility Building, Fire Water Pump house
 Keep the isolation valves for the Sprinkler systems of all the Buildings Closed.
 The function of the Sprinkler system may be verified only by simulations,
not to cause unnecessary flooding in the Building areas.
 Ensure the activation of Sprinkler system for any one building (Administration
Building) by shattering a few sprinklers.
 Confirm that the Zone Control valve opens (to admit Sprinkler water) for the
Building.
 Simulate the Flow / Pressure Switch in descending order and simultaneously

gradually simulate Pressure on the Controllers of Diesel driven Pumps in the
descending order from 10 Kg/cm2 down to 6 Kg /cm2.
 Confirm Auto start of Fire Water pumps (Engines) as per sequential priority
allotted to maintain the Fire Water Pumps 1, 2, 3 and 4 as mentioned in
paragraph 5.4.
 The above may be repeated for Other Buildings viz. Security Cabin, Utility
Building and Fire Water Pump house, one building at a time and keeping the
isolation valves Closed.
 If the occurrences in the field are as mentioned above, the Tests are
satisfactorily concluded and the Sprinkler system for the Buildings is
healthy.
 Replace the broken Quartzoid bulbs Restore the system to normal state.
5.9 Performance checks of MVWS
 After satisfactory conclusion of all the tests MVWS system as above, It is

desirable to actually carry out the Water Spray and Foam distribution on
one or more tanks, to be sure that the Water spray is uniform and as per
design and the Foam system is functional as required.
 Couple both the Jockey Pumps and the Diesel Engine Pumps to their
respective drivers, install coupling guards.
 Reinstate the systems to Normal operating positions.
 Keep two Diesel Engine driven FW pumps (Pumps 1 and 2) running in ‘Test’
position and maintaining Hydrant pressure in the line.

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 Manually activate the Deluge valve for any of the Storage Tanks in Dike I.
 Confirm that the Water Spray on the Tank is Uniform as per Design and
Satisfactory.
 If Water spray is satisfactory, the Performance check is satisfactorily

concluded.
 The same Performance check may be carried out for any Tank in Dyke II of
different diameter with different Diesel driven FW pumps (FW pumps 3 and 4)
running in ‘Test’ position.
 The Tests may be repeated on a few more Tanks, if desired, to fully ascertain
the effectiveness of the Spray system.
 Restore the system to normal state.

5.10 Performance Checks of Foam system
 Fill Foam Concentrates in the Foam tanks.

 Couple both the Foam pumps to their drivers and install coupling guards.
 Keep two Diesel Engine driven FW pumps (Pumps 1 and 2) running in ‘Test’
position and maintaining Hydrant pressure in the line.
 Keep the Foam distribution valves to all the Tanks closed. Ensure that the
Foam lines up to the Isolation valves of all the Tanks is kept under pressure
by running one of the Foam pumps and Stopping it.
 Simulate and Activate the Fire detection Alarm for any of the Storage Tanks
where Foam distribution is applicable (e.g. T-MTL-001/002, T-NPT-001/2/3…)
 Slowly Open the Foam distribution valves of the tank for which Fire detection
Alarm has been activated.
 Confirm Auto Start of both the Foam distribution pumps (Motor driven
and Diesel Engine driven) due to drop in pressure in the Foam line,
both the pumps contributing to 50% of Total Foam distribution.
 Confirm if the Inline Balance Proportioning unit is metering the correct
concentration of Foam after proportioning (3% AFF Foam).
 Check the Foam distribution in the Tank, to confirm if Foam sealing is
uniform on the Foam ring and good enough to offer protection.
 Stop one of the Pumps (Motor driven – keep the Stop push button locked in Stop
position).
 Confirm that one Pump (Diesel driven) is able to cater to the
requirement as mentioned above.
 Repeat the above by starting Motor driven pump and keeping Diesel driven pump
locked in Stop position.
 Confirm that one Pump (Motor driven) is able to cater to the
requirement as mentioned above.
 The above may be repeated on another Tank, if desired, to fully ascertain the
capability of the Foam system.
5.11 Performance Checks of Fire Hydrants and Monitors
 Keep the isolation valves for all Spray, Deluge, Sprinkler systems, Fire Monitors,
and Fire Hydrants in the Terminal Closed.
 Start Diesel pumps 1 and 2 in Test position and keep them running.
 Check all Fire Hydrants for unobstructed flow of Water

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 Check all the Monitors - Fire Monitors (FM), Water Cum Foam Monitors
(FMH), Water Cum Foam Monitors on Pipe Rack for Throw, Distance of
throw and Quantity as per specifications for the respective Monitors
 Check the performance of the Remote Controlled Water Cum Foam
Monitors, by operating it from the Control room.
 If all the above Tests are satisfactorily concluded the Systems are protected
against Fire as per Design.
 Keep all the MVWS System Fire and Foam Pumps, Valves and Components in
Normal operating positions.
 The Fire Protection System is ready and the Terminal Equipments and
Systems can be taken in line for Commissioning and Operations.

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FIRE & GAS DETECTION (F & G) SYSTEMS
(Ref. P&IDs: TCE.7410A-580-IN-026, TCE.7410A-IC-580-027, TCE.7410A-IC-580-028,
TCE.7410A-IC-580-029)

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Table of Contents
1. Test Summary


5.1 Chemical Terminal
5.1.1 Flame detection & Alarm

5.1.2 Point Type Gas detection & Alarm
5.1.3 Open path Gas detection & Alarm
5.1.4 Manual Call Points & Hooters / Strobes R1
1
5.2 MCC and Control room
5.2.1 Heat detection & Alarm

5.2.2 H2 detection & Alarm
5.2.3 Multi-Sensor detection & Alarm
5.2.4 Smoke detection above False ceiling with Response Indicator
5.2.5 Manual Call Points & Hooters / Strobes
R1
1
5.3 Administration Building

5.3.3 Smoke detection & Alarm
R1
1
5.4 Utility Area


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Signature
1.0 Test Summary

The aim of operational test is to demonstrate the safe operational capabilities of the Fire &
Gas Detection (F & G) Systems in the Terminal consisting of installations at the following
locations:
 Chemical Terminal
 MCC & Control room
 Administration Building
 Utility Area
The systems under this Test cover the following
 Chemical Terminal – Flame detector, Point type Gas detector, Open Path Gas
detector, Hooter / Strobe Outdoor weather proof, Hooter / Strobe Outdoor
Explosion proof , Manual Call points
 MCC & Control room – Multi sensor detector, Heat detector, Hydrogen detector
(Battery room), Smoke detector above False ceiling with Response indicator,
Hooter / Strobe, Manual Call points, Monitor Module
 Administration Building - Multi sensor detector, Heat detector, Smoke detector

above False ceiling with Response indicator, Hooter / Strobe, Manual Call points
 Utility Area - Smoke detector, Hooter / Strobe, Manual Call points
 F & G Panel and Repeater Panel at the main Security Gate
important to confirm and ensure that the integrated system is equipped to handle
contingencies arising out of Fire & Gas for the Safety of installations.
On successful conclusion of the Operational Tests, the systems are ready to support the
Nil
The Operational Tests would be carried out by simulation.
 Smoke detection may additionally be activated, to confirm performance, by

keeping a smoke emitting device like a piece of rope with one end lit up and only
emitting smoke and not fire. Due precautions may be taken in doing this to
safeguard against initiating fire in the area being tested.
 Gas detectors and H2 detectors may be optionally tested by slowly opening a

canister of Test Gas (HC / H2 respectively) close the detector to confirm

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performance. The following due precautions should be taken by the person

and people nearby:
 Wear Gas mask

 Ensure that there is no source of Fire like Cigarettes, Open fire or lit
stove near by
 The Transfer pumps from all the Storage Tanks of the Terminal may be kept
decoupled OR kept in ‘Test’ Position, as critical aspects of F or G detection
in the Terminal Tank storage area are the following:
 Stop All Process Operations
 Close the Inlet & Outlet valves of all the Tanks on Flame or Gas
detection.
F & G System Supply vendor.
5 days

 Utilities requirement – Power (LV), Test gas canisters for H2 and HC
 Keep the Personnel including the Security at the main gate of the Test and not to
panic on getting various Alarms.
 Assign Control room and Security personnel to monitor and confirm the Type and
Location of Alarm, when sounded, through communication sets.
 Simulate Process Operations of different Tanks for different Operations as
the Process Logic should Inhibit more than One Operation from any Tank –
An example of Simulated settings that can be kept is as follows:
 T-NPT-001 on receiving Naphtha from the Manifold (through Ship

unloading) – XV 5502 Open and XV 5501 Closed
 T-NPT-002 with Transfer Pump P-NPT-002 ‘Running’ for Truck Loading
– XV 5602 Closed and XV 5501 Open

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 T-NPT-003 on Pumping to the Manifold - XV 5602 Closed, XV 5501 Open

and P-SOL-003A ‘Running’.
 Simulations of Operations may be switched for different Tanks of Dike I and
Dike II for different F & G Tests so that, all the Tank Operations are Tested
for compliance to the Critical Logic –
“All process operations shall be stopped and actuated valves Inlet and
Outlet Actuated Valves of Tanks shall be closed on high level signal from
any Flame detector or Gas Detector.”
5.1 Chemical Terminal
5.1.1 Flame detection & Alarm
Locations:
Dike I - T-GSL-001 & 002, T-PHL-001, T-ETA-001, T-009-001, T-010-001, T-MTL-001 &
002, T-ETL-001, T-WSP-001, T-TOL-001
Dike II – T-NPT-001, 002 & 003, T-VAM-001, T-XYL-001
 Simulate different Process Operations for 3 different Tanks as mentioned

with example under Test Preparation in paragraph 4.
 Corresponding Pumps in operation should be in ‘Test’ position
simulated to be in ‘Running’ condition OR Motor ‘Running’ decoupled
from Pump, as mentioned in Special Precautions under paragraph 1.4.
 Simulate Fire at each of the above locations where Flame detection is installed.
 Confirm Local Fire Alarm at the respective places from the outdoor Explosion
proof Hooter / Strobe
 Confirm Fire Alarm in the Control room with indication of location
 Confirm Fire Alarm at the main Security Gate on the Repeater Panel with
indication of location
 Confirm all the Process Operations are Terminated – Inlet and Outlet
Actuated valves of the Tanks are Closed and the Running Pumps
Stopped.
 Follow other vendor recommended procedure, if any, to practically activate

the Fire in the above places
 An option could be to hold a small fire ball close to the detector with an
enclosure around the detector and the source of Fire, to simulate a Fire
condition, with due precautions mentioned below.
 In carrying out the above, care should be taken to ensure the following:
 None of the Tanks has been charged with Chemical for storage.
 There is no flammable or combustible material nearby.
 The material used for enclosure should be Resistant to Fire.
 PPE for the personnel carrying out the Test.
 Confirm Fire Alarms from the Local outdoor Explosion proof Hooter / Strobe,
Control room and at the Security Gate.
 Confirm Termination of all Process Operations - Inlet and Outlet
Stopped.
5.1.2 Point Type Gas detection & Alarm
Locations:

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Dike I - T-GSL-001 & 002, T-PHL-001, T-ETA-001, T-009-001, T-010-001, T-MTL-001 &
002, T-ETL-001, T-WSP-001, T-TOL-001, NORHT AND SOUTH PUMP HOUSES OF
DIKE I
Dike II – T-NPT-001, 002 & 003, T-VAM-001, T-XYL-001, NORHT PUMP HOUSE OF
DIKE II
Truck Loading Area – 5 Nos.

 Simulate Gas detection above the ‘Set Limit’ at each of the above locations
where ‘Point Type’ Gas detector is installed.
 Confirm Local ‘Point Type Gas detection’ Alarm at the respective places from
the outdoor Explosion proof Hooter / Strobe
 Confirm ‘Point Type Gas detection’ Alarm in the Control room with indication
of location
 Confirm ‘Point Type Gas detection’ Alarm at the main Security Gate on the
Repeater Panel with indication of location
Stopped.

Gas detection in the above places.
 An option could be by slowly opening a canister of Test Gas (HC) close
the detector, with due precautions as mentioned in Special precautions
under paragraph 1.4.
 Confirm Occurrence of all Alarms and Termination of Process Operations as
mentioned above.
5.1.3 Open path Gas detection & Alarm
Locations:
Manifold Area for Dike I Piping & Pigging – 1 No.

R1
Manifold Area for Dike II Piping & Pigging - 1 No. 1

 Simulate Gas detection above the ‘Set Limit’ at each of the above locations
where ‘Open Path’ Gas detector is installed.
 Confirm Local ‘Open Path Gas detection’ Alarm at the respective places from
the outdoor Explosion proof Hooter / Strobe
 Confirm ‘Open Path Gas detection’ Alarm in the Control room with indication
of location
 Confirm ‘Open Path Gas detection’ Alarm at the main Security Gate on the

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Stopped.

Gas detection in the above places.
 An option could be by slowly opening a canister of Test Gas (HC) close
the detector, with due precautions as mentioned in Special precautions
under paragraph 1.4.
 Confirm Occurrence of all Alarms and Termination of Process Operations as
mentioned above.
5.1.4 Manual Call Points & Hooters / Strobes –

‘Outdoor Weather Proof’ & ‘Outdoor Explosion Proof’
R1
Locations: 1
Explosion Proof Manual Call Points & Hooters around Dike I Tanks – 12 Nos.
Explosion Proof Manual Call Points & Hooters around Dike II Tanks - 5 Nos.
Weather Proof Manual Call Points & Hooters around Truck Loading– 1 No.
Weather Proof Manual Call Points & Hooters around Utilities – 2 Nos.
Weather Proof Manual Call Points & Hooters around Drum Storage – 1 No.

 Activate all the Manual Call Points physically

 Confirm Local ‘Manual Call point’ Alarms from the Hooters / Strobes from
their respective locations
 Confirm ‘Manual Call point’ Alarm in the Control room with indication of
location
 Confirm ‘Manual Call point’ Alarm at the main Security Gate on the
R1
 Confirm the Audibility & Volume of Hooters 1
 Confirm all the Process Operations are terminated – Inlet and
Outlet Actuated valves of the Tanks are Closed and the Running Pumps
Stopped (The validity of this Logic should be confirmed from the wiring
diagrams).
5.2 MCC and Control room
Locations:
Control room (Cabinets room) - 1 No.

Battery room – 1 No.
 Simulate Heat detection above the ‘Set Limit’ at each of the above locations
where Heat detectors are installed
 Confirm ‘Heat Detection’ Alarm from the Hooter / Strobe in the Control room
with indication of location on the Control Panel
 Confirm ‘Heat detection’ Alarm at the main Security Gate on the Repeater
Panel with indication of location

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Heat Detection in the above places.
 An option could be to hold an electrically heated rod (souldering iron) set to
high limit, close to the detector, with due precautions.
 Confirm Occurrence of Alarms as mentioned above.
5.2.2 H2 detection & Alarm
Locations:
Control room (Cabinets room) - 1 No.

Battery room – 1 No.
 Simulate H2 detection above the ‘Set Limit’ at each of the above locations where
Heat detectors are installed
 Confirm ‘H2 Detection’ Alarm from the Hooter / Strobe in the Control room
 Confirm ‘H2’ Alarm at the main Security Gate on the Repeater Panel with
indication of location
 Follow other vendor recommended procedure, if any, to practically activate H2

Detection in the above places.
 An option could be by slowly opening a canister of Test Gas (H2) close the
detector, with extreme precautions as mentioned in Special precautions
under paragraph 1.4. It should be ensured that there is no source of
Open fire nearby and a Fire extinguisher should be kept handy while
carrying out the Test.
Locations:
Control room (Cabinets room) – 2 Nos.

Control room - 2 Nos.
MCC - 4 Nos.
 Simulate Sudden rise of Temperature above the ‘Set Limit’ at each of the
above locations where Multi-Sensor detectors are installed.
 Confirm Local ‘Multi-Sensor’ (High Temperature rise) Alarm from the Hooter
/ Strobe in the Control room on the Control Panel, if the Simulation is from
Cabinets room or Control room with indication of location
 Confirm Local ‘Multi-Sensor’ (High Temperature rise) Alarm from the
Hooters / Strobes in the Control room with indication of location on the
Control Panel and also at MCC, if the Simulation is from MCC room
 Confirm ‘Multi-Sensor’ (High Temperature rise) Alarm at the main Security
Gate on the Repeater Panel with indication of location.
 Simulate Smoke at each of the above locations where Multi-Sensor detectors are
installed.
 Confirm Local ‘Multi-Sensor’ (Smoke detection) Alarm from the Hooter /
Strobe in the Control room with indication of location on the Control Panel, if
the Simulation is from Cabinets room or Control room
 Confirm Local ‘Multi-Sensor’ (Smoke detection) Alarm from the Hooters /
Strobes in the Control room with indication of location on the Control Panel
and also at MCC, if the Simulation is from MCC room
 Confirm ‘Multi-Sensor’ (Smoke detection) Alarm at the main Security Gate
on the Repeater Panel with indication of location.

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Multi-Sensor detectors both for High Temperature rise as well as Smoke
detection in the above places.
 An option for High Temperature could be holding an electrically heated
iron rod (souldering iron) close to the detector; for Smoke detection, it
could be holding an Incense stick (Dhoop stick / Agarbathis) close to the
detector. However, since the tests are to be carried out in a closed
room extreme precautions need to be exercised in carrying out
these tests with a Fire extinguisher kept nearby.
Locations:
Control room (Cabinets room) – 2 Nos.

Control room - 3 Nos.
 Simulate Smoke at each of the above locations where Smoke detector with
Response Indicator are installed.
 Confirm Response Indicator LED is lit up indicating Smoke / Fire above False
ceiling
 Confirm Local ‘Smoke’ detection Alarm from the Hooter / Strobe in the
Control room with indication of location on the Control Panel
 Confirm Smoke’ detection Alarm at the main Security Gate on the Repeater
Panel with indication of location.

Smoke detection above the false ceiling in the above places.
 An option could be holding an Incense stick (Dhoop stick / Agarbathis) close
to the detector. However, since the tests are to be carried out in a closed
room extreme precautions need to be exercised in carrying out these
tests with a Fire extinguisher kept nearby.
Locations:
Manual Call Point at Entrance to the Control room – 1 No.

Hooter / Strobe - 1 No. R1
1
 Activate all the Manual Call Point physically
 Confirm ‘Manual Call point’ Alarm from the Hooter / Strobe in the Control
room with indication of location on the Control Panel
 Confirm ‘Manual Call point’ Alarm at the main Security Gate on the Repeater
5.3 Administration Building
Locations:
Pantry – 1 No.
 Simulate Heat detection above the ‘Set Limit’ at the above locations where Heat
detector is installed

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 Confirm Detection’ Alarm from the Hooters / Strobes (2 Nos.) in the

Administrative Building
 Confirm ‘Heat Detection’ Alarm from the Hooter / Strobe in the Control room
 Confirm ‘Heat detection’ Alarm at the main Security Gate on the Repeater
Panel with indication of location

Heat Detection in the above place.
 An option could be to hold an electrically heated rod (souldering iron) set to
high limit, close to the detector, with due precautions.
Locations:
Server room – 1 No.
 Simulate Sudden rise of Temperature above the ‘Set Limit’ at the above
location where Multi-Sensor detector is installed.
 Confirm Local ‘Multi-Sensor’ (High Temperature rise) Alarm from the
Hooters / Strobes (2 Nos.) in the Administration Building
 Confirm Local ‘Multi-Sensor’ (High Temperature rise) Alarm from the Hooter
/ Strobe in the Control room with indication of location on the Control Panel
 Confirm ‘Multi-Sensor’ (High Temperature rise) Alarm at the main Security
Gate on the Repeater Panel with indication of location.
 Simulate Smoke at the above location where Multi-Sensor detector is installed.

 Confirm Local ‘Multi-Sensor’ (Smoke detection) Alarm from the Hooters /
Strobes (2 Nos.) in the Administration Building
 Confirm Local ‘Multi-Sensor’ (Smoke detection) Alarm from the Hooter /
Strobe in the Control room with indication of location on the Control Panel
 Confirm ‘Multi-Sensor’ (Smoke detection) Alarm at the main Security Gate
on the Repeater Panel with indication of location.

Multi-Sensor detectors both for High Temperature rise as well as Smoke
detection at the above place.
 An option for High Temperature could be holding an electrically heated iron
rod (souldering iron) close to the detector; for Smoke detection, it could be
holding an Incense stick (Dhoop stick / Agarbathis) close to the detector.
However, since the tests are to be carried out in a closed room extreme
precautions need to be exercised in carrying out these tests with a Fire
extinguisher kept nearby.
Locations:
Dining room, Prayer room & connected corridor – 5 Nos.

Storage, Open Office, Plant Manager, Conference room, - 6 Nos.
Meeting room AC room
 Simulate Smoke at the above locations where Smoke detector are installed.
 Confirm Local ‘Smoke’ detection Alarm from the Hooters / Strobes (2 Nos.) in
the Administration Building

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 Confirm ‘‘Smoke’ detection Alarm at the main Security Gate on the Repeater

Smoke detectors at the above place.
to the detector, with due precautions and a Fire extinguisher kept
nearby.
Locations:
Dining room, Prayer room & connected corridor – 6 Nos.

Storage, Open Office, Plant Manager, Conference room, - 10 Nos.
Meeting room AC room
 Simulate Smoke at each of the above locations where Smoke detector with
Response Indicator are installed.
 Confirm Response Indicator LED is lit up indicating Smoke / Fire above False
ceiling
 Confirm Local ‘Smoke’ detection Alarm from the Hooters / Strobes (2 Nos.) in
the Administration Building

to the detector. However, since the tests are to be carried out in a closed
room, extreme precautions need to be exercised in carrying out these
tests with a Fire extinguisher kept nearby.
Locations:
Manual Call point at Entrance to the Building – 1 No.

Hooters / Strobes near the Entrance - 3 Nos. R1
1

 Confirm ‘Manual Call point’ Alarm from the Hooters / Strobes (2 Nos.) in the
Administration Building
5.4 Utility Area
Locations:

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Total Area – 6 Nos.
 Simulate Smoke at the above locations where Smoke detector are installed.
 Confirm Local ‘Smoke’ detection Alarm from the Hooters / Strobe

to the detector, with due precautions and a Fire extinguisher kept
nearby.
Locations:
Manual Call Point Entrance to the Building – 1 No.

Hooter/ Strobe - 1 No. R1
1
 Confirm Local ‘Manual Call point’ Alarm from the Hooters / Strobe
 If all the above Tests are satisfactorily concluded the Systems are protected
against Fire & Gas as per Design.
 Keep the Fire & Gas System energized and ready for Service
 The F&G System is ready and the Terminal Equipments and Systems can be
taken in line for Commissioning and Operations.

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THERMIC FLUID SYSTEM (TERMINAL) HRT-06-HSD
Ref: Vendor (Maxima Boilers PVT. Ltd.) P&ID 7410A-81G-MAX-ME-PI-1351

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Table of Contents
1. Test Summary


5.1 High Level of Fuel Oil Service Tank & Intake of Fuel Oil cut off
5.2 Low Level of Fuel Oil Service Tank & Intake of Fuel Supply In
5.3 Preparations for Test Fire & Interlocks Check of Fired Heater E-TF-008A
5.4 Circulation of Thermic Fluid through the Heater coil E-TF-008A
5.5 Test Fire Heater E-TF-008A
5.6 Interlocks check of E-TF-008A–Burner Modulation: High/Low Fire & cut Off
5.7 Interlocks check of E-TF-008A - Expansion Tank Low Level & Burner Cut Off
5.8 Interlocks check of E-TF-008A – Flame Failure & Burner Cut Off
5.9 Interlocks check of E-TF-008A – Flue gas Outlet temp. High & Burner Cut Off
5.10 Interlocks check of E-TF-008A – Flue gas damper Closed & Burner Cut Off
5.11 Interlocks check of E-TF-008A – DP across Heater Low & Burner Cut Off
5.12 Interlocks check of E-TF-008A – TF Inlet temperature High & Burner Cut Off
5.13 Interlocks checks for the other Heater E-TF-008B

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Signature
1 Test Summary
 Confirm the safe operational capabilities of the Thermic Fluid System.

 Ensure proper distribution of Hot Fluid to the users
 Thermic Fluid Receipt & Storage

 Circulation of Thermic Fluid through the Fired Heater Coil to get heated up
 Burner Management System & Fired Heater Operations
 Distribution of Hot Thermic Fluid to End Users viz. T-BTM-001 & 2
 Return Thermic Fluid from End Users to Storage
ensure that the Integrated Thermic Fluid system conforms to the Process requirements

Make a temporary connection (hose) preferably from downstream of the Flow meter FM-TF-
016 to the De-Aeration cum Expansion Tank T-TF-001. If it is difficult to give the temporary
connection downstream of FM-TF-016, the temporary connection may be made from the blind
flange of the Common header on the discharge of circulation pumps P-TF-006 A/B. If
temporary connection is through hose, ensure that the hose is firmly tied and secured in
position.
None
Mechanical Technicians (Need based)

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1 day
 Pre-commissioning activities of the System including the Charging Pump and

Circulation Pumps should have been completed
 Test Run of the Charging Pump should have been completed R1
 Interlocks associated with TF Receipt, Storage and Circulation Pumps 1
have been completed as part of Pre-commissioning
 Control Panel Pre-commissioning checks have been done as applicable for PLC
Panels
 Utilities requirement – Power (LV), Oil Lubricant for the Pumps, HSD and top up
Thermic Fluid, if required.
 Keep the TF Circulation Pumps P-TF-006A&B Electrically Energized
(*Neither Jacket for the Circulation Pumps Casings Nor Cooling water supply for the
Casing Jackets for the Pumps Nor Cooling water for the Pumps seals are not shown
in the P&ID. If they are provided in actual installations, the Cooling water lines
should be kept Open)
 Keep the Control Panel Powered ON

 Ensure that the Lubricant for the bearings of the Pump is filled up to the correct
level
 Ensure high level of Thermic Fluid in the De-Aerator cum Expansion vessel
 Ensure level in the Storage / Dump vessel also for makeup of Thermic Fluid if
required
 Keep all the Instruments & System in working Interlock positions
5.1 High Level of Fuel Oil Service Tank & Intake of Fuel Oil cut off
 Simulate a healthy level (around 50%) in the Fuel oil service tank T-HSD-012 by
simulating LI-1351-01
 Gradually increase the simulated level above the High level by simulating LI-1351-
01 / by Activating LSH-1351-01
 Confirm that Fuel charging pump is switched Off / Supply Cut off
5.2 Low Level of Fuel Oil Service Tank & Intake of Fuel Supply In

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 Simulate a healthy level (around 50%) in the Fuel oil service tank T-HSD-012 by
simulating LI-1351-01
 Gradually decrease the simulated level below the Low level by simulating LI-1351-
02 / by Activating LSL-1351-02
 Confirm that Fuel charging pump is switched ON / Supply In
 Stop the simulation of LI-1351-01
5.3 Preparations for Test Fire & Interlocks Check of Fired Heater E-TF-008A
 Keep the Isolation valve To Process (End Users T-BTM-001 & 2) Closed
 Keep the Isolation valve of TF Return from the Plant also Closed
 Keep the Inlet Isolation valves (80 NB & 25 NB bypass valve in parallel) of
Thermic Fluid Inlet to the Heaters E-TF-008A & B Closed
 Keep the Outlet Isolation valves of Thermic Fluid Inlet to the Heaters E-TF-
008A & B Closed
 Keep the Fuel Oil Supply & Return Ball valves (20 NB) to the Heater E-TF-
008A & B Closed
5.4 Circulation of Thermic Fluid through the Heater coil E-TF-008A
 Establish circulation of Thermic Fluid through the Coil of Fired Heater E-TF-008A
with precautions as follows:
 Ensure that there is sufficient level in the Expansion vessel
 Keep the Thermic Fluid Tank outlet and the circulation pumps Suction valves Open
 Select Pump P-TF-006A
 Keep the Rotary switch on Circulation position
 Confirm that Circulation Pump P-TF-006A starts
 Crack Open the discharge valve of the Pump and Pressurize the Thermic Fluid
Inlet lines up to Inlet valves of both the Fired heaters
 Check for any leakage and take corrective actions, if required
 Open the 25 NB bypass valve on the TF Inlet line of E-TF-008A

 The coil of E-TF-008A should get pressurized up to the TF Outlet isolation
valve
 Peek through the inside of the Fired Heater E-TF-008A to confirm that there
is no leakage of TF inside the Heater
 If there is no leakage and circulation is Normal, Open the main TF Outlet isolation
valve (80 NB)
 Open the main 80 NB TF Inlet valve and Close the 25 NB bypass valve of the
Heater E-TF-008A
 Confirm visually that the circulation of TF is established in the loop:

Expansion vessel – Circulation Pump P-TF-006A - Fired Heater E-TF-008A –
Temporary Installation (Pl. Refer paragraph 1.3) – Expansion vessel (Confirm
flow into the Expansion vessel through the Temporary Installation)
 Keep the Rotary Switch in OFF position to Stop the circulation pump and all
simulations and proceed to the next step to Test Fire the
Heater R1
1
5.5 Test Fire Heater E-TF-008A R1

1
 Ensure a healthy level of around 50% HSD in the Fuel Oil Service Tank
 Keep the Fuel oil Supply & Return valves (20 NB) Open

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 Open the discharge damper on the Flue gas line (around 40%, which should be
finer adjusted on firing the Furnace for a stable Fire)
 Keep the Supply ON to the Control Panel
 Put the Rotary switch on Circulation position
 The Thermic Fluid circulation should start through the selected pump (e.g. P-TF-
006A)
 When a healthy circulation with steady pressure is established, Turn the Rotary
switch to Fire position
 Confirm the following cycle of operations on turning the Rotary switch to Fire
position
 The Blower starts commencing “Pre-purging”
 After Pre-purging Sparking starts (within 15 seconds)
 Burner solenoid valve gets energized and Fuel oil is sprayed into the
Combustion chamber
 Flame is established on Low Flame
 Sparking Stops
 After 12 Seconds from the time the Flame is established, the Burner
switches to High Flame
 If the Flame is not established within 15 seconds, and sensed by the

Photoresistor, confirm the following cycle of operation
 The Unit goes into Electrical Lock out position
 Alarm in the Control Panel
 If Electrical Lock out occurs, press the Reset Push button

 The above cycle of Sparking and Burner Fire should get repeated
 Otherwise the Unit should go into Electrical Lock out position again
with Alarm
 If the Burner does not light up on Low Flame and repeatedly goes to Electrical
Lock out position, check the following:
 Check if Sparking is alight; if not check the Burner solenoid valves and the
Electrical circuit for corrective actions
 The Fuel Air ratio to the Burner might require adjustment; this should be
done through the vendor representative.
 When the Burner Firing is established, the above process may be repeated a few
times to make sure that the Burner Management cycle is Consistent and
Established
 Keep the Burner ON and proceed to the next Test.
5.6 Interlocks check of E-TF-008A–Burner Modulation: High/Low Fire & cut Off
 Inlet Temperature of TF TI-1351-02 being at Temperature close to Ambient

temperature, the Burner should be on High Fire
R1
 The TF outlet temperature TI-1351-01 should start rising
1
 When the Outlet temperature of TF rises to around 80-90 deg. C,
Simulate & gradually increase the simulated Inlet temperature of TF through
TIC 1351-02, to be marginally lower than the Outlet Temperature TI-1351-01
 Monitor and confirm that when the difference between the Set point and the
simulated Inlet temperature of TF is lowered down, the Burner gets
modulated to Low Fire.
 Record the differential temperature between the Set point and the
simulated Inlet temperature of TF, at which the Burner switches to
Modulated Low Fire
 Increase the simulated Inlet temperature of TF through TIC 1351-02 further

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 Monitor and confirm that when the difference between the Set point and the
simulated Inlet temperature of TF is close to ‘0’, the Burner is cut Off and
Alarm is sounded
 Record the differential temperature between the Set point and the
simulated Inlet temperature of TF, at which the Burner is cut Off
 Decrease the simulation of Inlet temperature of TF through TIC 1351-02 to be

close to actual temperature of TF
 Reset & Restart the Burner from the Control Panel R1
1
 The Burner should get fired and go on High Fire
 Simulate & Gradually Increase the Inlet Temperature of TF TI-1351-02 to
be marginally lower than the Outlet Temperature TI-1351-01 R1
until the Burner modulates to Low Fire 1
 Maintain Low Fire of the Burner and proceed to the next step
5.7 Interlocks check of E-TF-008A - Expansion Tank Low Level & Burner Cut Off
 The Burner is ON at Low Fire from the previous step

 Simulate low level of the Expansion vessel by Activating LS – 1351-05
 Confirm Alarm and Burner is Cut Off.
 Confirm Alarm
 Restart the Burner from the Control Panel and confirm that the Burner is fired
 Simulate Very low level of the Expansion vessel by Activating LS – 1351-06
 Confirm that the Burner is Cut Off
 Confirm Alarm
 Reset & Restart the Burner from the Control Panel and confirm that the Burner is
fired and keep it on low fire and proceed to the next Test
5.8 Interlocks check of E-TF-008A – Flame Failure & Burner Cut Off

 Close the Fuel oil Supply & Return valves (20 NB) to E-TF-008A
 The Flame should go Off due to absence of Fuel
 Confirm ‘Flame Failure Alarm’ and Burner is cut Off
 Open the Fuel oil Supply & Return valves (20 NB) to E-TF-008A
5.9 Interlocks check of E-TF-008A – Flue gas Outlet temp. High & Burner Cut Off

 Simulate Flue gas temperature TIC 1351-01 from the Actual temperature and
gradually increase the simulated temperature of Flue gas
 Monitor and Confirm Burner cut Off at high temperature of Flue gas and
Alarm is sounded
 Record the simulated temperature of Flue gas at which the Burner is
cut Off
5.10 Interlocks check of E-TF-008A – Flue gas damper Closed & Burner Cut Off

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 Simulate Closed position of the Flue gas damper by Activating the Limit Switch ZS-
1351-01
 Monitor and Confirm Burner cut Off and Alarm is sounded
 Restart the Burner from the Control Panel and confirm that the Burner is fired and
keep it on low fire and proceed to the next Test
5.11 Interlocks check of E-TF-008A – DP across Heater Low & Burner Cut Off

 Simulate the differential pressure across the Heater to the current value by
simulating PID 1351-01
 Gradually reduce the simulated PID value (signifying low flow of TF through
the Coil of the Heater)
 Monitor and Confirm Burner cut Off and Alarm is sounded
 Record the simulated DP at which the Burner is Cut Off
 Restart the Burner from the Control Panel and confirm that the Burner is fired and
keep it on low fire and proceed to the next Test
5.12 Interlocks check of E-TF-008A – TF Inlet temperature High & Burner Cut Off
 Demonstrated under paragraph 5.6

5.13 Interlocks checks for the other Heater E-TF-008B
 Repeat the above Test Procedure from paragraph 5.3 to 5.11 for Heater E-
TF-008B
 After successful completion of Operational Tests for both the Heaters, Keep the
Rotary Switch in Circulation position and let the Temperature of the TF Cool
down to Atmospheric Temperature, before attempting to Reinstate TF
temporary line to normal position, as otherwise the remnant Hot oil in the
line can splash on the personnel reinstating the lines
 After the TF has cooled down to atmospheric temperature, keep the Rotary
Switch in OFF position R1
 Remove the Temporary Installations mentioned in paragraph 1.3 and 1
Reinstate the TF line of to normal Operating position.
 If the above Tests are satisfactory, the Thermic Fluid system is ready to be
pressed into service for onward Commissioning of Terminal Systems.

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STORAGE TANKS & DISTRIBUTION DIKE I –
PHL 1, GSL 1&2, STY 1, TOL 1, TBOL 1,2,3 & 4, WSP 1, POL 1, ETA 1, MPG 1, C09 1 &
2, C10 1, MTL 1&2, DEG, ETL
REF. P&IDs – 7410A-300-PI-8659, 8661, 8662, 8663, 8664, 8665, 8666, 8667, 8668, 8669,
8671, 8672, 8673, 8674, 8675, 8676, 8677, 8679, 8680, 8684

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Table of Contents
1. Test Summary


5.0 Tests & Procedure T-GSL-001
5.1 Interlocks Checks - Tank Gauging System

5.2 Interlocks Checks - Receipt from Jetty
5.3 Interlocks Checks - “RECEIPT – JETTY”– Tank High & High High Level
5.4 Interlocks Checks - “RECEIPT – JETTY”– Flame Detection
5.5 Interlocks Checks - “RECEIPT – JETTY”– Gas Detection
5.6 Interlocks Checks – Dispatch to TLF
5.7 Interlocks Checks - “DISP-TLF”– Pre-set Quantity to TLF
5.8 Interlocks Checks - “DISP-TLF”– Tank Low & Low Low Level
5.9 Interlocks Checks - “DISP-TLF”– Flame Detection
5.10 Interlocks Checks - “DISP-TLF”– Gas Detection
5.11 Interlocks Checks – Dispatch to Ship - Exclusivity of Pump for Service
5.12 Interlocks Checks - “DISP-SHIP”– Tank Low & Low Low Level
5.13 Interlocks Checks - “DISP-SHIP”– Flame Detection
5.14 Interlocks Checks - “DISP-SHIP”– Gas Detection
5.15 Interlocks Checks – Drum Filling - Exclusivity of Pump for Service
5.16 Interlocks Checks - “DISP-DRUM”– Tank Low & Low Low Level
5.17 Interlocks Checks - “DISP-DRUM”– Flame Detection
5.18 Interlocks Checks - “DISP-DRUM”– Gas Detection
5.19 Interlocks Checks – Unloading from Tanker
5.20 Interlocks Checks - “UNLOADING - TT”– High & High High Level
5.21 Interlocks Checks - “UNLOADING - TT”– Flame Detection
5.22 Interlocks Checks - “UNLOADING - TT”– Gas Detection
5.23 Interlocks Checks – Unloading from Tanker to Drum Filling
5.24 Interlocks Checks - “UNLOADING – TT - DRUM”– Flame Detection
5.25 Interlocks Checks - “UNLOADING – TT - DRUM”– Gas Detection
5.26 Additional Interlocks check Applicable for T-STY-001- Recirculation Pump

5.27 Additional Interlocks check Applicable for T-STY-001- Temp. Transmission

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Signature
1 Test Summary
 Confirm the safe operational capabilities of the Storage Tank Systems and
ancillaries.
 Ensure associated Logics & Interlocks for Safe distribution of Solvents for
downstream functions viz. Truck Loading, Truck Unloading, Drum Filling, Pumping to
Manifold for Export (Load Ship) / Blending
 The Terminal facility is intended to Store 20 different Solvents / Products in 30

Storage Tanks.
 Flexibility exists to Store alternative Solvents than intended, based on
requirements.
 A Plant is also put up to process the Solvents to produce other desired products
 A Blending Tank is also installed to blend different Solvents / Products to
produce Products as per requirements
 The Terminal carries two categories of Tanks for storage of Solvents / Products
based on their characteristics
 Fixed Roof Tanks
 Internal Floating roof Tanks
 The activities to satisfy the Aim of the Operational Test cover the following:
Tanks –
 The Interlocks associated with the Tanks need to be tested prior to intake of
Solvents / Products.
 Parameters associated with the Tanks shall be simulated to confirm that all the
Effects are as per Logics

Pumps –
 Since almost all the Solvent Pumps installed are designed for liquid of Specific
gravity less than 1, their performance cannot be tested with Water. Hence the
Interlocks associated with the Pumps shall be tested with the Pumps decoupled from
their Motors, by simulation of parameters.
 The running performance of Pumps shall be monitored and confirmed during
actual operation with their respective Solvents.
Fire & Gas detection –

 Fire & Gas conditions shall be tested for each case by simulation to confirm
Consequential occurrence as per Logic.
Operational Safety –
 Safety aspects associated with all the Operations intended to be carried out shall be
tested.
 Operations shall be simulated in with commands from the Control Room
(SCADA) to confirm Consequential occurrences as per Logics.

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Communication From & To SCADA –

 Communication from & to SCADA with Field Instruments & Equipment and
Personnel as per protocol shall also be established during the course of the above
Tests.
 Since Common Functions with respect to all the Storage Tanks and Process
Operations connected to them are identical, the Tests presented below are
detailed out with respect to one Tank – T-GSL-001.
 For other tanks, the modalities of Tests / Operations being the same, the
same procedure detailed for Tank – T-GSL-001 may be followed, with
appropriate Tag Nos. applicable for the Tank.
 Additional details, applicable for specific Tank (Styrene) are detailed out,
at the end of Checks for T-GSL-001.
The Loop checks of individual Components should have been completed as part of
Instrumentation procedure. However an integrated overall Functional Test of the total System
is important to ensure that the Integrated Solvent / Product Storage Tanks and associated
Process Operations conform to the requirements with all Safety aspects functional.
On successful conclusion of the Tests, the Storage Tanks and associated Functions shall be
ready for regular Operational Service.
Nil
None
(Field)
Control room Operator 1
Terminal Automation System (TAS) vendor necessary
30 days

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 Utilities requirement – Power (LV), Instrument air
 Control room & Control systems

 SCADA should be Powered ON after loading the Software and all Pre-
commissioning activities completed
 PLCs of all the associated Systems & Packages should be Powered ON and all
Pre-commissioning activities completed
 Terminal Equipment
 Storage Tanks - Ready in all respects with all Instruments in place, Pre-
commissioning completed
 Pumps – Pumps associated with the Tests Decoupled from their Motors
 Package Equipment - Pre-commissioning completed as per vendor

procedures, Lubricated and ready for Commissioning
 Piping
 Mechanically complete in all respects
 Flushing of all the lines completed
 Reinstatement of Piping done after Flushing
 All Instruments on the Piping are in place as per P&ID
 Electrical
 HV and LV Power charged after Pre-commissioning of the Equipment and
distribution System
 Pre-commissioning of MCC / individual Breakers for the Electrical Equipment /
Motors forming part of the Tests completed
 Pre-commissioning of all the Equipment / Motors forming part of the Tests
completed and
 Motors – Lubrication done for the Motors. No load runs completed.
 Instrumentation
 Pre-commissioning of all the Instruments forming part of the Systems under
Test are completed
 Functional Tests of individual loops forming part of the Tests have been
completed and certified
 Pre-commissioning of all the Packages e.g. F&G detection, FW System, Tanker
Loading etc. completed
 Keep the Control room informed prior to commencement of individual Test
5.0 Tests & Procedure T-GSL-001
Tank Level Indication & Transmission
 Ensure that all Interlocks are in place for all the Tanks
 Select Tank T-GSL-001 on the HMI screen of SCADA of Terminal Automation
System (TAS) in the Control Room
 With No level in the Tank the LI 6101 & LIT 6101 should be giving an indication of
Level ‘0’ in the Tank

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 Low Level and Low Low Level Alarms should be displayed in the Control room.
 Simulate any Level between the Low and How Level Set points for the Tank e.g.
60% on LIT 6101
 Confirm that the Local indication on LI 6101, LIT 6101 and the Level indicated
on the HMI screen conform to the same value.
 This confirms that LI 6101 and LIT 6101 are in agreement and both are OK.
Tank Pressure Indication & Transmission
 Keeping the simulated value of Level steady, simulate PT 6101 to a value of around
1.2 Kg/cm2 - Approximate value of Pressure corresponding to 60% Level of the
Tank
 Confirm that the Local indication on PI 6101 and the Level indicated on the HMI
screen conform to the same value.
 This confirms that PI 6101 and PT 6101 are in agreement and both are OK
Tank Temperature Indication & Transmission
 Keeping the above simulated values of LT and PT steady, simulate any value
between 30 to 45 deg. C (which is close to the atmospheric temperature at site) on
TIT 6101
 Confirm that the Local indication on TI 6101, TIT 6101 and the Level indicated
on the HMI screen conform to the same value.
 This confirms that TI 6101 and TIT 6101 are in agreement and both are OK
Density Compensation for Temperature & Pressure
 Vary the simulated values of LIT and PIT simultaneously from the simulated
values above, within a narrow band of around 10% from the above simulated
values
 Confirm that the Indicated Density of the Solvent DI 6101 also varies
corresponding to the changes of LIT and PIT simulated values
 This confirms that the Density compensation for Pressure (Level) and
Temperature variations in the Tank Gauging system is OK
Alarm for Sudden Loss of Level
 Select any Tank on the HMI screen -Not necessarily the Tank under Test - which in
this case is Tank T-GSL-001
 Suddenly and quickly bring down the simulated value of LT 6101 from e.g. 60%
to a lower value e.g. 40%.
 Confirm Alarm in the Control Room for Sudden / Unusual Loss of Tank
Inventory
 If the above parameters are Normal, stop the above simulations and proceed to the
next step.
 Ensure that all the Flame and Gas detectors in the Tank Dike area, Pumping area
and Open path area are healthy and there are no High Level Alarms from any of
them
 Select T-GSL-01 on the HMI screen in the Control Room
 Select “RECEIPT – JETTY”
 Ensure that the Actuated valves on the Inlet from the Manifold to the Tank XV 6102
and on the Tank Outlet XV 6101 are in Remote Auto mode
 Once the *Remote Auto” mode is selected, on selection of “RECEIPT –
JETTY” for the Tank on the HMI screen, confirm that the Actuated Inlet valve
XV 6102 Opens and the Outlet valve XV 6101 Closes.

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 *( C9-1, C10 Tanks -Actuated Inlet valves from C-001 and C-002 of Process
Block should be Closed in Remote Auto)
*C9-1, C10
 If the above conditions are fulfilled, the Tank shall be ready to receive the Tanks -
Solvent from the Jetty Actuated Inlet
 Connection of hose at the Manifold for Solvent Transfer to the correct Tank, and valves from C-
transfer from the Jetty end (Ship) etc. shall be manually coordinated with the 001 and C-002
Jetty and Control room by the responsible person on the field. of Process
Block should
 If the above parameters are Normal, proceed to the next step. remain Closed
in Remote Auto
mode
 Maintain the above Conditions conducive for Receipt of Solvent from the Jetty, with
all conditions Healthy
 Simulate LIT 6102 and gradually increase the Simulated Level of the Tank
 Confirm Alarm for High Level in the Tank at the Set point
 Record the Simulated level at which the Alarm is sounded
 Gradually further simulated level of the Tank until the High High Level set point is
reached.
 Confirm High High Level Alarm.
 Confirm that the Actuated valve on the Inlet XV 6102 Closes in Auto.
 Record the Simulated level at which the High High Alarm is sounded and the
Inlet Actuated valve closes in Auto.
 If the above parameters are Normal, simulate the Tank level to a healthy level of 40
– 50%, so that there is no Low or High Alarm for the Tank level, Reset the Trip and
 Maintain healthy condition for “RECEIPT – JETTY” from the previous step with
Actuated valve on the Inlet XV 6102 Open and Actuated valve on the Outlet XV
6101 Closed.
 Simulate the Flame detector in the vicinity of the Tank for Flame detection
 Confirm Alarm in the Control Room and simultaneous Closure of Actuated
valve on the Inlet XV 6102, thus stopping the Receipt of Solvent from
Jetty.
 Remove the above simulation for Flame detection and Restore the condition back to
a healthy state for “RECEIPT – JETTY” from the previous step with Actuated valve
on the Inlet XV 6102 Open and Actuated valve on the Outlet XV 6101 Closed. “
 Simulate the Flame detection in any other Detector in the Storage Tank Area for
Flame detection
Jetty.
 If the above steps are Normal, Proceed to the next step
6101 Closed.

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 Simulate the Gas detector in the Point type Gas detector in the vicinity of the Tank
for Gas detection
 Confirm Alarm in the Control Room and simultaneous Closure of Actuated *C9-1, C10
valve on the Inlet XV 6102, thus stopping the Receipt of Solvent from Tanks -
Jetty. Actuated Inlet
valves from C-
 Remove the above simulation for Gas detection and Restore the condition back to a 001 and C-002
healthy state for “RECEIPT – JETTY” from the previous step with Actuated valve of Process
on the Inlet XV 6102 Open and Actuated valve on the Outlet XV 6101 Closed. Block should
remain Closed
in Remote Auto
 Simulate the Gas detection in any other Detector in the Storage Tank Area
mode
Jetty.
 Remove the above simulation for Gas detection and Restore the condition back to a
healthy state for “RECEIPT – JETTY” from the previous step with Actuated valve
on the Inlet XV 6102 Open and Actuated valve on the Outlet XV 6101 Closed.
 Simulate the Gas detection in any of the Open Path Gas detectors in the Storage
Tank Area
Jetty.
 If the above steps are Normal, Remover all simulations for “RECEIPT – JETTY” and
them
 Select T-GSL-01 on the HMI screen in the Control Room
 Select “DISP-TLF”
 Once the “Remote Auto” mode is selected, on selection of “DISP-TLF” for the Tank
on the HMI screen, confirm that the Inlet valve XV 6102 Closes and the Outlet valve
XV 6101 should also remain Closed because Tank is empty and the Level is ‘0’
 Ensure that Pump P-GSL-001 is decoupled from the Motor.

 Try to Kick Start (ON & OFF immediately) P-GSL-001.
 The Pump should not take start since the Tank is empty and the Level is ‘0’
 If the above conditions are fulfilled, the Tank shall be ready to dispatch the
Solvent from the Storage Tank
 Maintain the above Conditions conducive for Dispatch of Solvent from the Storage “
Tank, with all conditions Healthy
 Simulate a healthy level of Solvent in the Tank e.g. around 60% through LIT 6102
 The Outlet Actuated valve XV 6101 Opens on Remote Auto mode.
 Try to Kick start the Pump (ON & OFF immediately) P-GSL-001

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 The Motor (Pump decoupled from Motor) of P-GSL-001 should not take start since
the ‘Pump Demand’ has Not been initiated by the ‘Batch Controller’ of TLF
 Simulate the ‘Pump Demand’ from the ‘Batch Controller’ of TLF

 Simulate the Demand Quantity from the ‘Batch Controller’ and Pre-set the Quantity
on the SCADA
 Start the Pump P-GSL-001 in Remote Auto mode **Not

 The Motor (Pump decoupled from Motor) should Start Applicable for
 The Pump should Stop after a few seconds of Start since there is No Flow BOL & POL
 **This is not applicable for P-BOL- 001 to 004 and P-POL-001 as these are
Geared Pumps and carry a Pressure switch on the discharge line for Trip
on High pressure.
 **Simulate a healthy Flow / Activate the Flow Switch FS 6101 to Flow conditions
 Restart the Pump P-GSL-001 in Remote Auto mode

 The Motor (Pump decoupled from Motor) should Start and keep running
 Monitor to confirm that there are no abnormalities in the running Motor
 Simulate the Quantity Dispatched and gradually increase it to the Pre-set Quantity
 Confirm that the Motor (Pump decoupled from Motor) Stops when the
simulated value of the Quantity Dispatched equals the Pre-set Quantity.
 If the above parameters are Normal, keep the simulated value of the Dispatched
Quantity below the Pre-set Quantity, keep to Pump (Motor) running and proceed to
the next step.
5.8 Interlocks Checks - “DISP-TLF”– Tank Low & Low Low Level *C9-1, C10
Tanks -
 The Pump (Motor) P-GSL-001 should be running from the previous step with the Actuated Inlet
following conditions & simulations: valves from C-
 Inlet valve XV 6102 is Closed 001 and C-002
 Outlet XV 6101 is Open of Process
 Healthy level of Solvent in the Tank e.g. around 60% through LIT 6102 Block should
 ‘Pump Demand’ from the ‘Batch Controller’ of TLF remain Closed
 **Flow Switch FS 6101 Activated to Flow conditions in Remote Auto
 Dispatched Quantity below the Pre-set Quantity mode
 Gradually decrease the Simulated Level of the Tank through LIT 6102 **Not
 Confirm Alarm for Low Level in the Tank at the Set point Applicable for
 Record the Simulated level at which the Alarm is sounded BOL & POL
 Gradually further decrease the simulated level of the Tank until the Low Low Level
set point is reached.
 Confirm Low Low Level Alarm.
 Confirm that the Actuated valve on the Outlet XV 6101 Closes in Auto and
the Pump Trips on Interlock.
 Confirm Alarm for Pump P-GSL-001 Trip in the Control room
 Record the Simulated level at which the Low Low Alarm is sounded and the
Outlet Actuated valve closes in Auto.
 If the above parameters are Normal, Reset the Trip, Restore running conditions of
the Pump, and proceed to the next step.
 The Pump (Motor) P-GSL-001 should be running from the previous step with the
following conditions & simulations:

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 Inlet valve XV 6102 is Closed

 Outlet XV 6101 is Open
 Healthy level of Solvent in the Tank e.g. around 60% through LIT 6102 “
 ‘Pump Demand’ from the ‘Batch Controller’ of TLF
 **Flow Switch FS 6101 Activated to Flow conditions
 Dispatched Quantity below the Pre-set Quantity
 Confirm Alarm in the Control Room for Flame detection.
the Pump Trips on Interlock, thus stopping the Dispatch for Truck
Loading.
a healthy state for ““DISP-TLF”” from the previous step with Actuated valve on the
Inlet XV 6102 Closed and Actuated valve on the Outlet XV 6101 Open.
Flame detection
 Confirm Flame detection Alarm in the Control Room

Loading.
 The Pump (Motor) P-GSL-001 should be running from the previous step with the
 Healthy level of Solvent in the Tank e.g. around 60% through LIT 6102
 **Flow Switch FS 6101 Activated to Flow conditions **Not
 Dispatched Quantity below the Pre-set Quantity Applicable for
BOL & POL
for Gas detection
 Confirm Gas detection Alarm in the Control Room
Loading.
healthy state for “DISP-TLF” from the previous step with Actuated valve on the
Loading.

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Tank Area
Loading.
 If the above steps are Normal, Remover all simulations for “DISP-TLF” and proceed
to the next step.
 Ensure that all the Flame and Gas detectors in the Tank Dike area, Pumping area *C9-1, C10
and Open path area are healthy and there are no High Level Alarms from any of Tanks -
them Actuated Inlet
 Select T-GSL-001 on the HMI screen in the Control Room valves from C-
001 and C-002
 Select “DISP-SHIP”
of Process
Block should
remain Closed
 Once the “Remote Auto” mode is selected, on selection of “DISP-SHIP” for the Tank in Remote Auto
on the HMI screen, confirm that the Inlet valve XV 6102 Closes and the Outlet valve mode
XV 6101 should also remain Closed because Tank is empty and the Level is ‘0’
 *Confirm if Pump P-SOL-009 is selected by default in Remote Auto mode

 *If Pump P-SOL-009 is not selected, Select P-SOL-009 for service
 *Select any other Tank having connection to the same Pump P-SOL-009 for *These need to
pumping to the Manifold e.g. T-STY-001 / T-ETL-001 on the HMI screen in the be confirmed
Control Room from the Final
 Try to select the same Pump P-SOL-009 for service Revision
document -
 *It should not be possible since P-SOL-009 is already selected for Service ‘Control
for T-GSL-001 Narratives &
Interlocks
 Ensure that Pump P-SOL-009 is decoupled from the Motor. Description’
 Try to Kick Start (ON & OFF immediately) P-SOL-009 on Remote Manual mode.
 The Pump should not take start since the Tank is empty and the Level is ‘0’ in T- For POL & BOL
GSL-001 the Pump for
dispatch to
 If the above conditions are fulfilled, the Tank shall be ready to dispatch the ship is P-SOL-
Solvent from the Storage Tank 002
 Maintain the above Conditions conducive for Dispatch of Solvent from the Storage
 Start the Pump P-SOL-009 in Remote Manual mode
 The Motor (Pump decoupled from Motor) should Start
 **The Pump should Stop after a few seconds of Start since there is No Flow
 Simulate a healthy Flow / Activate the Flow Switch on the Pump discharge FS 8206
to Flow conditions

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 Restart the Pump P-SOL-009 in Remote Manual mode **Not

 The Motor (Pump decoupled from Motor) should Start and keep running Applicable for
 Monitor to confirm that there are no abnormalities in the running Motor BOL & POL
 Gradually decrease the Simulated Level of the Tank through LIT 6102
 Confirm Alarm for Low Level in the Tank at the Set point
 Confirm Alarm for Pump P-SOL-009 Trip in the Control room
5.13 Interlocks Checks - “DISP-SHIP”– Flame Detection *C9-1, C10

Tanks -
 The Pump (Motor) P-SOL-009 should be running from the previous step with the Actuated Inlet
following conditions & simulations: valves from C-
 Inlet valve XV 6102 is Closed 001 and C-002
 Outlet XV 6101 is Open of Process
 Healthy level of Solvent in the Tank e.g. around 60% through LIT 6102 Block should
 Flow Switch on the Pump discharge FS 8206 Activated to Flow conditions remain Closed
in Remote Auto
 Simulate the Flame detector in the vicinity of the Tank for Flame detection mode
the Pump Trips on Interlock, thus stopping dispatch to ship.
a healthy state for “DISP-SHIP” from the previous step with Actuated valve on the
Flame indication
 The Pump (Motor) P-SOL-009 should be running from the previous step with the “
 Inlet valve XV 6102 is Closed
 Outlet XV 6101 is Open
 Healthy level of Solvent in the Tank e.g. around 60% through LIT 6102
 Flow Switch on the Pump discharge FS 8206 Activated to Flow conditions

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for Gas detection
healthy state for “DISP-SHIP” from the previous step with Actuated valve on the
Tank Area
 If the above steps are Normal, Remove all simulations for “DISP-SHIP” and proceed
to the next step.
5.15 Interlocks Checks – Drum Filling - Exclusivity of Pump for Service *C9-1, C10
Tanks -
 Ensure that all the Flame and Gas detectors in the Tank Dike area, Pumping area Actuated Inlet
and Open path area are healthy and there are no High Level Alarms from any of valves from C-
them 001 and C-002
 Select T-GSL-001 on the HMI screen in the Control Room of Process
 Select “DISP-DRUM” Block should
 Ensure that the Actuated valves on the Inlet from the Manifold to the Tank XV 6102 remain Closed
and on the Tank Outlet XV 6101 are in Remote Auto mode in Remote Auto
 Once the “Remote Auto” mode is selected, on selection of “DISP-DRUM” for mode
the Tank on the HMI screen, confirm that the Inlet valve XV 6102 Closes and
the Outlet valve XV 6101 should also remain Closed because Tank is empty
and the Level is ‘0’
 *Select Pump P-SOL-005 for service *These need to

 *Select any other Tank having connection to the same Pump P-SOL-005 for be confirmed
Drum Filling e.g. T-STY-001 / T-TOL-001 on the HMI screen in the Control from the Final
Room Revision
 Try to select the same Pump P-SOL-005 for service document -
 *It should not be possible since P-SOL-005 is already selected for Service ‘Control
for T-GSL-001 Narratives &
Interlocks
Description’

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 Operate the Pump (AODD Pump) – Just momentarily Start & Stop - P-SOL-005
in Manual mode
 Confirm that Pump P-SOL-005 ‘Running’ & ‘Stopped’ indications appear on the
HMI screen
 Gradually decrease the Simulated Level of the Tank through LT 6102

 Confirm that the Actuated valve on the Outlet XV 6101 Closes in Auto,
thus stopping dispatch for Drum filling.
 If the above parameters are Normal, Reset the Trip, Restore healthy conditions and
 Maintain healthy conditions from the previous step with the following conditions & *C9-1, C10
simulations: Tanks -
 Inlet valve XV 6102 is Closed Actuated Inlet
 Outlet XV 6101 is Open valves from C-
 Healthy level of Solvent in the Tank e.g. around 60% through LIT 6102 001 and C-002
of Process
 Simulate the Flame detector in the vicinity of the Tank for Flame detection Block should
remain Closed
in Remote Auto
 Confirm simultaneous Closure of the Outlet Actuated valve XV 6101, thus
mode
stopping the Dispatch for Drum Filling.
a healthy state for “DISP-DRUM” from the previous step with Actuated valve on
the Inlet XV 6102 Closed and Actuated valve on the Outlet XV 6101 Open.
Flame detection
 Maintain healthy conditions from the previous step with the following conditions &
simulations:
 Outlet XV 6101 is Open “

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for Gas detection
healthy state for “DISP-DRUM” from the previous step with Actuated valve on the
Tank Area
 If the above steps are Normal, Remove all simulations for “DISP-DRUM” and
5.19 Interlocks Checks – Unloading from Tanker *C9-1, C10

Tanks -
 Ensure that all the Flame and Gas detectors in the Tank Dike area, Pumping area Actuated Inlet
and Open path area are healthy and there are no High Level Alarms from any of valves from C-
them 001 and C-002
 Select T-GSL-01 on the HMI screen in the Control Room of Process
 Select “UNLOADING - TT” on the HMI Block should
 Once the “Remote Auto” mode is selected, on selection of “UNLOADING - TT” for remain Closed
the Tank on the HMI screen, confirm that the Inlet valve XV 6102 Opens and the in Remote Auto
Outlet valve XV 6101 Closes. mode
 If the above conditions are fulfilled, the Tank shall be ready to receive the
Solvent from the Tanker
 Connection of hose at the discharge of Tanker Product Unloading Pump P- For BOL &
SOL-008 and at the Manifold, for Solvent Transfer to the correct Tank etc. shall POL, the
be manually coordinated with the Control room by the responsible person on Product
the field. Unloading
Pump is P-
 If the above parameters are Normal, proceed to the next step. SOL-007
5.20 Interlocks Checks - “UNLOADING - TT”– High & High High Level
 Maintain the above Conditions conducive for Receipt of Solvent from the Tanker, ***Trip of
with all conditions Healthy Tanker
 Simulate LIT 6102 and gradually increase the Simulated Level of the Tank Unloading
 Confirm Alarm for High Level in the Tank at the Set point Pump on
 Record the Simulated level at which the Alarm is sounded Closure of
Tank Inlet valve
should be
confirmed from
reached.
the Final

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 Confirm High High Level Alarm. Revision of

 ***Confirm that the Actuated valve on the Inlet XV 6102 Closes in Auto. Control
 Record the Simulated level at which the High High Alarm is sounded and the Narratives &
Inlet Actuated valve closes in Auto. Interlocks
 Maintain healthy condition for “UNLOADING - TT” from the previous step with
6101 Closed.
 Simulate the Flame detector in the vicinity of the Tank for Flame detection ***Trip of
 ***Confirm Alarm in the Control Room and simultaneous Closure of Tanker
Actuated valve on the Inlet XV 6102, thus stopping Unloading of Solvent Unloading
from the Tanker to the Tank. Pump on
Closure of
 Remove the above simulation for Flame detection and Restore the condition back to Tank Inlet valve
a healthy state for “UNLOADING - TT” from the previous step with Actuated valve should be
on the Inlet XV 6102 Open and Actuated valve on the Outlet XV 6101 Closed. confirmed from
 Simulate the Flame detection in any other Detector in the Storage Tank Area for the Final
Flame detection Revision of
 ***Confirm Alarm in the Control Room and simultaneous Closure of Control
Actuated valve on the Inlet XV 6102, thus stopping Unloading of Solvent Narratives &
from the Tanker to the Tank. Interlocks
6101 Closed.
for Gas detection
 ***Confirm Alarm in the Control Room and simultaneous Closure of “
Actuated valve on the Inlet XV 6102, thus stopping Unloading of Solvent
from the Tanker to the Tank.
healthy state for “UNLOADING - TT” from the previous step with Actuated valve
 ***Confirm Alarm in the Control Room and simultaneous Closure of
Actuated valve on the Inlet XV 6102, thus stopping the Unloading of
Solvent from the Tanker to the Tank. “
Tank Area

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 ***Confirm Alarm in the Control Room and simultaneous Closure of

Solvent from the Tanker to the Tank.
 If the above steps are Normal, Remover all simulations for “UNLOADING - TT”.
 The Interlocks Checks for T-GSL-001 are completed.
5.23 Interlocks Checks – Unloading from Tanker to Drum Filling
them
 Select “UNLOADING – TT - DRUM”
 Once the “Remote Auto” mode is selected, on selection of “UNLOADING – TT -
DRUM” for the Tank on the HMI screen, confirm that the Actuated valve at the Inlet
of Drum Filling Unit XV 8202 Opens.
 If the above conditions are fulfilled, the Drum Filling Unit shall be ready start For BOL &
receiving the Solvent from the Tanker for Drum Filling. POL, the
 Connection of hose at the discharge of Tanker Product Unloading Pump P- Product
SOL-008 to the Drum filling Unit shall be manually coordinated with the Control Unloading
room by the responsible person on the field. Pump is P-
SOL-007
5.24 Interlocks Checks - “UNLOADING – TT - DRUM”– Flame Detection
 Maintain healthy condition for “UNLOADING – TT - DRUM” from the previous step
with Actuated valve on the Inlet of Drum Filling Unit XV 8202 Open
valve on the Inlet of Drum Filling Unit XV 8202, thus stopping Unloading of
Tanker to the Drum Filling Unit.
a healthy state for “UNLOADING – TT- DRUM” from the previous step with
Actuated valve on the Inlet of Drum Filling Unit XV 8202 Open
Flame detection
5.25 Interlocks Checks - “UNLOADING – TT - DRUM”– Gas Detection
 Maintain healthy condition for “UNLOADING – TT - DRUM” from the previous step
with Actuated valve on the Inlet of Drum Filling Unit XV 8202 Open
for Gas detection
healthy state for “UNLOADING – TT - DRUM” from the previous step with Actuated
valve on the Inlet of Drum Filling Unit XV 8202 Open

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healthy state for “UNLOADING – TT - DRUM” from the previous step with Actuated
valve on the Inlet of Drum Filling Unit XV 8202 Open
Tank Area
 If the above steps are Normal, Remover all simulations for “UNLOADING – TT -
DRUM”.
 The Interlocks Checks for Unloading from Tanker to Drum Filling are
completed.
5.26 Additional Interlocks check Applicable for T-STY-001- Recirculation Pump
 All the Tests mentioned above for T-GSL-001 are applicable for T-STY-001
 In addition the following Tests should be carried out
 Select T-STY-001 on the HMI screen in the Control Room

 Actuated valves on the Inlet from the Manifold to the Tank XV 6302 and on the
Tank Outlet XV 6301 should remain Closed when No selection is made
 Ensure that Pump P-STY-002 (Recirculation Pump) is decoupled from the

Motor.
 Try to Kick Start (ON & OFF immediately) P-STY-002.
 Simulate a healthy level of around 50% in the Tank through LIT-6302.
 Start the Pump P-STY-002
 The Motor (Pump decoupled from Motor) should Start and Stop after a few seconds
since there is No flow on the Recirculation line.
 Confirm Alarm for Trip of P-STY-002 in the Control room
 Maintain the Simulation of Level in the Tank at around 50% through LIT-6302.
 Start the Pump P-STY-002 and Activate the Flow Switch FSL-6302 to Flow
conditions
 The Motor (Pump decoupled from Motor) should Start and continue to run
5.27 Additional Interlocks check Applicable for T-STY-001- Temp. Transmission
 Maintain Conditions mentioned above to keep the Motor (Pump decoupled from
Motor) running.
 Tank level simulated to a healthy level of around 50% through LIT-6302.
 Flow Switch FSL-6302 Actuated to Flow conditions
 TI -6303 should read the Atmospheric Temperature

 The Temperature indicated on the HMI screen should match the indicated value
on TI -6303

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 Simulate a Temperature of around 25 deg. C on TIT-6303

 Confirm that the Temperature on the HMI screen matches the Simulated value
 Vary the simulated Temperature on TIT-6303 Up and Down

 Confirm that the Temperature on the HMI screen matches the variations
Simulated value
 This confirms that TI and TIT-7003 are OK
 With the Additional checks for T-STY-001 in addition to the checks mentioned
above as for T-GSL-001, Interlocks Checks for T-STY-001 are completed.
 Remove all Simulations, Couple the Pumps to their Motors and install coupling
guards.
 If the above Tests are satisfactory, the Storage Tanks are ready for service for
onward Commissioning & Operation of Terminal Systems.

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STORAGE TANKS & DISTRIBUTION DIKE 2 (EXCEPT BITUMEN TANKS) –
NPT -1, 2 & 3, MEG-1, XYL- 1, VAM-1, BAT-1
REF. P&IDs – 7410A-300-PI-8655, 8656, 8657, 8658, 8660, 8670, 8678

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Table of Contents
1. Test Summary


5.0 Tests & Procedure – T-NPT-001

5.20 Interlocks Checks - “UNLOADING - TT”– Tank High & High High Level
5.23 Additional Interlocks check Applicable for T-VAM-001- Recirculation Pump

5.24 Additional Interlocks check Applicable for T-VAM-001- Temp. Transmission

Signature

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1 Test Summary
ancillaries.
downstream functions viz. Truck Loading, Truck Unloading, Drum Filling, Pumping
to Manifold for Export (Load Ship) / Blending
 The Terminal facility is intended to Store 20 different Solvents / Products in 30

Storage Tanks.
 Flexibility exists to Store alternative Solvents than intended, based on
requirements.
 A Plant is also put up to process the Solvents to produce other desired products
 A Blending Tank is also installed to blend different Solvents / Products to
produce Products as per requirements
 The Terminal carries two categories of Tanks for storage of Solvents / Products
based on their characteristics
 Fixed Roof Tanks
 Internal Floating roof Tanks
 The activities to satisfy the Aim of the Operational Test cover the following:
Tanks –
Solvents / Products.
 Parameters associated with the Tanks shall be simulated to confirm that all
the Effects are as per Logics

Pumps –
 Since almost all the Solvent Pumps installed are designed for liquid of Specific
gravity less than 1, their performance cannot be tested with Water. Hence the
Interlocks associated with the Pumps shall be tested with the Pumps decoupled
from their Motors, by simulation of parameters.
 The running performance of Pumps shall be monitored and confirmed during
actual operation with their respective Solvents.

 Safety aspects associated with all the Operations intended to be carried out shall
be tested.

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 Communication From & To SCADA with Field Instruments & Equipment and
Tests.
Modalities of Tests -
 Since Common Functions with respect to all the Storage Tanks and Process
Operations connected to them are identical, the Tests presented below are
detailed out with respect to one Tank – T-NPT-001.
 For other tanks, the modalities of Tests / Operations being the same, the
same procedure detailed for Tank – T-NPT-001 may be followed, with
appropriate Tag Nos. applicable for the Tank.
 Additional specific details, applicable for specific Tank (VAM) are
detailed out at the end of Checks for T-NPT-001.
Instrumentation procedure. However an integrated overall Functional Test of the total
System is important to ensure that the Integrated Solvent / Product Storage Tanks and
associated Process Operations conform to the requirements with all Safety aspects
functional.
On successful conclusion of the Tests, the Storage Tanks and associated Functions shall
be ready for regular Operational Service.
Nil
None
(Field)

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10 days


 PLCs of all the associated Systems & Packages should be Powered ON and
all Pre-commissioning activities completed

 Piping
 Electrical
distribution System
completed and
 Instrumentation
Test are completed
 Pre-commissioning of all the Packages e.g. F&G detection, FW System,
Tanker Loading etc. completed
5.0 Tests & Procedure – T-NPT-001
 Select Tank T-NPT-001 on the HMI screen of SCADA of Terminal Automation

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 Low Level and Low Low Level Alarms should be displayed in the Control
room.
60% on LIT 5501
 Confirm that the Local indication on LI 5501, LIT 5501 and the Level indicated on
the HMI screen conform to the same value.
 Keeping the simulated value of Level steady, simulate PT 5501 to a value of

around 1.3 Kg/cm2 - Approximate value of Pressure corresponding to 60%
Level of the Tank
 Confirm that the Local indication on PI 5501 and the Level indicated on the HMI
TIT 5501
 Confirm that the Local indication on TI 5501, TIT 5501 and the Level indicated on
values
 Confirm that the Indicated Density of the Solvent DI 5501 also varies
 Select any Tank on the HMI screen -Not necessarily the Tank under Test - which
in this case is Tank T-GSL-001
 Suddenly and quickly bring down the simulated value of LT 5501 from e.g.
60% to a lower value e.g. 40%.
Inventory
next step.

them
 Select T-NPT-001 on the HMI screen in the Control Room

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 Once the “Remote Auto” mode is selected, on selection of “RECEIPT –

JETTY” for the Tank on the HMI screen, confirm that the Inlet valve XV 5502
Opens and the Outlet valve XV 5501 Closes. *Not applicable
 * XV 5503 Actuated Inlet valve for Product from C-001 of Process Block for T-VAM-001
and XV 5504 Actuated Inlet valve for Product from C-002 of Process and T-BAT-001
Block remain Closed in “RECEIPT – JETTY” Remote Auto mode.
Solvent from the Jetty
 Connection of hose at the Manifold for Solvent Transfer to the correct Tank,
and transfer from the Jetty end (Ship) etc. shall be manually coordinated with
the Jetty and Control room by the responsible person on the field.
reached.
 Confirm High High Level Alarm.
 If the above parameters are Normal, simulate the Tank level to a healthy level of
40 – 50%, so that there is no Low or High Alarm for the Tank level, Reset the Trip
and proceed to the next step.
Actuated valve on the Inlet XV 5502 Open and Actuated valve on the Outlet
XV 5501 Closed.
*Not applicable
 * XV 5503 & XV 5504 Actuated Inlet valves for Products from C-001 & C-
for T-VAM-001
002 of Process Block Closed.
and T-BAT-001
 Confirm Alarm in the Control Room and simultaneous Closure of
Actuated valve on the Inlet XV 5502, thus stopping the Receipt of
Solvent from Jetty.
 Remove the above simulation for Flame detection and Restore the condition back
to a healthy state for “RECEIPT – JETTY” from the previous step with Actuated
valve on the Inlet XV 5502 Open and Actuated valve on the Outlet XV 5501
Closed. *Not applicable
 * XV 5503 & XV 5504 Actuated Inlet valves for Products from C-001 & C- for T-VAM-001
002 of Process Block Closed. and T-BAT-001
Flame detection
Solvent from Jetty.

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XV 5501 Closed.
 * XV 5503 & XV 5504 Actuated Inlet valves for Products from C-001 & C- “
for Gas detection
Solvent from Jetty.
 Remove the above simulation for Gas detection and Restore the condition back to
a healthy state for “RECEIPT – JETTY” from the previous step with Actuated
Closed.
002 of Process Block Closed. “
Solvent from Jetty.
Closed.
Tank Area
Solvent from Jetty.
 If the above steps are Normal, Remover all simulations for “RECEIPT – JETTY”
them
 Once the “Remote Auto” mode is selected, on selection of “DISP-TLF” for the
Tank on the HMI screen, confirm that the Inlet valve XV 5502 Closes and the
Outlet valve XV 5501 should also remain Closed because Tank is empty and the
Level is ‘0’

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 *XV 5503 Actuated Inlet valve for Product from C-001 of Process Block *Not applicable
and XV 5504 Actuated Inlet valve for Product from C-002 of Process for T-VAM-001
Block remain Closed in “DISP-TLF” Remote Auto mode. and T-BAT-001
 Ensure that Pump P-NPT-001 is decoupled from the Motor.

 Try to Kick Start (ON & OFF immediately) P-NPT-001.
 Try to Kick start the Pump (ON & OFF immediately) P-NPT-001
 The Motor (Pump decoupled from Motor) of P-NPT-001 should not take start since

on the SCADA
 Start the Pump P-NPT-001 in Remote Auto mode

 The Pump should Stop after a few seconds of Start since there is No Flow
 Simulate a healthy Flow / Activate the Flow Switch FS 5501 to Flow conditions
 Restart the Pump P-NPT-001 in Remote Auto mode
the next step.
 The Pump (Motor) P-NPT-001 should be running from the previous step with the
 Outlet valve XV 5501 is Open *Not applicable
 *Inlet valves from Process Block XV 5503 & XV 5504 Closed for T-VAM-001
 Healthy level of Solvent in the Tank e.g. around 60% through LIT 5502 and T-BAT-001
 Flow Switch FS 5501 Activated to Flow conditions

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 Confirm that the Actuated valve on the Outlet XV 5501 Closes in Auto
and the Pump Trips on Interlock.
 Confirm Alarm for Pump P-NPT-001 Trip in the Control room
 *Inlet valves from Process Block XV 5503 & XV 5504 Closed
 Healthy level of Solvent in the Tank e.g. around 60% through LIT 5502 “
 Flow Switch FS 5501 Activated to Flow conditions
 Confirm Alarm in the Control Room for Flame detection.
and the Pump Trips on Interlock, thus stopping the Dispatch for Truck
Loading.
to a healthy state for ““DISP-TLF”” from the previous step with Actuated valve
on the Inlet XV 5502 Closed and Actuated valve on the Outlet XV 5501 Open.
Flame detection
Loading.
 Healthy level of Solvent in the Tank e.g. around 60% through LIT 5502 *Not applicable
 ‘Pump Demand’ from the ‘Batch Controller’ of TLF for T-VAM-001
 Flow Switch FS 5501 Activated to Flow conditions and T-BAT-001

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for Gas detection
Loading.
a healthy state for “DISP-TLF” from the previous step with Actuated valve on the
Loading.
a healthy state for “DISP-TLF” from the previous step with Actuated valve on the
Tank Area
Loading.
 If the above steps are Normal, Remover all simulations for “DISP-TLF” and
them
 Once the “Remote Auto” mode is selected, on selection of “DISP-SHIP” for the
ank on the HMI screen, confirm that the Inlet valve XV 5502 Closes and the Outlet
valve XV 5501 should also remain Closed because Tank is empty and the Level
is ‘0’
 * XV 5503 Actuated Inlet valve for Product from C-001 of Process Block *Not applicable
and XV 5504 Actuated Inlet valve for Product from C-002 of Process for T-VAM-001
Block remain Closed in “DISP-SHIP” Remote Auto mode. and T-BAT-001
 Select Pump P-SOL-003A in Remote Auto mode

 *Select any other Tank having connection to the same Pump P-SOL-003A for *These need to
pumping to the Manifold e.g. T-BAT-001 / T-XYL-001 on the HMI screen in the be confirmed
Control Room from the Final
 *Try to select the same Pump P-SOL-003A for service Revision
document -

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 *It should not be possible since P-SOL-003A is already selected for ‘Control
Service for T-NPT-001 Narratives &
Interlocks
 Ensure that Pump P-SOL-003A is decoupled from the Motor. Description’
 Try to Kick Start (ON & OFF immediately) P-SOL-003A on Remote Manual mode.
 The Pump should not take start since the Tank is empty and the Level is ‘0’ in
T-NPT-001
 Start the Pump P-SOL-003A in Remote Manual mode
 The Pump should Stop after a few seconds of Start since there is No Flow
 Simulate a healthy Flow / Activate the Flow Switch on the Pump discharge FS
8202 to Flow conditions
 Restart the Pump P-SOL-003A in Remote Manual mode
and the Pump Trips on Interlock, thus stopping the Dispatch for Ship
Loading.
 Confirm Alarm for Pump P-SOL-003A Trip in the Control room
 The Pump (Motor) P-SOL-003A should be running from the previous step with the
 Flow Switch on the Pump discharge FS 8202 Activated to Flow conditions for T-VAM-001
and T-BAT-001
Loading.

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to a healthy state for “DISP-SHIP” from the previous step with Actuated valve on
Flame indication
Loading.
 The Pump (Motor) P-SOL-003A should be running from the previous step with the
 Outlet XV 5501 is Open “
 Flow Switch on the Pump discharge FS 8202 Activated to Flow conditions
for Gas detection
 Confirm Trip of the Pump P-SOL-003A & Alarm
 Confirm simultaneous Closure of the Outlet Actuated valve XV 5501,
thus stopping the Dispatch for Ship Loading.
a healthy state for “DISP-SHIP” from the previous step with Actuated valve on
a healthy state for “DISP-SHIP” from the previous step with Actuated valve on
Tank Area
 If the above steps are Normal, Remove all simulations for “DISP-SHIP” and

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them
 Select “DISP-DRUM”
 Once the “Remote Auto” mode is selected, on selection of “DISP-DRUM” for the *Not applicable
Tank on the HMI screen, confirm that the Inlet valve XV 5502 Closes and the for T-VAM-001
Outlet valve XV 5501 should also remain Closed because Tank is empty and the and T-BAT-001
Level is ‘0’
 *XV 5503 Actuated Inlet valve for Product from C-001 of Process Block *These need to
and XV 5504 Actuated Inlet valve for Product from C-002 of Process be confirmed
Block remain Closed in “DISP-SHIP” Remote Auto mode. from the Final
Revision
document -
 *Select Pump P-SOL-004B for service
‘Control
 *Select any other Tank having connection to the same Pump P-SOL-004B for Narratives &
Drum Filling e.g. T-MEG-001 / T-BAT-001 on the HMI screen in the Control Interlocks
Room Description’
 Try to select the same Pump P-SOL-004B for service
 *It should not be possible since P-SOL-004B is already selected for
Service for T-NPT-001
 Operate the Pump (AODD Pump) – Just momentarily Start & Stop - P-
SOL-004B in Manual mode
 Confirm that Pump P-SOL-004B ‘Running’ & ‘Stopped’ indications appear on
the HMI screen
 Gradually decrease the Simulated Level of the Tank through LT 5502

 Confirm that the Actuated valve on the Outlet XV 5501 Closes in Auto.
 If the above parameters are Normal, Reset the Trip, Restore healthy conditions
simulations:

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for T-VAM-001
 Simulate the Flame detector in the vicinity of the Tank for Flame detection and T-BAT-001
thus stopping the Dispatch for Drum Filling.
to a healthy state for “DISP-DRUM” from the previous step with Actuated valve
Flame detection
thus stopping the Dispatch for Drum Filling.
 If the above parameters are Normal, Reset the Trip, Restore healthy conditions
simulations:
 Outlet XV 5501 is Open *Not applicable
 *Inlet valves from Process Block XV 5503 & XV 5504 Closed for T-VAM-001
 Healthy level of Solvent in the Tank e.g. around 60% through LIT 5502 and T-BAT-001
for Gas detection
thus stopping the Dispatch for Drum Loading.
Tank Area

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them
 Select “UNLOADING - TT” on the HMI
 Once the “Remote Auto” mode is selected, on selection of “UNLOADING - TT” for
the Tank on the HMI screen, confirm that the Inlet valve XV 5502 Opens and the
Outlet valve XV 6101 Closes. *Not applicable
 * XV 5503 Actuated Inlet valve for Product from C-001 of Process Block for T-VAM-001
and XV 5504 Actuated Inlet valve for Product from C-002 of Process and T-BAT-001
Block remain Closed in “DISP-SHIP” Remote Auto mode.
 Connection of hose at the discharge of Tanker Product Unloading Pump P-
SOL-008 and at the Manifold, for Solvent Transfer to the correct Tank etc.
shall be manually coordinated with the Control room by the responsible
person on the field.
 Maintain the above Conditions conducive for Receipt of Solvent from the Tanker,
with all conditions Healthy
reached.
 If the above parameters are Normal, simulate the Tank level to a healthy level of
40 – 50%, so that there is no Low or High Alarm for the Tank level, Reset the Trip
XV 5501 Closed. *Not applicable
for T-VAM-001
 Simulate the Flame detector in the vicinity of the Tank for Flame detection and T-BAT-001
to a healthy state for “UNLOADING - TT” from the previous step with Actuated
Closed.

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Flame detection
XV 5501 Closed.
for Gas detection
a healthy state for “UNLOADING - TT” from the previous step with Actuated
Closed.
a healthy state for “UNLOADING - TT” from the previous step with Actuated
Closed.
Tank Area
 The Interlocks Checks for T-NPT-001 are completed.
5.23 Additional Interlocks check Applicable for T-VAM-001- Recirculation Pump
 All the Tests mentioned above for T-NPT-001 are applicable for T-VAM-001
 In addition the following Tests should be carried out
 Select T-VAM-001 on the HMI screen in the Control Room

 Actuated valves on the Inlet from the Manifold to the Tank XV 7002 and on
the Tank Outlet XV 7001 should remain Closed when No selection is made
 Ensure that Pump P-VAM-002 (Recirculation Pump) is decoupled from the
Motor.
 Try to Kick Start (ON & OFF immediately) P-VAM-002.
 Simulate a healthy level of around 50% in the Tank through LIT-7002.

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 Start the Pump P-VAM-002

 The Motor (Pump decoupled from Motor) should Start and Stop after a few
seconds since there is No flow on the Recirculation line.
 Confirm Alarm for Trip of P-VAM-002 in the Control room
 Maintain the Simulation of Level in the Tank at around 50% through LIT-7002.
 Start the Pump P-VAM-002 and Activate the Flow Switch FSL-7002 to Flow
conditions
 The Motor (Pump decoupled from Motor) should Start and continue to run
5.24 Additional Interlocks check Applicable for T-VAM-001- Temp. Transmission
 Maintain Conditions mentioned above to keep the Motor (Pump decoupled from
Motor) running.
 Tank level simulated to a healthy level of around 50% through LIT-7002.
 Flow Switch FSL-7002 Actuated to Flow conditions
 TI -7003 should read the Atmospheric Temperature

 The Temperature indicated on the HMI screen should match the indicated
value on TI -7003
 Simulate a Temperature of around 25 deg. C on TIT-7003

 Confirm that the Temperature on the HMI screen matches the Simulated
value
 Vary the simulated Temperature on TIT-7003 Up and Down

 Confirm that the Temperature on the HMI screen matches the variations
Simulated value
 This confirms that TI and TIT-7003 are OK
 With the Additional checks for T-VAM-001 in addition to the checks

mentioned above as for T-NPT-001, Interlocks Checks for T-VAM-001 are
completed.
 Remove all Simulations, Couple the Pumps to their Motors and install coupling
guards.
 If the above Tests are satisfactory, the Storage Tanks are ready for service
for onward Commissioning & Operation of Terminal Systems.

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BITUMEN STORAGE TANKS & DISTRIBUTION DIKE 2 –
BTM 1 & 2
REF. P&IDs – 7410A-300-PI-8653, 8654

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Table of Contents
1. Test Summary


5.0 Tests & Procedure T-BTM-001

5.23 Interlocks Checks – Recirculation of Bitumen in Tank
5.24 Interlocks Checks - “RECIRCULATION”– Flame Detection
5.25 Interlocks Checks - “RECIRCULATION”– Gas Detection

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Signature
1 Test Summary
ancillaries.
downstream functions viz. Truck Loading, Truck Unloading, Drum Filling, Pumping
to Manifold for Export (Load Ship) / Blending
Tanks –
Product.
 Parameters associated with the Tanks shall be simulated to confirm that all the
Effects are as per Logics
Pumps –
 Since Bitumen Pumps are Geared Pumps, their performance cannot be tested with
Water. Hence the Interlocks associated with the Pumps shall be tested with the
Pumps decoupled from their Motors, by simulation of parameters.
 The running performance of Pumps shall be monitored and confirmed during actual
operation with their respective Solvents.

 Safety aspects associated with all the Operations intended to be carried out shall
be tested.

 Communication From & To SCADA with Field Instruments & Equipment and
Tests.
Modalities of Tests -
 Since Common Functions with respect to the Bitumen Storage Tanks and
Process Operations connected to them are identical, the Tests presented
below are detailed out with respect to one Tank – T-BTM-001.
 For Tank – T-BTM-002, the modalities of Tests / Operations being the
same, the same procedure detailed for Tank – T-BTM-001
may be followed, with appropriate Tag Nos. applicable for the Tank.
Instrumentation procedure. However an integrated overall Functional Test of the total
System is important to ensure that the Integrated Solvent / Product Storage Tanks and

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associated Process Operations conform to the requirements with all Safety aspects
functional.
On successful conclusion of the Tests, the Storage Tanks and associated Functions shall be
ready for regular Operational Service.
Nil
None
(Field)
3 days


 PLCs of all the associated Systems & Packages should be Powered ON and
all Pre-commissioning activities completed

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 Piping
 Electrical
distribution System
completed and
 Instrumentation
Test are completed
 Pre-commissioning of all the Packages e.g. F&G detection, FW System,
Tanker Loading etc. completed
5.0 Tests & Procedure T-BTM-001
 Select Tank T-BTM-001 on the HMI screen of SCADA of Terminal Automation
 Low Level and Low Low Level Alarms should be displayed in the Control room.
60% on LIT 5301
 Confirm that the Local indication on LI 5301, LIT 5301 and the Level indicated on
 Keeping the simulated value of Level steady, simulate PT 5301 to a value of around
1.7 Kg/cm2 - Approximate value of Pressure corresponding to 60% Level of
the Tank
 Confirm that the Local indication on PI 5301 and the Level indicated on the HMI

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TIT 5301
 Confirm that the Local indication on TI 5301, TIT 5301 and the Level indicated on
values
 Confirm that the Indicated Density of the Solvent DI 5301 also varies
 Suddenly and quickly bring down the simulated value of LT 5301 from e.g.
60% to a lower value e.g. 40%.
Inventory
next step.
them
 Select T-BTM-001on the HMI screen in the Control Room
 Ensure that the Actuated valves on the Inlet from the Manifold to the Tank XV 5305,
on the Tank Outlet XV 5301 , Actuated valve on P-BTM-001 discharge to TLF XV
5304 and Actuated valve on the Recirculation line to the Tank XV 5303 are in
Remote Auto mode
 Once the “Remote Auto” mode is selected, on selection of “RECEIPT –
JETTY” for the Tank on the HMI screen, confirm that the Inlet valve XV 5305
Opens and all the other three Actuated valves should Close viz. Tank
Outlet XV 5301, to TLF XV 5304 and to Recirculation XV 5303 should Close.
Solvent from the Jetty
 Transfer from the Jetty end (Ship) etc. shall be manually coordinated with the
Jetty and Control room by the responsible person on the field.

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reached.
Actuated valve position as follows:
 Inlet XV 5305 Open
 Outlet XV 5301 Closed
 Recirculation XV 5303 Closed
 To TLF XV 5304 Closed
 Confirm Alarm in the Control Room and simultaneous Closure of Actuated
valve on the Inlet XV 5305, thus stopping the Receipt of Solvent from Jetty.
valve position as follows:
Flame detection
Actuated valve on the Inlet XV 5305, thus stopping the Receipt of Bitumen
from Jetty.
Actuated valve position as follows:
for Gas detection
from Jetty.

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position as follows:
from Jetty.
position as follows:
Tank Area
from Jetty.
 If the above steps are Normal, Remover all simulations for “RECEIPT – JETTY”
them
 Select T-BTM-01 on the HMI screen in the Control Room
5304 , Actuated valve on the Recirculation line to the Tank XV 5303 and the Digital
Control valve downstream of the Flow meter in the Loading Bay DCV 8101 are in
Remote Auto mode
 Once the “Remote Auto” mode is selected, on selection of “DISP-TLF” for the Tank
on the HMI screen, confirm that the Inlet Actuated valve positions are as follows:
 Inlet XV 5305 Closed
 Outlet XV 5301 Closed (because Level in the Tank is ‘0’)
 *DCV 8101 Open *This needs to
 To TLF XV 5304 Open be confirmed
from the Final
 Ensure that Pump P-BTM-001 is decoupled from the Motor. Revision
document -
 Try to Kick Start (ON & OFF immediately) P-BTM-001.
‘Control
Narratives &
Interlocks
 If the above conditions are fulfilled, the Tank shall be ready to dispatch the Description’
Bitumen from the Storage Tank

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 Maintain the above Conditions conducive for Dispatch of Bitumen from the Storage
Tank, with all conditions Healthy as follows:
 Outlet XV 5301 Closed (because Level in the Tank is ‘0’)
 *DCV 8101 Open
 To TLF XV 5304 Open
 The Outlet Actuated valve XV 5301 and Actuated valve to TLF XV 5304 Open on
Remote Auto mode.
 Try to Kick start the Pump (ON & OFF immediately) P-BTM-001
 The Motor (Pump decoupled from Motor) of P-BTM-001 should not take start since

on the SCADA
 Start the Pump P-BTM-001 in Remote Auto mode

 The Pump should Not Start since there is No communication of Earthing
circuit of the Tanker
 Simulate Earthing of the Tanker circuit

 Restart the Pump P-BTM-001 in Remote Auto mode
 Simulate / Activate the Pressure Switch on the discharge of P-BTM-001 - PS 5301

 Confirm Pump (Motor) P-BTM-001 Trips
 Remove the above simulation with all the other conditions being healthy for TLF as
before
 Simulate Closure of DCV 8101

 Remove the above simulation and keep DCV 8101 Open with all the other
conditions being healthy for TLF as before
 Restart P-BTM-001 in Remote Auto mode and keep it running
the next step.
 The Pump (Motor) P-BTM-001 should be running from the previous step with the
 Outlet XV 5301 Open
 *DCV 8101 Open

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 Tanker circuit Earthed
 Confirm Alarm for Pump P-BTM-001 Trip in the Control room
 The Pump (Motor) P-BTM-001 should be running from the previous step with the
 *DCV 8101 Open
 Confirm Closure of the Outlet Actuated valve XV 5301, thus stopping the
Dispatch for Truck Loading.
 Confirm simultaneous Trip of the Pump P-BTM-001 & Alarm
a healthy state for ““DISP-TLF”” from the previous step with Actuated valve on
the Inlet XV 5305 Closed and Actuated valve on the Outlet XV 5301Open.
Flame detection

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0  The Pump (Motor) P-BTM-001 should be running from the previous step with the
 *DCV 8101 Open
for Gas detection
Tank Area
 If the above steps are Normal, Remover all simulations for “DISP-TLF” and
1  Ensure that all the Flame and Gas detectors in the Tank Dike area, Pumping area
them
Remote Auto mode
 Once the “Remote Auto” mode is selected, on selection of “DISP-SHIP” for the
Tank on the HMI screen, confirm that the position of the Actuated valves connected
to the Tank are as follows:

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 Outlet valve XV 5301 Closed (because of ‘0’ level in the Tank)

 Inlet from the Manifold XV 5305 Closed
 to TLF XV 5304 Closed
 *Confirm if Pump P-BTM-003 is selected by default in Remote Auto mode

 *If Pump P-BTM-003 is not selected, Select P-BTM-003 for service
 *Select the other Tank T-BTM-002 having connection to the same Pump P-
BTM-003 for pumping to the Manifold on the HMI screen in the Control Room
 Try to select the same service “DISP-SHIP” on the HMI screen *These need to
 *It should not be possible since T-BTM-001 & hence P-BTM-003 are be confirmed
already selected for “DISP-SHIP” from the Final
Revision
 Ensure that Pump P-BTM-003 is decoupled from the Motor. document -
 Try to Kick Start (ON & OFF immediately) P-BTM-003 on Remote Manual mode. ‘Control
 The Pump should not take start since the Tank is empty and the Level is ‘0’ in T- Narratives &
BTM-001 Interlocks
Description’
2  Maintain the above Conditions conducive for Dispatch of Solvent from the Storage
 Start the Pump P-BTM-003 in Remote Manual mode
 Confirm simultaneous Trip of Pump P-BTM-003 and Alarm in the Control
room

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 Outlet valve XV 5301 Open
Dispatch for Ship Loading.
 Confirm simultaneous Trip of the Motor (Pump decoupled) P-BTM-003 &
Alarm
a healthy state for “DISP-SHIP” from the previous step with Actuated valve on the
Inlet XV 5305 Closed, Actuated valve on the Outlet XV 5301 Open and Pump P-
BTM-003 running.
Flame indication
Alarm
for Gas detection
Alarm
BTM-003 running.

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Alarm
BTM-003 running.
Tank Area
Alarm
 If the above steps are Normal, Remove all simulations for “DISP-SHIP” and
them
 Select “DISP-DRUM”
Remote Auto mode
 Once the “Remote Auto” mode is selected, on selection of “DISP-DRUM” for the
Tank on the HMI screen, confirm that the position of the Actuated valves connected
to the Tank are as follows:
 Drum Filling Actuated valve XV 8201 Open
 *Confirm if Pump P-BTM-004 is selected by default in Remote Auto mode

 *If Pump P-BTM-004 is not selected, Select P-BTM-004 for service *These need to
 *Select the other Tank T-BTM-002 having connection to the same Pump P- be confirmed
BTM-003 for pumping to the Manifold on the HMI screen in the Control Room from the Final
 Try to select the same service “DISP-DRUM” on the HMI screen Revision
 *It should not be possible since T-BTM-001 & hence P-BTM-003 are already document -
selected for “DISP-DRUM” ‘Control
Narratives &
Interlocks
 Ensure that Pump P-BTM-003 is decoupled from the Motor.
Description’
 Try to Kick Start (ON & OFF immediately) P-BTM-003 on Remote Manual mode.
 The Pump should not take start since the Tank is empty and the Level is ‘0’ in T-
BTM-001

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6  Maintain the above Conditions conducive for Dispatch of Solvent from the Storage

 Simulate Closure of XV 8201

 Confirm Alarm in the Control room
 Remove the above simulation with all the other conditions being healthy for Drum
Filling as before
 Confirm that the Actuated valve on the Outlet XV 5301 Closes in Auto.
room
7  Maintain healthy conditions from the previous step with the following conditions &
simulations:
 Healthy level simulated to around 60% through LIT 5302
Dispatch for Drum Filling.
room

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Flame detection
room
simulations:
for Gas detection
room
room
Tank Area
stopping the Dispatch for Drum Loading.

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them
 Select “UNLOADING - TT” on the HMI
Remote Auto mode
 Once the “Remote Auto” mode is selected, on selection of “UNLOADING - TT” for
the Tank on the HMI screen, confirm that the position of the Actuated valves
connected to the Tank are as follows:
 Outlet valve XV 5301 Closed
 Inlet from the Manifold XV 5305 Open
 Ensure that Tanker unloading Pump P-BTM-005 is decoupled from Motor

 Start the Motor (Pump decoupled) P-BTM-005
 The Motor (Pump decoupled) should start and keep running
 Simulate / Activate the Pressure Switch PS-8501 on the discharge of P-BTM-005

 Confirm the Trip of Motor (Pump decoupled) P-BTM-005
 Confirm Alarm in the Control room
 Remove the Simulation / Activation of PS-8501 to restore healthy conditions again
 Connection of hose to the Tanker, Opening the Suction & Discharge valve of
Bitumen Tanker unloading Pump P-BTM-005, Opening / Closing of requisite
valves etc. shall be manually coordinated with the Control room by the
responsible person on the field.
0  Maintain the above Conditions conducive for Receipt of Solvent from the Tanker,
with all conditions Healthy
 Confirm Alarm for High Level in the Tank at the Set point
* Trip of P-BTM-
reached.
005 on Closure
 Confirm High High Level Alarm.
of Inlet valve XV
 Confirm that the Actuated valve on the Inlet XV 5305 Closes in Auto.
5305 in
“UNLOADING –
Inlet Actuated valve closes in Auto. TT” mode is to
 *(The Pump P-BTM-005 should Trip on High discharge Pressure in actual be confirmed
operation with Alarm in the Control room) from the Final
Revision of
 If the above parameters are Normal, simulate the Tank level to a healthy level of 40 ‘Control
– 50%, so that there is no Low or High Alarm for the Tank level, Reset the Trip and Narratives &

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Interlocks
Description’
1  Maintain healthy condition for “UNLOADING - TT” from the previous step with
5301 Closed.
 *(The Pump P-BTM-005 should Trip on High discharge Pressure in actual
operation with Alarm in the Control room) “
a healthy state for “UNLOADING - TT” from the previous step with Actuated valve
* Trip of P-BTM-
 Simulate the Flame detection in any other Detector in the Storage Tank Area for 005 on Closure
Flame detection of Inlet valve XV
 Confirm Alarm in the Control Room and simultaneous Closure of 5305 in
Actuated valve on the Inlet XV 5305, thus stopping Unloading of Solvent “UNLOADING –
from the Tanker to the Tank. TT” mode is to
 *(The Pump P-BTM-005 should Trip on High discharge Pressure in actual be confirmed
operation with Alarm in the Control room) from the Final
Revision of
 If the above steps are Normal, Proceed to the next step ‘Control
Narratives &
Interlocks
Description’
2  Maintain healthy condition for “UNLOADING - TT” from the previous step with
5301 Closed.
for Gas detection
 *(The Pump P-BTM-005 should Trip on High discharge Pressure in actual “
operation with Alarm in the Control room)
valve on the Inlet XV 5305, thus stopping the Unloading of Solvent from the
Tanker to the Tank.
 *(The Pump P-BTM-005 should Trip on High discharge Pressure in actual “

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Tank Area
valve on the Inlet XV 5305, thus stopping the Unloading of Solvent from the
Tanker to the Tank.
 *(The Pump P-BTM-005 should Trip on High discharge Pressure in actual
“
 The Interlocks Checks for T-BTM-001 are completed.
5.2 Interlocks Checks – Recirculation of Bitumen in Tank

3 and Open path area are healthy and there are no High Level Alarms from any of
them
 Select “RECIRCULATION” on the HMI
Remote Auto mode
 Once the “Remote Auto” mode is selected, on selection of “RECIRCULATION” for
the Tank on the HMI screen, confirm that the position of the Actuated valves
connected to the Tank are as follows:
 Outlet valve XV 5301 Closed (because the Tank level is ‘0’)
 Recirculation XV 5303 Open
 Ensure that Pump P-BTM-001 is decoupled from the Motor.

 Try to Kick Start (ON & OFF immediately) P-BTM-001 on Remote Manual mode.
 The Pump should not take start since the Tank is empty and the Level is ‘0’ in T-
BTM-001 and Outlet valve XV 5301 is Closed

5.2 Interlocks Checks - “RECIRCULATION”– Flame Detection
simulations:
 Confirm Closure of the Outlet Actuated valve XV 5301, thus stopping
Recirculation.
room

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a healthy state for “RECIRCULATION” from the previous step with Actuated valve
Flame detection
Recirculation.
room
5.2 Interlocks Checks - “RECIRCULATION”– Gas Detection
simulations:
for Gas detection
Recirculation.
room
healthy state for “RECIRCULATION” from the previous step with Actuated valve
Recirculation.
room
healthy state for “” from the previous step with Actuated valve on the Inlet XV
5305 Closed and Actuated valve on the Outlet XV 5301 Open.
Tank Area
stopping the Dispatch for Drum Loading.
 If the above steps are Normal, Remove all simulations for “RECIRCULATION”.
 The Interlocks Checks for T-BTM-001 are completed.

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6  Remove all Simulations, Couple the Pumps to their Motors and install coupling
guards.
 If the above Tests are satisfactory, the Bitumen Storage Tanks are ready for
service for onward Commissioning & Operation of Terminal Systems.

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PIG LAUNCHER & RECIVER – TAG NOS. PLR 001 & 002, PLR 003 & 004, PLR 005 &
006, PLR 007 & 008, PLR 009 & 010
Vendor (Multitex)

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Table of Contents
1. Test Summary


Tests & Procedure (Ship Loading Mode)
5.1 Preparations for Utility Water filling in the Pipe line

5.2 Water filling in the Pipe line – PLR to PLR
5.3 Launching of Pig at the Manifold end
5.4 Receipt of Pig at the destination & Pig Retraction
5.5 Maintenance of QOC
5.6 OTP for all the PLRs

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Signature
1 Test Summary
 Confirm the safe operational capabilities of the Process Pig Launcher & Receiver
Systems.
 Ensure proper function of the PLRs and accessories
 Confirm that the Pipe line is clear without obstacles prior to Unloading / Loading of
Solvents / Products through the Pipe line.
 Running of the Pigs through their respective Pipe lines, with Water filled in the
Pipeline
 Confirm Water being pushed out from the other end
 Confirm indication of Pig signaler on the Pig reaching the destination
Other vendor recommended procedures if any, for Operational Tests, would take
precedence over this document and shall govern the proceedings.
On successful conclusion of the Operational Tests, the Pig Launcher & Receiver systems
are ready to be pressed into regular Operational Service.
 Hose connections at the end of discharge lines Barred Tee at both the Jetty
end and the Manifold end, to drain the water to the closest drain
None
Vendor assistance to be availed for guidance.

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3 days
 The Lines from PLR to PLR are Mechanically complete in all respects including
Hydro tests and Flushing of the lines.
 The lines are reinstated with all valves, fittings and Instruments as per drwing
 Utilities requirement – Power (LV), Service water through Utility connection.
 Check the Quick Opening Closure (QOC) for the following

 Leak proof seating with proper seating of Seal
 Integral Pressure Alert valve (PAV) in place
 Small removable ring of the Swing door locks with the PAV to prevent
accidental opening of the door with pressure in the system
 Confirm that Pig signalers are mounted at both the Launching end and the
Receiving end as per vendor recommended installation procedure
 Confirm that all the valves, Instruments, PRVs etc. are mounted in place as per
drawing
5.0 Tests & Procedure (Ship Loading Mode)
5.1 Preparations for Utility Water filling in the Pipe line
Manifold end
 Make Service water connection to the Utility connection downstream (from the
Ship Unloading point of view) of one of the Barred Tees
 Keep the main isolation valves from Barred Tees fully closed
 Keep all the vents, drains and Utility connections Closed.
Jetty end
 Keep the main isolation valves from both Barred Tees fully closed
 Keep all the vents, drains and Utility connections Closed initially
 Confirm that the Temporary hose connection the end of discharge line of one of
the Barred Tees to the closest drain is in tact
 Keep personnel at the Jetty end of Water to be sent to the drain
 Open one of the vents to vent air as the water fills in the Pipe line
 Communicate to the Manifold end Operator to start filling Utility service water in the
Pipe line
5.2 Water filling in the Pipe line – PLR to PLR
Step 1 - Manifold end
 Open the isolation valve from Barred Tee downstream of which Utility Service
water connection is made
 Open Service water and let in fill the Pipe line
 Monitor for leakages and take corrective actions, if any required

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Step 2 - Jetty end
 Confirm from the vent that is Open if air is being displaced, signifying water filling
in the Pipe line.
 When water comes out the vent, signifying that the line is full with water, inform the
Manifold end Operator and Close the vent
 Close the Utility water connection on communication of the Pipe line being full from
the Jetty end Operator
 Close the isolation valve downstream of the Barred Tee and also Utility
isolation valve.
 Remove the Service water connection
5.3 Launching of Pig at the Manifold end
Step 1 - Jetty end
 Open the isolation valve downstream of the Barred ‘Tee’ to which Temporary hose
connection is made to the drain
 Open QOC of barrel and insert Pig into Barrel and push it into neck of barrel.
 Ensure proper push fit of pig into neck to avoid leakage of Kicker Liquid.
 Close all valves and QOC but open vent valve.

 Connect Service water to the Utility connection point on the Barrel of the PLR.
 Fill the barrel with liquid (Utility water) for pressure balancing.
 Vent the air displaced and close vent.
 Pressurize kicker liquid (Utility water) and open kicker valve slowly. When pressure
builds into barrel, it will push pig into neck of barrel and then into pipeline.
 Confirm that Pig alert provided on Neck/Pipeline gives signal that Pig has
passed through pipeline.
 Through pressure on the Kicker liquid (Utility water) pig travels into pipeline.
Step 3 - Jetty end
 Confirm water in the Pipe line is being pushed out through the temporary
connection hose to the drain.
5.4 Receipt of Pig at the destination & Pig Retraction
Jetty end
 After the Pipe line hold up liquid is pushed out, Stop the Kicker liquid (Utility water)
by closing the Utility connection isolation valve.
 Open the bypass (Ball) valve on the Pig Receiver end.

 Pressurized liquid passes through the bypass connection
 Confirm after the Pig signaler at the Jetty end gives signal that the Pig has
reached the Neck of the Receiver at the Jetty end
 Open the drain valve and drain out the water in the Receiver to depressurize the
system before opening the QOC

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 Open the QOC

 Pull the pig outside from barrel and take out pig on pig handling device with help of
Jib crane (if available).
 Above is a manual operation
5.5 Maintenance of QOC
 Due to frequent opening / closing of QOC, its seal may get damaged and hence in
case of any leakage, seal of QOC should be replaced by new one.
5.6 OTP for all the PLRs
 Carry out the above Test Procedure for all the Pipe lines connected to PLRs
from Jetty to Manifold – Total 4 Nos viz. PLR 1 & 2, PLR 3 &4, PLR 5&6 and
PLR 7&8.
 The Pig may be run in the Reverse direction from the Jetty end to the
Manifold end following the above procedure, to confirm the functionality
at the Manifold end Receiver also (Ship Unloading Mode)
 The same Procedure may be followed for the Pipe line from Manifold to
McGraw Terminal viz PLR 9 & 10
 Remove the Temporary Installations mentioned in paragraph 1.3 and Reinstate the
System to normal Operating position.
 If the above Tests are satisfactory, the Ship Loading / Unloading lines from
Manifold to Jetty are ready to be pressed into service for onward
Commissioning of Terminal Systems.

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TERMINAL AUTOMATION SYSTEM (TAS) FOR TANKER LOADING
REF. P&ID: TCE.7410A-300-PI-8681
Vendor (Honeywell) Doc. No. P15M456697-102-TM

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Table of Contents
1. Test Summary


5.1 Security Entry Gate Operation – Issue of Filling Advisory Note (FAN)
5.1.1 Security Gate Operation – Failure to Print Filling Advisory Note (FAN)
5.1.2 Emergency Shut down before Printing FAN
5.1.3 Print out of FAN
5.2 Tare Weighing of the Vehicle
5.2.1 Emergency Shut down during Tare Weighing

5.2.2 Failures & Success of Tare Weighing
5.3 Truck Loading
5.3.1 Failures & Success of Truck Loading

5.3.2 Emergency Shut down during Truck Loading
5.3.3 Loading Completion
5.4 Gross Weighing
5.4.1 Failures & Success of Gross Weighing

5.4.2 Emergency Shut down during Gross Weighing
5.5 BOL and Exit
5.5.1 Emergency Shut down before BOL & Exit

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Signature
1.0 Test Summary
The aim of operational test is to demonstrate the safe operational capabilities of the
Terminal Automation Software Systems in the Terminal and its associate Network
The systems under this Test covers the Automation of the following stages of Truck
loading from Entry of Empty Truck to the Exit of the Loaded Truck from the Terminal with
the Checks involved in each step to ensure that the correct material is loaded in the correct
Truck with the correct weight of the material and the associated communication Network:
 Entry Gate Operation

 Tare Weighing
 Truck Loading
 Gross Weighing
 Exit Gate Operation
 Shut down of Operations in case of Emergencies
important to confirm and ensure that the integrated system functions as per requirements.
On successful conclusion of the Operational Tests, the system is ready to support the
Nil
Nil
(Field)
Truck Loading Operator 1
Truck Loading Supervisor 1
Security Gate Personnel 1

(Entry Gate)

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Security Gate Personnel 1

(Exit Gate)
Dispatch section Operator 1
Control Room Operator 1
TAS vendor (Honeywell)
2 days

 Utilities requirement – Power (LV), Empty Truck, Calibrated weights to load the
Truck
 Keep the Personnel including the Security at the main gate briefed on the Tests to
be carried out
 The personnel involved in the Tests should be aware of the Procedures to be
followed in actual Operation.
 A coaching session by the Vendor (Honeywell) for all the Security
Personnel , Truck Loading Supervisors and Operators intended to be
posted for Truck loading Operations explaining the features of the
System and detailing the functions of each person involved in the
Operation is recommended
 Keep all the TAS Servers and the Network connections Powered ON to commence
the Tests
 The OTP shall be carried out by simulation of parameters as mentioned
in each step
 The Field Operator (TLF) should accompany the Driver of the vehicle during
all stages of the Test and should represent the Driver for all interactions
5.1 Security Entry Gate Operation – Issue of Filling Advisory Note (FAN)
 The Driver reports to Security and present the relevant papers for getting the Truck
filled with the requisite material

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 Security to look for details to on the Terminal Manager User Interface (TMUI) to
Print Filling Advisory Note (FAN)
 Confirm that the Security is unable to do so, in the absence of details on the
Terminal Manager User Interface (TMUI)
 The Security informs the Supervisor the details of the Truck that has arrived for
Loading
 The Supervisor fills the following parameters and Authorizes Shipment manually
through TMUI.
 i) Compartment wise Product to be loaded
 ii) Information about Driver & Vehicle
 iii) Quantity to be Loaded
 iv) Customer & Destination
 Security to confirm visibility of the Shipment Authorization by the Supervisor on the

TMUI and should try to Print the Filling Advisory Note (FAN)
 Security to confirm Print out of FAN successfully
5.1.1 Security Gate Operation – Failure to Print Filling Advisory Note (FAN)
 The above Test should be repeated for failure to Print FAN as follows:
 The supervisor should fill in the details ii) to iv) mentioned above except i) viz.
Compartment wise Product to be loaded and try to Authorize the Shipment on
TMUI *This should be
 *Confirm that the Authorization is not accepted on TAS due to the confirmed by
information being incomplete. the Vendor
 *Confirm that the Security is unable to print the FAN due to the (Honeywell)
information being incomplete / Print failure reported
 The above Test for FAN Printing Failure may be repeated for the cases of missing
details individually as follows:
 Detail ii) Information about Driver & Vehicle missing but other details i),iii) and
iv) present
 Detail iii) Quantity to be loaded missing but other details i),ii) and iv) present
 Detail iv) Customer & Destination missing but other details i),ii) and iii)
present
 *Confirm that the Authorization is not accepted on TAS due to the

information being incomplete for each of the above cases
 *Confirm that the Security is unable to print the FAN due to the
“
information being incomplete / Print failure reported for each of the
above cases
5.1.2 Emergency Shut down before Printing FAN
 Immediately after the Authorization of Shipment by the Supervisor, Simulate one of

the Point type Gas detectors in the Truck Loading Area for Gas detection (as
explained under F&G OTP)
 Confirm Gas detection Alarm in the Control room as well as the Truck loading
Bay.
 The security should try to print the FAN after the Alarm is sounded.
 Confirm that the Security is unable to do print the FAN, because of the
Emergency
 Remove the above simulation for Gas detection in the Truck loading Bay
 Repeat the above Tests by simulating Fire Detection in one of the Detectors in the
Storage Tanks area

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 Confirm that the Security is unable to do print the FAN, because of the
Emergency
5.1.3 Print out of FAN
 If the above parameters are Normal, the Supervisor should fill all the details as
above i) to iv) as above and Authorize Shipment on TMUI and Authorize 2
Shipment with the following variations
 FAN 1 – Operator Authorizes Quantity exceeding the limit i.e. Tare Weight
of the Vehicle + Quantity Approved Exceeding the Capacity of the
Vehicle (Safe Fill Level SFL)
 FAN 2 - Operator Authorizes Correct Quantity within the limit i.e. Tare Weight
of the Vehicle + Quantity Approved Less the Capacity of the Vehicle
(Safe Fill Level SFL)
 The Security Prints out both FAN 1 & 2 and hands over to the Driver
(*Print out of two FANs – one valid & the other invalid is for Test purpose only. In
actual practice only One valid FAN should be printed)
 The Driver should collect the above (FAN 1 &) FAN 2 (and also the Failed
Reports for the 4 Failure cases mentioned above, if any, only for the
Test of the next step and Not in actual practice) and drive the Vehicle for
Tare Weighing
 If the above steps are Normal, proceed to the next step
5.2 Tare Weighing of the Vehicle
 The Driver drives and parks the vehicle at Entry to the Weigh Bridge
5.2.1 Emergency Shut down during Tare Weighing
 Activate the Gas Detection in the Truck Loading Bay

 Confirm corresponding Alarm
 Try to Present the FAN 2 (Valid FAN) to the Card Reader
 Confirm that even the Valid FAN is not Validated and there is Nothing
displayed on the 22” LED TV (Shipment details)
 Repeat the above for any Fire Detection in the Terminal

 Confirm that even the Valid FAN is not Validated and there is Nothing
displayed on the 22” LED TV (Shipment details)
5.2.2 Failures & Success of Tare Weighing
The following Tests are carried out to Validate the System Software that Only
Correct FAN will be accepted for further proceedings
 i) The Driver presents one of the Failed Reports to the Card Reader
 Confirm that the Card Reader indicates Failure for Validation of the FAN
 ii) The Driver presents FAN 1 (Quantity Authorized Exceeding the limit of SFL)
to the Card Reader
 Confirm that the Card Reader indicates Failure for Validation of the FAN

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 ii) The Driver presents FAN 2 (Valid FAN with Quantity Authorized Less than
the limit of SFL) to the Card Reader
 Confirm that the System indicates “Success”
 Confirm that the Shipment details are displayed on the 22” LED TV
5.3 Truck Loading
 The Driver drives the vehicle to the allocated Loading Bay and hands over the
FAN(s) to the Truck Loading Operator
5.3.1 Failures & Success of Truck Loading
*This Test is being carried out including the Failure Steps to Validate the System
Software
 Invalid FAN & Shipment Details - The Loading Operator presents the
‘Failure for Validation of the FAN’(Invalid Shipment Details) to the
Card Reader
 Confirm that the TAS System indicates ‘Error Message’
 The Loading Operator then presents the Correct FAN with valid
Shipment Details
 Confirm that the TAS system displays the Shipment Number on the Batch
Controller
 Confirm that the Batch Controller asks for the Compartment Number
 Wrong Compartment Number keyed by the Loading Operator - The

Loading Operator Fills in the Wrong Compartment Number viz. if
Compartment Number 1 is mentioned in the FAN with valid Shipment
details, the Filling Operator should key in wrong Compartment i.e. keys in
Compartment Number 2
 Confirm that the System displays ‘Invalid Compartment’
 The Loading Operator then Fills in the Correct Compartment Number

 Confirm that TAS displays the Correct Name of the Product and Quantity
to be loaded
 Confirm that the displayed Name & Quantity of Product to be loaded
matches with the authorized FAN with Shipment Details
 Loading Operator Does Not Authorize the displayed Name of the

Product and Quantity to be loaded -
 Confirm that the System displays ‘Batch Plan Terminated’
 The Loading Operator Authorizes the Name & Quantity of Product to be

loaded
 Confirm that the System displays the Correct Quantity and Arm
Number
 Grounding is not connected to the Truck - The Driver proceeds to the

Correct Arm displayed on the System and Presses the Button to Start
Loading the Product in the Truck
 Confirm that the Loading does not start and ‘Connect Overfill’ is
displayed on the System
 The Loading Operator connects Grounding (Earthing) to the Truck

 Confirm that the System displays “Restart?”
 The Operator presses the “Start” button
 Confirm that the BCU indicates “Press Start to Start Loading”

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 The Driver Presses the Button to Start Loading the Product in the Truck
 Confirm that the Loading Starts
 If the above Steps are Normal, keep the System Simulated for Loading
of the Truck and proceed to the next step
5.3.2 Emergency Shut down during Truck Loading
 The Loading Operation should be in progress (by Simulation) from the previous
step

 Confirm that Filling is Terminated

 Confirm that Filling is Terminated
 Remove all Simulations for Fire & Gas detection

 Confirm if Batch Controller Unit (BCU) shows message “Restart?”
 The Operator presses the “Start” button
 Confirm that the Loading Starts
 If the above Steps are Normal, Remove the Simulations for F & G detection, keep
the System Simulated for Loading of the Truck and proceed to the next step
5.3.3 Loading Completion
 Simulate the Quantity being Loaded and gradually increase the simulated value
of the Quantity Loaded
 Confirm that the Loading Operator is able to view the following on the HMI in the
Truck Bay Overview:
 Shipment Code
 Vehicle & Driver details - Vehicle No., No. of Compartments, Driver Code
 Loading details – Arm No., Compartment Capacity, Compartment Status,
Permissive Status, Flow rate, Temperature, Pressure and Density
 Gradually increase the Simulated Quantity of the Product Loaded equal to the
Authorized Quantity *This should be
 *Confirm that the Loading Stops signifying that Loading is Complete confirmed by
the Vendor
 The Loading Operator disconnects the Loading Arm and Grounding Permissive (Honeywell)
 If the above Steps are Normal, Remove all Simulations and proceed to the next
step
5.4 Gross Weighing
 The Driver drives the vehicle out of the Loading Bay towards the Exit gate
 If Calibrated Weight is available equal to the Authorized Quantity Loaded,

place it on the vehicle
 If Calibrated weight is not available and if the Truck has a Water Tanker,
which can be filled with water, fill the Tanker with water, Quantity slightly
less than the Authorized Quantity of Product filled i.e. Volume of water X
Density of Product = Authorized Quantity

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 If both the above options are not possible, the Gross weighing shall
have to be done by Simulation of the Weighbridge output
 The Driver drives the vehicle out of the Exit gate and enters the Entry gate for
Gross weighing
5.4.1 Failures & Success of Gross Weighing
*This Test is being carried out including the Failure Steps to Validate the System
Software
 Invalid FAN & Shipment Details - The Driver presents the ‘Failure for
Validation of the FAN’(Invalid Shipment Details) to the Card Reader
 Confirm that the System indicates “Failure”
 The Loading Operator then presents the Correct FAN with valid Shipment Details
and drives the vehicle on to the Weigh Bridge
 The TAS system Logs the Gross Weight
 Gross weight Exceeding the Capacity of the vehicle - Add some Calibrated
weight to the Truck OR Simulate the Weight Bridge output to exceed the
Maximum capacity of the vehicle (SFL)
 Confirm that the Weigh Bridge logs the correct weight including the Added *To be
weight confirmed by
 *The Weigh Bridge Operator can assign Decant Quantity the Vendor
(Honeywell) if
 Gross weight below the Permissible range – Remove the Added weight OR this is a Manual
Simulate the Weight Bridge output to be less than the Authorized Quantity to be step & No
filled Automation
 Confirm that the Weigh Bridge logs the correct weight which is less than the
Authorized Quantity
 *The Weigh Bridge Operator can assign Top Up Quantity (indicating the
Quantity to be topped up)
(In actual practice - If Decant Quantity OR Top Up Quantity is assigned by the Weigh
Bridge Operator, the Driver can drive the vehicle to the Top Up / Decant location for
appropriate manual actions)
 Gross weight Correct as per Approved Quantity - Simulate the Weigh Bridge
output equal to the Authorized Quantity to be filled
 Confirm that the TAS System indicates “Success”
 The TAS system stores the Gross weight
 If the above steps are Normal, Remove all simulations and proceed to the next
step
(The next step is the driver should collect the Bill of Lading (BOL) from the Exit gate)
5.4.2 Emergency Shut down during Gross Weighing
 The Gross Weighing Operation should be in progress (by Simulation) from the
previous step

 Confirm that the TAS System Neither indicates any Gross Weight Nor
“Success”

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 Confirm that the TAS System Neither indicates any Gross Weight Nor
“Success”

 Confirm that Gross Weighing is Active and TAS System indicates the
Gross Weight
 If the above Steps are Normal, Remove the Simulations for F & G detection, keep
the System Simulated Gross Weighing of the Truck and proceed to the next
step
5.5 BOL and Exit
 The Driver drives the Loaded vehicle towards the Exit gate to collect the BOL
 Shipment Status is to be closed in the Terminal Manager User Interface (TMUI) at
the Exit Gate
 Dispatch section to take Print out of the BOL (Manual)

 Cross check Preset Quantity and Actual Loaded Quantity from the Control
Room
 Hands over BOL to the Driver
 After final inspection, the Security allows the vehicle to Exit the Terminal
5.5.1 Emergency Shut down before BOL & Exit
 The Driver should be at the Exit Gate to collect the BOL from the previous step

 Confirm that the Dispatch section Cannot print the BOL and hence the
vehicle cannot Exit the Terminal

 Confirm that the Dispatch section Cannot print the BOL and hence the
vehicle cannot Exit the Terminal

 Confirm that the Dispatch section is Active on the TAS System and
Printing of BOL is possible for the vehicle to Exit the Terminal
 If the above Steps are Normal, Remove the Simulations for F & G detection
 The above Tests complete all the Operational Tests for the Terminal
Automation System for Truck Loading Facility.
 If all the above Tests are satisfactorily concluded, The TLF facility is ready
for Automated Service as per Design and can be taken in line for Operations.

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STARTUP & OPERATIONS
The first step towards the Startup of the Terminal Operations is taking the Operating Fluids into the
System. But before taking the Operating Fluids into the System, all the Support & Safety Systems
have to be in line.
The mandatory requirements before commencement of the Startup & Operations of the total Terminal
are as follows:
 All the Operational Tests (OTP) have been carried out for all Operations that are being detailed
in the following sections
 The above would ensure that all the Interlocks and built-in Safety of the Terminal are ensured
 All the temporary installations made for Operational Tests have been removed and all the lines
and installations that are part of the Terminal are reinstated to Normal Operating positions
 All the Instruments have been taken in line and are in Operating positions as per drawings
 All the simulations made during Commissioning have been removed and the Instruments are
in healthy Operating state
 The Interlocks have been exhaustively covered in the previous sections and the
Operating personnel should be thorough with the Interlocks & Operational Safety and
hence will not be repeated during the Startup & Operations
 All the Interlocks that have been tested are in line and no by-pass of Interlocks are made
 All the Rotary Equipment have been lubricated, lubricants kept filled up to the requisite levels,
Barrier fluid kept filled wherever applicable (Centrifugal Pumps) etc. and the Equipment are ready
for Startup
 All the Static Equipment are kept inertized with N2, and are ready to receive the Process fluids
 All the individual package basic requirements like Coolants (Air Compressors), Refrigerants
(Chilled water Package), Packings (N2/IA Package) etc. have been made up during Pre-
commissioning & Commissioning stage and the Packages are ready for Startup
The Startup of the Unit Operations of the Terminal are detailed in the following sequence and with the
outline of features mentioned below:
Startup & Operation of Support Systems
 The support systems cover all the Packages & Systems that are tools for the Terminal
Operations
 All the Safety Systems like Fire Water and Fire & Gas detection systems are covered under this
head, to ensure the Safety of the Systems & Infrastructure during Startup and Regular Operation
of the Terminal
 The Procedures detailed are for Operational guidance only and are not intended to
supersede the Supplier’s Manual which should be referred to for all maintenance details
and shall be governing
Operating Fluids Intake to Storage Tanks
 Operation of the Support System specific to the Storage Tank, if any, under the right parameters
Stepwise Startup & Unit Operations
 Maintenance of Performance parameters
 Monitor the Performance Parameters

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 Safety aspects & Precautions to be exercised, if any applicable, for the fluid handled and Unit
Operation in progress
 The Unit Operations cover all the intended Unit Operations in the Terminal namely the following
with the outline of features mentioned below:
i) Truck Loading
 Loading of the Stored materials in Road Tankers
 Compliance to Terminal Automation System (TAS)
ii) Drum Filling
 Filling of Solvents / Products in Drums as per requirement
 Manual operations of the process and precautions to be exercised are detailed out
iii) Ship Loading
 Pumping the stored materials to the Manifold for onward Ship loading as per requirements
 Manual Operations involved at the Manifold and at the Jetty end are detailed out with
Precautions to be exercised
iv) Blending
 Pumping the requisite materials from their Storage Tanks to the Blending Tank
 Manual Operations involved at the Manifold with Precautions to be exercised

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3. STARTUP & OPERATION OF SUPPORT SYSTEMS
3.1 Startup & Operation of HVAC Cooling water system CT-811-001
The importance of HVC Cooling water system to be Commissioned & Started up first has been
explained above viz. Its necessity for HVAC Chilled water System and the necessity of Chilled water
for HVAC of the Control room where the Control systems for the entire Terminal through SCADA is
housed.
The HVAC Cooling water should have been already been started up during the Commissioning stage
and its parameters certified for regular service. Explained below are some of the salient features to
be maintained on keeping the HVAC Cooling water service for regular operations.
 Keep the Shutdown valves XV0204 & XV0203 Closed (CW Supply & Return valves to & from
Process Cooling water system), so that the HVAC Cooling Tower is in exclusive service only for
HVAC Chiller Package WCP-811-001A/B.
 HVAC Cooling water may be utilized for Process Chilled water Package CHP M501 / CHP
M502 in case of Shutdown of Process Cooling water system CTM-501 after the same has
been pressed into regular service and material intake to VAM and Styrene storage Tanks, by
starting one of the pumps CWP-811-04A/B and opening Shutdown valves XV0204 &
XV0203.
 Ensure that the Cooling Tower is filled with water and make up water is kept open
 Keep the Cooling Tower outlet isolation valves Open
 Open the suction isolation valves of Cooling water circulation pumps CWP-811-03A and B
 Start One of the Pumps CWP-811-03A OR (CWP-811-03B)
 Open both the discharge isolation valves of the Pump running pump CWP-811-03A
 Discharge isolation valves of the Standby Pump (CWP-811-03B) may also be kept Open
 Start the Cooling Tower Fans and keep them running

 Keep the Cooling water Supply and Return isolation valves of the HVAC Chiller Package WCP-
811-001A and WCP-811-001B Open
 When the HVAC Chilled water Package WCP-811-001A / B is started MOV at Outlet of the HVAC
Chilled water package will open automatically, thus establishing the Cooling water circulation
through the Chilled water package in operation.
 Check the Cooling water circulation loop for any leakage and take corrective action, if any
required.
 Monitor the Performance of the Cooling water circulation Pump, Cooling Tower Fans and the
Cooling Tower (Cooling water Supply & Return Temperatures), until the performance of the
System is fully established
 Recirculation Pumps & Motors parameters
 Suction & Discharge Pressures

 Current drawn
 Bearings & Body Temperatures and Vibrations
 Fans parameters
 Current drawn

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 Motor Bearings & Body Temperatures and Vibrations

 Drive assembly (Gear box, if applicable) Temperatures and Vibrations
 Cooling Tower Plenum vibrations
 Even after the performance of the Cooling water system is well established, it is recommended to
maintain a periodic log of parameters (say once in 2 hours) of the Equipment and the System.
This would enable timely actions, if any required, for preventive maintenance and thus enhance
the longevity of the System
 Doze the Cooling Tower with Chemicals regularly, as recommended by the supplier, in the
right quantity, to prevent corrosion of Piping and downstream Equipment
3.1.1 Preventive maintenance of HVAC CW system Equipment

i) High vibrations / Trip etc. of Running Cooling water circulation Pump
 In case any abnormality is observed on the running circulation pump CWP-811-03A, start the
Standby circulation pump CWP-811-03B immediately
 Since the Suction & Discharge valves of the Standby pump were already kept open even when
the pump was a Standby, the pump immediately comes in line.
 Stop the running Pump CWP-811-03A

 Close the Suction & Discharge valve of the Pump
 Handover the pump for preventive checkup & maintenance by Mechanical and Electrical
maintenance
 Electrically isolate the Motor for the pump from the MCC before commencing any
maintenance operation, to prevent accidents
 Expedite the maintenance activities
 After maintenance of the pump (CWP-811-03A) is completed, carry out the following activities:
 Get the motor energized from the MCC
 Open the Suction & Discharge isolation valves
 Start the pump in parallel with the running pump CWP-811-03B
 Check the operating parameters of CWP-811-03A
 If the operating parameters are normal, one of the pumps may be stopped
ii) High vibrations / Trip etc. of the Cooling Tower Fan
 In case any abnormality is observed on any of the Cooling Tower fans, Stop the distressed Fan
immediately
 The Cooling Tower and Cooling water circulation can continue to be in service with the other
Cooling Tower Fan running
 Handover the Fan for preventive checkup & maintenance by Mechanical and Electrical
maintenance
 Electrically isolate the Motor for the Fan from the MCC before commencing any
 After maintenance of the Fan is completed, carry out the following activities:

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 Start the Fan

 Observe the running parameters and if normal keep the Fan running
3.1.2 Breakdown & Shutdown of HVAC Cooling water system

(All CT Fans / Pumps Breakdown / Electrical Problem in CT circuit etc.)
 In case of Total Breakdown of HVAC Cooling water system, take the following actions
 Shutdown HVAC Chilled water System
 Please refer Breakdown & Shutdown of HVAC Chilled water System for other actions

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3.2 Startup & Operation of Process Cooling water system CT-M501
The importance of Process Cooling water system to be Commissioned & Started up is because of its
necessity for the Aftercoolers of Compressed Air at the inlet to the N2/IA Package and importance of
Instrument Air for the Pneumatic controls associated with the Process operations.
The Process Cooling water has been already been started up during the Commissioning stage and
its parameters certified for regular service. Explained below are some of the salient features to be
maintained on keeping the Process Cooling water service for regular operations.
 Keep the Shutdown valves XV0204 & XV0203 Closed (CW Supply from HVAC Cooling water
system & Return valves back) and XV0202 & XV0201 Open, so that the Process Cooling system
is self-sustained for Process Chilled water Package CHP M501 / CHP M502 and its other service
commitments.
 HVAC Cooling water may be utilized for Process Chilled water Package CHP M501 / CHP
M502 in case of Shutdown of Process Cooling water system CTM-501 after the same has
been pressed into regular service and material intake to VAM and Styrene storage Tanks, by
starting one of the pumps CWP-811-04A/B (HVAC Cooling water system) and opening
Shutdown valves XV0204 & XV0203 & closing Shutdown valves XV0201 & XV0202.
 Keep the Supply & Return Cooling water isolation valves of all the consumers Open namely the
following:
 Process Water Chilling Package CHP-M501 and CHP-M502 - When the Water Chilling
Package is started, MOV at Outlet of the Package will open automatically, thus establishing
the Cooling water circulation through the package
 Aftercoolers of Compressed Air (inlet to N2 / IA Package) AF-0101 to AF-0104
 Process Block Condensers & Coolers – E001, E004, E011, E012; E007 to E010
 If the cooling water lines to any of the above consumers is under maintenance, the same
should be kept isolated by keeping the Supply & Return isolation valves closed and with
positive isolation with blinds, if necessary.
 Ensure that the Cooling Tower is filled with water and make up water is kept open
 Keep the Cooling Tower outlet isolation valves Open
 Open the suction isolation valves of Cooling water circulation pumps P-M5069A,B,C and D
 Start any three of the four Pumps one after the other P-M5069A,B and C (P-M5069D
Standby)
 Open both the discharge isolation valves of all the Pump running pumps P-M5069A,B and C
 Discharge isolation valves of the Standby Pump (P-M5069D) may also be kept Open
 Start the Cooling Tower Fans and keep them running

 Monitor the Performance of the Cooling water circulation Pumps, Cooling Tower Fans and the
Cooling Tower (Cooling water Supply & Return Temperatures), until the performance of the
System is fully established
 Recirculation Pumps & Motors parameters

 Current drawn

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 Fans parameters
 Current drawn
 Motor Bearings & Body Temperatures and Vibrations
 Drive assembly (Gear box, if applicable) Temperatures and Vibrations
 Cooling Tower Plenum vibrations
 Even after the performance of the Cooling water system is well established, it is recommended to
 Doze the Cooling Tower with Chemicals regularly, as recommended by the supplier, in the
right quantity, to prevent corrosion of Piping and downstream Equipment
3.2.1 Preventive maintenance of Process CW system Equipment

i) High vibrations / Trip etc. of Running Cooling water circulation Pump
 In case any abnormality is observed on any of the running circulation pumps P-

M5069A/B/C (e.g. P-M5069A), start the Standby circulation pump P-M5069D immediately
 Stop the running Pump running with abnormal parameters (P-M5069A)

maintenance
 After maintenance of the pump (P-M5069A) is completed, carry out the following activities:
 Start the pump in parallel with the other running pumps viz. P-M5069 B,C and D
 Check the operating parameters of P-M5069 A
ii) High vibrations / Trip etc. of the Cooling Tower Fan
 In case any abnormality is observed on any of the Cooling Tower fans, Stop the distressed Fan
immediately
 The Cooling Tower and Cooling water circulation can continue to be in service with the other
Cooling Tower Fan running
maintenance

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 Start the Fan
3.2.2 Breakdown & Shutdown of Process Cooling water system

(All CT Fans / Pumps Breakdown / Electrical Problem in CT circuit etc.)
 In case of Total Breakdown of Process Cooling water system, take the following actions, to
keep the Process Chilled water package running for uninterrupted Chilled water supply to prevent
Polymerization of VAM / Styrene in their storage tanks:
 Start one of the Cooling water circulation pumps CWP-811-04A/B attached to the HVAC
Cooling Tower
 Close Shutdown valves XV0201 (Supply) & XV0202 (Return) of Process Cooling water system
 Open Shutdown valves XV0203 (Return) & XV0204 (Supply) of HVAC Cooling water system
 Line up HVAC cooling water for Process Chilled water Package CHP-M501/502
 The N2 / Instrument Air package would have to remain Shut down during this period &
hence there would be not Utility N2 or Instrument Air available during this period
 Please refer Total Breakdown & Shutdown N2 / IA Package for other actions
 The Process Block would have to remain Shut down during this period due to non-
availability of Cooling water for Condensers & Coolers – E001, E004, E011, E012; E007 to
E010
 Expedite maintenance of the cause for Total Breakdown by the concerned Discipline/s
 After the maintenance activities are completed, Restart the Process Cooling water system and
reinstate the System to Normal position

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3.3 Startup & Operation of HVAC Chilled water System & HVAC
After Startup of Cooling water system, the onus falls on the HVAC Chilled water system and HVAC,
to get the Control Room up and ready to support the Control systems it houses.
A. Chilled water loop (P&ID Chilled Water System TCE 7410A-811-PI-1007)
 Keep the Supply & Return Chilled water isolation valves of the AHU of the HVAC system Open
 Keep the isolation valves on the Chilled water Inlet and Outlet lines of the Chilled water coil of
the AHU of HVAC package
 The Motorized valve PIBCV on the outlet line from the Chilled water coil of the AHU is
controlled on Auto as per the TIC setting of HVAC as explained under HVAC
 Keep the Makeup water Open to the Dual Pump Pressurization Unit, to ensure that the circulation
remains steady in the Chilled water circuit.
 Auto start of the Pressurization unit pumps on low pressure impulse of Pressure switches
installed on their discharge would ensure Auto addition of makeup water to the circuit
 Keep the Suction isolation valves of the Chilled water Primary pumps CHP-811-01 A & B Open
 Start one of the primary Pumps (CHP-811-01 A) and Open its discharge valve
 The discharge valve of the Standby pump (CHP-811-01 B) may also be kept open, since there
is an NRV on the pump discharge
 Keep the isolation valves on the Inlet and Outlet line of the Evaporator/s of the Chilled water
package WCP-811-01 A / B Open
 The MOV on the Chilled water Supply line from the Evaporator WCP-811-01 A / B would
Open Automatically when the respective unit is started
 Keep Suction isolation valves of Chilled water Secondary Pumps (CHP-811-02 A & 2B) Open
 After the Chilled water Package is started, when the Chilled water starts flowing from the
Chilled water package, Start one of the Secondary Pumps (CHP-811-02 A) and Open its
discharge valves
 The discharge valve of the Standby pump (CHP-811-02 B) may also be kept open, since
there is an NRV on the pump discharge
 With the above settings, the Chilled water circulation loop would be completed as follows, after
the Startup of the Chilled water package WCP-811-01 A / B:
 Chilled water Return from HVAC AHU & Makeup Water – Primary Pump - Inlet to Chilled
Evaporator of water package – Evaporator Outlet of Chilled water (Chilled water Supply) –
Secondary Pump – Chilled water supply to HVAC package AHU
 In regular operation, the Speed of the (Motors) of Primary and Secondary Pumps would be Auto
controlled by the variable speed drives they are equipped with, based on the differential pressure
between the Chilled water Supply and Return lines
 The differential pressure across Supply & Return lines is dependent on the TIC setting of the
HVAC unit which controls the opening of the MOV on the Chilled water Outlet line of the AHU
of the HVAC unit

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B. Chilled water package WCP-811-01 A/B (P&ID 7410A-81J-KCP-ME-PI-1502)
 Make a Set point for LWT (Low Water Temperature) of 20 deg. C (this should be lower than the
atmospheric temperature at site).
 Start one of the units (WCP-811-01 A) from the Control Panel as follows:
 Start the Compressor from the Control Panel by turning the ‘Run / Stop’ Selector Switch
to ‘Run’ position and wait for 30 seconds for the Loading Vanes to Close.
 Turn the System ‘Run / Stop’ Selector Switch to ‘Run’ position R1
1
 Confirm that the Motor operated valve (MOV) on the Chilled water outlet line Opens within 30
seconds
 After the start of the Compressor & opening of the MOV on the Chilled water outlet line,
one of the Secondary Pumps (CHP-811-02 A) should be started, as explained above
 The Compressor Loading / Unloading based on HVAC load and other parameters of the Package
would be maintained by the Interlocks inherent to the Chilled water package as detailed under
Commissioning & the Operational Test Procedure
 Monitor the Performance of the Chilled water package and the Chilled water circulation loop until
the performance of the System is fully established:
 Chiller Package WCP-811-01 A/B

Compressor
 Current consumed (Amperes)

 Vibrations
 Suction Pressure PT-01
 Discharge Pressure PT-02
 Oil Feed Pressure PT-03
 Compressor discharge temperature TE-06
Oil Separator
 Level
Condenser
 Cooling water Inlet and Outlet temperatures

 Level of the Condenser
Expansion valve
 Opening and Closing to maintain the Suction pressure of Compressor and hence
indirectly the Performance (Capacity) of the Package against Set points
Evaporator
 Chilled Water (CHW) Inlet and Outlet temperatures

 Pressure (PT-01), which is the Suction pressure to the Compressor

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 Level of Evaporator
 Primary & Secondary Pumps

 Current drawn
 Even after the performance of the Chilled water system is well established, it is recommended to
C. HVAC Package (P&ID Chilled Water System TCE 7410A-811-PI-1007)
 Adjust the Supply & Return Air dampers as required as per vendor recommendations
 FS on the discharge line of the Air Handling Unit (AHU) Fan would trip the Fan in case no Air
Flow is detected
 Start the AHU Fan as per procedure

 Make a set point on the TIC of AHU (Return Air), slightly above the LWT (Low Water
Temperature) set point of the Chilled water package (e.g. TIC set point of AHU 25 deg. C)
 The TIC controls the Chilled water outlet flow from the AHU Chilled water coil through
the Motor Operated Valve PIBCV on the Chilled water outlet line and hence effectively is
the Master control for the Temperature control of HVAC unit
 When Chilled water starts flowing through the Chilled water coil of the AHU, the incoming Fresh
Air mixed with Return Air gets cooled and discharges Cool Air at the controlled temperature to
different sections based on the TIC set point and Air damper/s openings
 Vary the LWT (Low Water Temperature) set point of the Chilled water package and the HVAC
TIC set point correspondingly e.g. LWT set point on Chilled water package from 20 to 22 deg. C
and correspondingly HVAC TIC set point from 25 to 27 deg. C
 Confirm that Chilled water package control & HVAC control are effective
 Monitor the performance of the AHU and the HVAC unit until the performance of the System is
fully established:
 Air Handling Unit (AHU)
 Current drawn by the Fan

 FAN Bearings & Body Temperatures and Vibrations
 Differential Pressure (DPS) across the Fan Suction Filter of the Fan
 If the differential pressure across the Filter increases, stop the Fan for some time,
clean the Suction filter (using compressed Air) and Restart the Fan
3.3.1 Preventive maintenance of HVAC CHW Package Equipment

i) Compressor High vibrations / Trip / Abnormal –
 In case any abnormality is observed on the Compressor, take the following actions immediately
 Start the Standby Chiller unit (WCP-811-01 B) as follows:

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to ‘Run’ position and wait for 30 seconds for the Loading Vanes to Close.
1
seconds
 Stop the running Chiller unit (WCP-811-01 A) as follows:

 Stop the Compressor from the Control Panel by turning the ‘Run / Stop’ Selector
Switch to ‘Stop’ position. R1
 Turn the System ‘Run / Stop’ Selector Switch to ‘Stop’ position 1
 Confirm that the Motor Operated valve (MOV) on the Chilled water outlet line Closes within 30
seconds
 Handover the Compressor (WCP-811-01 A) for preventive checkup & maintenance by

Mechanical and Electrical maintenance
 If the Compressor needs to be opened / major overhaul, isolate and depressurize the
Compressor before commencement of maintenance activities as follows:
 Close the isolation valve on the Evaporator outlet Refrigerant line to the Compressor
 Close the Solenoid operated valve on the oil feed line from the Oil separator to the
Compressor
 Close the SOV on the Oil separator outlet line to the Condenser
 Close the Oil recovery isolation valves from the Evaporator to the feed line of the Compressor
 Depressurize the compressor through a convenient point - if necessary through the
vent provided on the Oil separator, which would depressurize the compressor through
the discharge line along with the Oil separator
 When fully depressurized, purge the depressurized loop with N2

 Hand over the Compressor for maintenance
 After the maintenance activities are completed,

 Restore all the isolation valves to operating positions
 Top up the Refrigerant, if required
 Start the Unit that has been returned after maintenance as follows:
 Start the Compressor from the Control Panel by turning the ‘Run / Stop’ Selector SwitchR1
to ‘Run’ position and wait for 30 seconds for the Loading Vanes to Close. 1
 Turn the System ‘Run / Stop’ Selector Switch to ‘Run’ position
seconds
 If parameters of the above unit are normal, it may be kept in line, if desired
 Stop the running Chiller unit (WCP-811-01 B) as follows:

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 Stop the Compressor from the Control Panel by turning the ‘Run / Stop’ Selector Switch to
R1
‘Stop’ position. 1
 Turn the System ‘Run / Stop’ Selector Switch to ‘Stop’ position
 Confirm that the Motor Operated valve (MOV) on the Chilled water outlet line Closes within 30
seconds
ii) Leakage of Evaporator / Condenser Tubes
 In case Leakage is suspected in the Evaporator or Condenser tubes, take the following actions:
 Start the Standby Chiller unit (WCP-811-01 B) as explained above

 Stop the running Chiller unit (WCP-811-01 A) as explained above
 Isolate the Equipment (Evaporator / Condenser) by closing the requisite valves
 If isolation of Equipment is not possible / Valves passing etc., then depressurize the whole
system
 Depressurize the Equipment (Shell side) by venting the refrigerant to atmosphere

 Drain the shell side of the Equipment and collect the remnant holdup in drums
 Purge the Equipment with N2

 Close the Chilled water Inlet & Outlet valves of the Evaporator
 If the leakage of the Evaporator is suspected, drain the tube side holdup upstream of the
isolation vales
 Close the Cooling water Inlet & Outlet lines of the Condenser
 If the leakage of the Condenser is suspected, drain the tube side holdup upstream of the
isolation valves
 Hand over the leaky Evaporator / Condenser for maintenance

 Refill Refrigerant, in the system
 Start the Unit that has been returned after maintenance and observe the parameters
 If parameters are normal, it may be kept in line, if desired
 Stop the running unit (WCP-811-01 B) as explained above
3.3.2 Preventive maintenance of CHW System & HVAC Equipment

i) High vibrations / Trip etc. of Primary or Secondary Pump (CHW System)
 In case any abnormality is observed on any of the running pumps viz. Chilled water Primary
Pump or Secondary Pump, start the corresponding Standby pump immediately
 Stop the running Pump running with abnormal parameters

maintenance

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 After maintenance of the pump is completed, carry out the following activities:
 Start the pump in parallel with the other running pump
 Check the operating parameters of the pump taken in line after maintenance
ii) High vibrations / Trip etc. of the AHU Fan of HVAC
 In case any abnormality is observed on the AHU Fan, Stop the Fan
 If the Shutdown of the for maintenance of the Fan is expected to be only for a short duration
(e.g. 4 hours), the following actions may be taken and the Chilled water package and Chilled
water circulation may be kept running until the Fan is attended for the abnormality and
restarted:
 Slightly increase the Set Point of the LWT (Low Water Temperature) set point of the
 Chilled water package and keep the package running. The Chilled water package Load
/ Unload would be Auto controlled based on the set point
 Keep the Primary and Secondary pumps running as before
 Keep pedestal fans in front of the SCADA Panels & PLC Panels in the Control Room to
dissipate the heat during the period of Shutdown of the Fan
 Ceiling / pedestal fans may be used for Operator comfort during this period
maintenance
 Start the Fan
 Restore the Chilled water package Set Point of the LWT (Low Water Temperature) set point to
original level (20 deg. C) or as desired
 Pedestal Fans / Ceiling fans in the Control Room may be switched off
3.3.3 Breakdown & Shutdown of HVAC Chilled water System
 In case the Shutdown of the HVAC Chilled water system and the Shutdown of the system
is for a long duration, and if the pedestal fans are not able to dissipate the heat of SCADA
Panels & PLC Panels in the Control Room in the peak summer of UAE, then the following
actions may be taken to keep the rest of the operations going in the Terminal:

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 Fix Split / Window Air conditioners of adequate capacity in the Control room to
dissipate the heat of SCADA Panels & PLC Panels
 The same would also offer succor to the occupants
 In case the season happens to be winter when the HVAC Cooling Tower is shutdown,
pedestal fans for the panels and ceiling fans for the Operators might suffice
 Portable Electrical room heaters may be used in the Control room, if required for
Operator comforts

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3.4 Startup & Operation of Process Chilled water System
Process Chilled water system becomes critical when VAM and Styrene are taken into their respective
Storage tanks, since the Chillers in the recirculation loop of the fluids utilize Chilled water to keep
them at around 20 deg. C to prevent their Polymerization. Chilled water is also required for Process
Block operations.
Process Chilled water package is identical to HVAC Chilled water package, but the Chilled water
circulation loop is different.
A. Chilled water loop (P&ID Chilled Water System (P&ID TCE.7410A-622-PI-1001)
 On startup of the circulation pumps, Chilled water circulation will be established in the
following circuits. Keep all the Supply & Return Chilled water isolation valves Open as
mentioned below for each recipient.
 Styrene Chiller Chilled water inlet & outlet isolation vales

 Styrene Tank vent inlet & outlet isolation vales
 VAM Chiller Chilled water inlet & outlet isolation vales
 VAM Tank vent inlet & outlet isolation vales
 Process Block Steam Condenser for Column C001 – Chilled water Inlet & Outlet isolation
valves
 Process Block Steam Condenser for Column C002 – Chilled water Inlet & Outlet isolation
valves
 If the Chilled water lines to any of the above consumers is under maintenance or if the
System is not ready, the same should be kept isolated by keeping the Chilled water
isolation valves closed and with positive isolation with blinds, if necessary.
 Keep the Makeup water isolation valve to the Hot Well Open
 The ball float valve on the Makeup water line would ensure that the Tank is always full
 Open the suction valves of the Chilled water Primary pumps P-M5040 A & B
 Start one of the Chilled water Primary pumps (P-M5040 A) and Open its discharge valve
 The discharge valve of the Standby pump (P-M5040 B) may also be kept open, since there is
an NRV on the pump discharge
 Keep the isolation valves on the Inlet and Outlet line of the Evaporator/s of the Chilled water
package CHP-M501 & CHP-M502 Open
 The Automatic (ON/OFF) Valve XV-0101 / XV-0102 on the Chilled water Supply line from
the Evaporator would Open Automatically when the respective unit is started
 Keep Suction isolation valves of Chilled water Secondary Pumps (P-M5045 A,B,C & D) Open
 After the Chilled water Package is started, when the Chilled water starts flowing from the
Chilled water package, Start three of the Secondary Pumps one after the other (P-M5045 A,B
&C) and Open their discharge valves
 After starting one Secondary pump, ensure that there is flooded suction before starting
the next Secondary Pump
 The discharge valve of the Standby pump (P-M5045 D) may also be kept open, since there is
an NRV on the pump discharge

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 With the above settings, the Chilled water circulation loop would be completed for all the
recipients mentioned above
B. Chilled water package CHP-M501/502 (P&ID 7410A-81J-KCP-ME-PI-1502)
 Make a Set point for LWT (Low Water Temperature) of 20 deg. C (this should be lower than the
atmospheric temperature at site).
 Start one of the units (CHP-M501) from the Control Panel as follows:
to ‘Run’ position and wait for 30 seconds for the Loading Vanes to Close. R1
 Turn the System ‘Run / Stop’ Selector Switch to ‘Run’ position 1
 Confirm that the Automatic valve (XV 0101) on the Chilled water outlet line Opens within 30
seconds
 After the start of the Compressor & opening of the Automatic valve (XV-0101) on the
Chilled water outlet line, when the Cold well fills up, Start three of the Secondary Pumps
(P-M5045 A, B & C), one after the other, ensuring flooded suction for the pumps, as
explained above
 The Compressor Loading / Unloading based on the load and other parameters of the Package
would be maintained by the Interlocks inherent to the Chilled water package as detailed under
Commissioning & the Operational Test Procedure
 Monitor the Performance of the Chilled water package and the Chilled water circulation loop until
the performance of the System is fully established:
 Chiller Package CHP-M501/502
Compressor
 Current consumed (Amperes)

 Vibrations
 Suction Pressure PT-01
 Discharge Pressure PT-02
 Oil Feed Pressure PT-03
 Compressor discharge temperature TE-06
Oil Separator
 Level
Condenser
 Cooling water Inlet and Outlet temperatures

 Level of the Condenser

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Expansion valve
 Opening and Closing to maintain the Suction pressure of Compressor and hence indirectly
the Performance (Capacity) of the Package against Set points
Evaporator
 Chilled Water (CHW) Inlet and Outlet temperatures

 Pressure (PT-01), which is the Suction pressure to the Compressor
 Level of Evaporator
 Primary & Secondary Pumps

 Current drawn
 Even after the performance of the Chilled water system is well established, it is recommended to
C. Chilled water loop (P&ID Chilled Water System (P&ID TCE.7410A-622-PI-1001
 Check the entire Chilled water circulation loop for any leakage & corrective actions viz.
 Styrene Chiller & Tank vent
 VAM Chiller & Tank vent
 Process Block - C001 & C002 Steam condensers
 Note the Pressure and Temperature of Chilled water on the PG and TG provided on the
Chilled water outline of C001 & C002 Steam condensers in the Process Block
 Vary the LWT (Low Water Temperature) set point of the Chilled water package
 Confirm that Chilled water package control are effective
 Since the Chilled water circulation loop is not loaded by Process, maintain a LWT (Low Water
Temperature) set point of the Chilled water package at around 25 deg. C (below the Atmospheric
temperature)
 When material intake to VAM and Styrene tanks take place / When the Process Block is
started up, the LWT of the Chilled water package can be lowered as desired (20 deg. C)
 Monitor the performance of the Chilled water Package & the circulation loop until the performance
of the System is fully established.
 If the performance is fully established and if there is going to be a long gap before the Process
loads the Chilled water system, the Chilled water package CHP-M501/502 and the Primary &
Secondary pumps may be kept stopped.
3.4.1 Preventive maintenance of CHW Package Equipment

i) Compressor High vibrations / Trip / Abnormal –
 In case any abnormality is observed on the Compressor, take the following actions immediately:

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 Start the Standby Chiller unit (CHP-M502)

 Start the Compressor from the Control Panel by turning the ‘Run / Stop’ Selector Switch to
‘Run’ position and wait for 30 seconds for the Loading Vanes to Close.
1
 Confirm that the Automatic valve (XV 0102) on the Chilled water outlet line Opens within 30
seconds
 Stop the running Chiller unit (CHP-M501) as follows:

 Stop the Compressor from the Control Panel by turning the ‘Run / Stop’ Selector Switch to
‘Stop’ position.
R1
 Turn the System ‘Run / Stop’ Selector Switch to ‘Stop’ position 1
 Confirm that the Automatic valve (XV 0101) on the Chilled water outlet line Closes
within 30 seconds
 Handover the Compressor for preventive checkup & maintenance by Mechanical and Electrical
maintenance
Compressor before commencement of maintenance activities as follows:
 Close the isolation valve on the Evaporator outlet Refrigerant line to the Compressor
 Close the Solenoid operated valve on the oil feed line from the Oil separator to the
Compressor
 Close the SOV on the Oil separator outlet line to the Condenser
 Close the Oil recovery isolation valves from the Evaporator to the feed line of the Compressor
 Depressurize the compressor through a convenient point - if necessary through the
vent provided on the Oil separator, which would depressurize the compressor through
the discharge line along with the Oil separator
 When fully depressurized, purge the depressurized loop with N2

 Hand over the Compressor for maintenance

 Top up the Refrigerant, if required
 Stop the running unit (WCP-811-01 B)
ii) Leakage of Evaporator / Condenser Tubes
 In case Leakage is suspected in the Evaporator or Condenser tubes, take the following actions:
 Start the Standby Chiller unit (CHP-M502) as explained above

 Stop the running Chiller unit (CHP-M501) as explained above
 Isolate the Equipment (Evaporator / Condenser) by closing the requisite valves

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 If isolation of Equipment is not possible / Valves passing etc., then depressurize the whole
system
 Depressurize the Equipment (Shell side) by venting the refrigerant to atmosphere

 Drain the shell side of the Equipment and collect the remnant holdup in drums
 Purge the Equipment with N2

 Close the Chilled water Inlet & Outlet valves of the Evaporator
 If the leakage of the Evaporator is suspected, drain the tube side holdup upstream of the
isolation vales
 Close the Cooling water Inlet & Outlet lines of the Condenser
 If the leakage of the Condenser is suspected, drain the tube side holdup upstream of the
isolation valves
 Hand over the leaky Evaporator / Condenser for maintenance

 Refill Refrigerant, in the system
 Stop the running unit (CHP-M502)
3.4.2 Preventive maintenance of CHW System

i) High vibrations / Trip etc. of Primary or Secondary Pump (CHW System)
 In case any abnormality is observed on any of the running pumps viz. Chilled water Primary
Pump or Secondary Pump, start the corresponding Standby pump immediately
 Stop the running Pump running with abnormal parameters
maintenance
 After maintenance of the pump is completed, carry out the following activities:
 Start the pump in parallel with the other running pump
 Check the operating parameters of the pump taken in line after maintenance
3.4.3 Breakdown & Shutdown of Process CHW System

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 In case of Total Shutdown of the Process Chilled water Package or Chilled water system,
and if the Shutdown is expected to be prolonged, take the following actions:
 Shut down the Process Block since Chilled water will not be available for Steam
Condenser for Column C001 and Steam Condenser for Column C002
 Avoid further intake of VAM / Styrene to their respective storage tanks to conserve Cold
temperature
 Stop the continuous recirculation of VAM / Styrene in their storage tanks, as continuous
recirculation would impart heat to the Stored material
 Occasional recirculation for a few minutes (e.g. once in 1 - 2 hours) with
Polymerization inhibitor chemical may be given to prevent polymerization of contents
 If ready offtake is available for Ship loading of VAM or Styrene, take the opportunity to
offload the materials by offering preferential berth for the Tankers at the Ship Loading
Arm
 Maximize preferred Truck loading of VAM & Styrene
 If ready offtake of Drummed material is available, Drum filling of VAM / Styrene is an
added avenue to lessen the stock
 Expedite the maintenance activities to get the system back to normal

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3.5 Startup & Operation of Air Compressors
Startup & Operation of Air Compressors, which is also the source for Instrument Air, sets the tone for
the Startup of the rest of the Terminal Operations Startup activities.
A. Compressed Air distribution Network
 Compressed Air distributed throughout the Terminal for Utility Air connections
 Keep the drain points on the Air Utility lines crack open (around 10%) so that the line gets
flushed and purged of impurities
 After the startup of the Air compressor, after bleeding compressed Air for at least 30 minutes
through the above Utility stations, the above may be closed
 The openings of Utility stations being purged may be adjusted by maintaining a back pressure
of 10 bar G on the Air Compressor discharge line
 Compressed Air is the source for N2 and Instrument Air. Compressed Air should have been
vented upstream of the N2 / IA package during the Operational Tests (OTP) of the Air
Compressors.
 However, some more purging of Air from the drain points upstream of the N2 / IA package for
around half an hour may be done to ensure that the Compressed Air Feed to the N2 / IA
package is clean, ensuring a back pressure of 10 bar G on the Air Compressor discharge line.
 If the Compressed Air lines to any of the above consumers is under maintenance, the
same should be kept isolated by keeping the isolation valves closed and with positive
isolation with blinds, if necessary
B. Air Compressors Package (Vendor P&ID 7410A-810-IRL-ME-PI-1801)
 Keep the Control Panel for the Compressors energized and ON

 Start any three of the Air Compressors (1,2 and 3), one after the other from the Control panel
 Keep Compressor 4 as the Standby Compressor
 Keep an Offline Pressure set point of 10.2 Kg/Cm2 g for the discharge pressure (on the
common discharge line of Compressors)
 The Online Pressure set point should be 9.7 Kg/Cm2 g
 If the above Offline & Online Pressure set points are Factory set by the vendor, do not
disturb the settings
 The loading and unloading of the Compressors and Operational parameters of the Equipment
would be Auto controlled by the built in features of the Equipment
 Check the entire Compressed Air Network for leakages if any and corrective actions
 Monitor the Performance of the Air compressors until their performances are fully established:
 Current drawn by the Compressors
 Temperatures and Vibrations of the DE, NDE and Body of the Compressor
 Temperatures and Vibrations of the DE, NDE and Body of the Drive Motor
 Wet sump Pressure (3APT)
 Temperature Transmitter on the discharge of the Compressor (2ATT)
 Differential Pressure (SCPT Out - In) across the Oil Filter (OF) - (should be <0.3 Kg / cm2)
 Injected coolant Temperature (2CTT)

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 Vacuum at suction of the Compressor (1AVPT)

 Confirm that the Filter Breather (BR) is unobstructed and functions normally
 Even after the performance of the Air Compressors are well established, it is recommended to
maintain a periodic log of parameters (say once in 2 hours) of the Equipment. This would enable
timely actions, if any required, for preventive maintenance and thus enhance the longevity of the
Equipment
3.5.1 Preventive maintenance of Air Compressors

i) Compressor High vibrations / Trip / Abnormal sound / behavior
 In case any abnormality is observed on the Compressor (e.g. 1), take the following actions
immediately
 Start the Standby Air Compressor (4)
 Stop the running Compressor (1)
 Handover the Compressor for preventive checkup & maintenance by Mechanical and Electrical
maintenance
Compressor through before commencement of maintenance activities
 Collect the Coolant drained during opening of the Compressor in a can

 Top up the Coolant, if required
 Start the Compressor (1) that has been returned after maintenance and observe the
parameters
 Stop one of the running Compressors (2 or 3)
3.5.2 Breakdown & Shutdown of all the Air Compressors

(Compressors Breakdown, Electrical circuit, N2/IA Package S/D for CW etc.)
 Please refer Breakdown & Shutdown of N2 / IA Package for necessary actions

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3.6 Startup & Operation of N2 & IA Package
Instrument Air is a crucial Utility for Pneumatic Instruments and N2 is a crucial Utility to keep the
contents of some Storage Tanks and vessels in an inert atmosphere with N2 Blanketing to prevent
their degradation. N2 is also a crucial Utility in all the Utility Stations. The dual critical Utilities are
derived from the N2 & IA Package.
A. N2 distribution Network (P&ID 7410A-300-PI-8691)
 N2 is distributed throughout the Terminal for Utility N2 connections

 Keep the drain points on the main headers connecting Utility stations N2 Utility stations crack
open (around 10%) so that the line gets flushed and purged of impurities
 After the startup of the N2/IA Package, after bleeding N2 for around 30 minutes through the
above Utility stations, the above may be closed
 The openings of Utility stations being purged may be adjusted by maintaining a back pressure
of 8.5 bar G on the N2 Storage Tank in the N2/IA Package on Startup
 N2 is utilized for Blanketing of VAM, MEG and Styrene Storage Tanks

 The main isolation valves for N2 inlet to the above storage tanks may be kept closed
until the respective contents are charged into the tanks
 Keep the drain points upstream of the inlet isolation valves crack open (around 10%) so that
the line gets flushed and purged of impurities
 N2 is utilized in the Process Block in the following Equipment for Blanketing

 V001 – Feed vessel for Column C001
 V002 A/B – Intermediate Storage vessel for the Bottom product of C001
 V003 A/B – Intermediate Storage vessel for the Top product of C001 (N2 inlet line not shown
on P&ID 74108-300-PI-8002 R2)
 V004 A/B – Intermediate Storage vessel for the Top product of C002 (N2 inlet line not
shown on P&ID 74108-300-PI-8002 R2)
 V005 A/B – Intermediate Storage vessel for the Bottom product of C002
 V006 – TEG Feed vessel for C001
 The main isolation valves for N2 inlet to the above vessels may be kept closed until the
Process plant goes on stream and respective contents are charged into the vessels
 Keep the drain points upstream of the inlet isolation valves crack open (around 10%) so that
 Adjust the drain openings of N2 in all the above drain points viz. Utility Stations, upstream
of inlet to Storage Tanks and upstream of the Blanket N2 inlet valves to the vessels in the
Process Block, so that a back pressure of 8.5 bar G on the N2 Storage Tank in the N2/IA
Package, on Startup
 If the N2 lines to any of the above consumers is under maintenance, the same should be
kept isolated by keeping the isolation valves closed and with positive isolation with blinds,
if necessary
B. Instrument Air distribution Network

(P&IDs 7410A-300-PI-1011, 7410B-300-UF-8005)

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 Terminal
 Instrument Air distribution Manifolds (AMF) in the Terminal

 Drum Filling Pumps P-SOL- 4A/B, P-SOL-5, P-SOL-6
 Polymerization Inhibitor Dozing Pumps
 Styrene P-TBC-001
 VAM P-HQ-001
 Keep the drain points of the on the main headers connecting Utility stations in the Terminal crack
open (around 10%) so that the line gets flushed and purged of impurities
 Process Block
 Instrument Air is distributed in Instrument Air manifolds 1 to 8 in the Process Block
 Keep the drain points of the on Instrument Air manifolds crack open (around 10%) so that
 The isolation valves on the manifolds to the downstream instruments to which the
manifolds cater may be kept closed until the Instrument Air line up to the manifolds are
clean and free of dirt / particles that might otherwise block the impulse lines to the
individual instruments
 Adjust the drain openings of Instrument in all the above drain points in the Terminal and
the Process Block, so that a back pressure of 8.5 bar G on the Instrument Air receiver in
the N2/IA Package, on Startup
 If the Instrument Air lines to any of the above consumers is under maintenance, the same
should be kept isolated by keeping the isolation valves closed and with positive isolation
with blinds, if necessary
C. N2 / Instrument Air Package (Vendor P&ID 7410A-81B-SAM-CN-PI-1001)
 Keep the Control panel for the Package energized and in ON position
 Confirm that the isolation valves Cooling water Supply and Return lines are kept Open
 Maintain a Cooling water pressure of around 4 Kg / cm2 g
 Open some convenient drain points upstream of the N2/IA package and bleed air for around 10
minutes so that the line gets flushed and purged of impurities
 Close the drains
 Open the Compressed Air isolation valves inlet to all the After coolers
 Confirm that 3 Air Compressors are in line and maintain the Compressed Air Pressure inlet to the
Package at 10 bar G
 Press the Start push button on the Control panel

 The rest is taken care by the Package
 One PSA and one IDU unit will come in line
 PSA Units & IDU will Change over & Regenerate as per Logic
 Maintain Air pressure inlet to the PSA units at 9.5-10 Kg / cm2 g by adjusting the Globe
valve at the inlet of PSA module

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 Open the valve upstream of Rotameter (FT-0101) and keep venting from the 3 way vent
valve for 5-10 minutes
 Check the entire Package for leakages and corrective actions, if any required
 When the Oxygen content is less than 0.5% as indicated on the oxygen Analyzer, Close
the 3 way vent valve from the Control panel and stop venting upstream of N2 storage
vessel
 Monitor the Performance of the N2 / IA package until their performances are fully established
 N2 Generation
 Confirm Auto Changeover of PSA and Regeneration cycle being initiated for the spent
PSA every 1 minute as per Logic
 O2 content in the N2 (Max. 0.5%)
 Dew point of Product N2 (-40 deg. C)
 Instrument Air Driers

 Confirm Auto Changeover of ADU and Regeneration cycle being initiated for the spent
ADU every 5 minutes as per Logic
 Dew point of Instrument Air by Lab Analysis (-40 deg. C)
 Even after the performance of the Package is well established, it is recommended to maintain a
periodic log of parameters (say once in 2 hours) of the parameters. This would enable timely
actions, if any required, for preventive maintenance and thus enhance the longevity of the
Equipment
3.6.1 Preventive maintenance of N2 / IA Package

i) Routine Preventive maintenance
 Monitor the 4 stage filters upstream of the PSA Molecular sieves to prevent the Molecular sieves
from being poisoned due to oil & foreign particles
 Check their drains at an interval of 30 – 45 minutes
 Follow the schedule recommended by the vendor for Filters for replacement of the Filter
elements:
 Activated Carbon Filter every 6 months
 Other Filter elements 6 – 8months
ii) O2 Content of N2 or Dew point of N2 is high
 The normal Operating range for the above parameters are as follows:
 O2 in N2 is 0.5%
 Dew point of N2 is -40 Deg. C
 If the O2 content in N2 exceeds the maximum allowable limit (Value to be confirmed), carry out
the following:
 Stop the PSA units from the Control panel
 Open the 3-way vent valve
 Close Rota meter inlet valve
 Stop the air compressors

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 Switch OFF Control supply and manual supply

 Do not disturb the setting of manual valves
 Open the PSA vessels & check the status of the Coconut Fiber mat on top and the Molecular
sieves
 If necessary top up the Molecular sieves and replace the Coconut Fiber mats if they appear
damaged or frayed
 Box up the PSA vessels and tighten the flange so that the Coconut Fiber mat gets compressed
and prevents undesirable voids in the Molecular sieves
 Restart the PSA units from the Control Panel and follow the Startup sequence
mentioned above
 If the O2 content in N2 or the Dew point of N2 still exceeds the maximum allowable limit, it is time
to replace the Carbon Molecular Sieves in the PSA vessels
 If both O2 content and Dew point are high and beyond acceptable limits, it is a clear
confirmation that the Carbon Molecular Sieves in the PSA vessels have degraded and it is time
to replace it.
 N2 is a continuous requirement even during Annual Shut downs, since there might be
materials stored in VAM / MEG / Styrene Storage Tanks, which cannot be allowed to
degenerate without N2 Blanketing for a long duration of time
 Utility N2 is also a requirement during Annual Shut downs, since the Hydrocarbon lines
/ Systems to be taken up for Hot jobs during Annual maintenance need to be purged
with N2
 Hence there are only two alternatives to ensure continuous supply of N2 in the Terminal
Option 1 (Recommended Option)
 Keep fresh charge of Carbon Molecular sieves for both the PSA vessels ready as per vendor
specifications
 Shut down the PSA unit
 Open the 3-way vent valve
 Close Rota meter inlet valve
 Stop the air compressors
 Switch OFF Control supply and manual supply
 Do not disturb the setting of manual valves
 Open the top covers and replace the isolated PSA units with a fresh charge of Carbon
Molecular sieves as per vendor procedure
 Restart the PSA units from the Control Panel and follow the Startup sequence
mentioned above
 Confirm from Instrument readings that the O2 content and Dew point from the PSA units have
come within limits
Option 2
 This is the ultimate option in the absence of ready stock of Carbon Molecular sieves or
other unavoidable circumstances, the only alternative is as detailed below for Breakdown
as detailed below.

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 Additionally take the following steps:

 Expedite the necessary actions to get the Carbon Molecular sieves replaced in the PSA units
 On startup, confirm from Instrument readings that the O2 content and Dew point from both the
PSA units have come within limits
 When normalcy is established, discontinue the Temporary emergency measures

mentioned under Total Breakdown
iii) Dew point of Instrument Air is high
 The normal Operating range for the above parameter is as follows:

 Dew point of Instrument Air is -40 Deg. C
 If the Dew point of Instrument Air is high beyond acceptable limits (Value to be confirmed), it is a
clear indication that the Activated Alumina beds have degenerated and it is time to replace them
in the Drier units
Option 1 (Recommended Option)
 The replacement of Activated Alumina beds in the Drier units can be conveniently taken up
during Annual Shutdown or temporary Shutdown of the Process Block
 Close the Compressed Air isolation valve from the Air Receiver to the Instrument Air
drier unit, so that N2 Generation can continue to be in progress
 Keep the PLC for Instrument Air Drier OFF
 Replace the Activated Alumina beds in both the Drier units as per vendor procedure
 Open the Compressed Air isolation valve from the Air Receiver to the Instrument Air drier unit
 Keep the PLC for Instrument Air Drier unit ON
 The Instrument Air Drier units come in line as normal
 Confirm from Lab Analysis of Instrument Air that the Dew point has improved to a healthy level (-
40 deg. C or lower)
Option 2
 If the IA Drier unit beds have to be necessarily replaced without any Shutdown of Process
Plant, and if the Shutdown is prolonged, due to the non-availability of Activated Alumina or
other unavoidable reasons for a long length of time, the only alternative is as detailed
below for Breakdown of the system as detailed below.
 Additionally take the following steps:

 Expedite the necessary actions to get the Activated Alumina beds replaced with a fresh batch
 Confirm from Lab Analysis of Instrument Air that the Dew point has improved to a healthy level
(-40 deg. C or lower)
 When normalcy is established, discontinue the Temporary emergency measures

mentioned under below for Breakdown of the system
3.6.2 Breakdown & Shutdown of N2 / IA Package

(Breakdown of Electrical System / Breakdown of Process CW system etc.)

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 If there is a Breakdown and if the Shutdown of N2 / IA package is prolonged, due to the

above or other unavoidable reasons for a long length of time, take the following actions
 Procure a Bank of N2 cylinders

 Confirm by Analysis the purity of N2 to meet the specifications
 Connect the N2 from the Bank to the outlet line of N2 storage tank
 Hire a portable Instrument Air Compressor & Drier

 Check Air sample outlet of the Driers of portable unit to Instrument Air specs. (Dew
point)
 Connect the Instrument Air from the portable unit to the Instrument Air outlet line
 When the Breakdown / Shutdown issues are resolved, restore Normalcy of System and
disconnect the above emergency & temporary measures

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3.7 Startup & Operation of Fire Water system
Importance of Safety is well known, and even more so in a Chemical Terminal handling multiple
Solvents, some of which are highly inflammable. FW system might have a role to play even during
the Project stage before the Solvents are taken into the Storage tanks.
A. Fire Water distribution Networks (P&ID 7410A-300-PI-1004 and 1005)
 Fire water gets distributed from the Fire water pumps to the Hydrant Network in the Terminal
 Keep the individual isolation valves outlet of all the Monitors & Hydrants Closed, to
avoid wastage of water, since the Hydrant header would get pressurized on Startup of
the FW pumps
 The Hydrant Network in turn feeds the following means for Firefighting:
 Automatic Water Spray System for the Loading Gantry
 Automatic Water Spray System for the Product Pump houses
 Automatic Water Spray System for Tanks
 Foam System (Inline Balance Proportioning Unit)
 Sprinkler System for Buildings

 Administration Building, Security Cabin
 Utility Building
 Fire Water Pump house
 Ensure and Confirm that there are no false F & G signals from any of the Detectors, as
faulty signals can activate the FW system and can flood the area with water on Startup
of the FW pumps
 Keep all the isolation valves Open to all the Networks from the Hydrant header. The
individual Deluge Valves (DVs) would remain closed unless activated by Fire detection
signal
 If the Fire Water lines to any of the above recipients is under maintenance, the same
should be kept isolated by keeping the isolation valves closed and with positive isolation
with blinds, if necessary
B. Fire Water Pumping System

(P&ID 7410A-81P-CME-ME-PI-1852, P&ID 7410A-300-PI-1004
 Confirm that water inlet make up valve to Fire water tank T-FRW-001 is kept open and the Tank
is full
 The float valve on the water inlet line would ensure that the Tank is full and the water does not
keep overflowing from the tank
 Keep both the Jockey pumps 617-JP-001 and 617-JP-002 Electrically energized
 Ensure that Diesel level is full in all the Diesel Day Tanks for the four Diesel engine operated Fire
water Pumps viz. 617-FP-01, 02, 03 and 04
 As a matter of practice, the Diesel engines should be test run periodically to ensure that they
are in perfect working condition and the Diesel engine driven Pumps are ready to be pressed
into service any time, in case emergency arises

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 Keep all the Jockey Pumps and Diesel engine driven Pumps on Auto mode and the Fire Control
panel ON at all times
 Keep the Fire water tank T-FRW-001 outlet valves feeding the Fire water pumps open all the time
 Keep all the Jockey pumps and Diesel Pumps Recirculation valves feeding the 250 NB header
back to the tank Closed
 Keep the Gate valve on the Recirculation line back to the Fire water tank closed
 The recirculation valves and line are to be used Only for Test run of individual pumps (Routine
Test run of Diesel Pumps & Spare Jockey Pump) – after closing the individual main discharge
valve, Opening its individual recirculation valve and Opening the Recirculation valve back to
the Fire water tank.
 The recirculation valves should be kept Closed and the individual Pumps main
discharge valves should be kept Open after Test runs
 Keep the Suction and Discharge valves of all the Jockey and Diesel engine driven Pumps Open
 Start the Jockey Pump 617-JP-001, with the discharge valve closed
 Open the discharge valve slowly, venting some air and pressurize the Fire Water Hydrant
Network
 When the Hydrant Network header is pressurized, Open the discharge valve of the Pump fully
and keep it Open thereafter
 NRVs on the discharge lines of other Jockey and Diesel pumps would ensure that there is no
reverse flow to those pumps and the discharge valves of all the pumps should be kept Open
 Check the entire Hydrant Network for any leakages and corrective actions
 Confirm that the complete Network is pressurized with water up to the Operating pressure. It
should remain so at all times
 Keep Foam concentrate prepared in the Foam concentrate tanks and ready at all times
 Keep Diesel filled in the Diesel Day tank for the Diesel Engine driven Foam Pump at all times
 As a matter of practice, the Diesel engine should be test run periodically to ensure that it is in
perfect working condition and the Diesel engine driven Pump is ready to be pressed into
service any time, in case emergency arises
 Keep the motor driven Foam pump electrically energized
 Keep the Foam distribution valves to all the Tanks closed. Ensure that the Foam lines
up to the Isolation valves of all the Tanks is kept under pressure by running one of the
Foam pumps and Stopping it.
3.7.1 Preventive maintenance of Fire water system

i) Fire water distribution Network Leakages / Online Equip / Instruments
 In case of preventive maintenance to Network or Equipment in the Firefighting Network, Isolate

Fire water Only the segment of leakage or the segment to which the Equipment belongs
 Expedite the maintenance activity on Top Priority
 If the segment is in critical areas like the Storage Tanks area, it is recommended to keep
a Fire tender stationed close to the area of maintenance for quick actions in case of Fire
during the maintenance period
ii) Jockey / Diesel Pumps High vibrations / Trip / Abnormal sound or behavior
 In case any abnormality is observed on any of the Fire water pumps, take the following actions
immediately

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 If it is a Jockey Pump Start the Standby pump

 If it is one of the Diesel pumps Keep the other 3 Diesel Pumps in absolute readiness for
service
 Stop the running / distressed Pump
 Handover the Pump for preventive checkup & maintenance by Mechanical and Electrical
maintenance
 Electrically isolate the Motor for the pump from the MCC if it is a Jockey Pump / local
isolation , if it is a diesel Pump, before commencing any maintenance operation, to
prevent accidents
 If the Pump needs to be opened / major overhaul, close the suction & discharge valves and drain
the holdup water, before commencement of maintenance activities
 Expedite the maintenance activities on Top Priority

 Close the drain, Open the Suction valve, the Recirculation valve and the Fire water Tank
Recirculation valve (250 NB)
 Start the Pump that has been returned after maintenance, run it on recirculation and observe
the parameters
 If parameters are normal, it may be kept on Standby; if it is a Jockey pump, it may be kept in
regular operation for sustained observation and the running Jockey pump may be stopped and
kept as Standby
3.7.2 Breakdown & Shutdown maintenance of Fire water system

i) Both the Jockey Pumps are under maintenance
 If both the Jockey pumps have broken-down, take the following actions immediately:
 Start Diesel Engine Pump 1 and keep the Firewater Network pressurized continuously
 Close the Suction & Discharge valves of the Jockey pumps and drain the holdup water
 Electrically isolate the Motor for the pump from the MCC and commence Mechanical /
Electrical maintenance
 Works on both the Jockey pumps have to be done in parallel and the jobs expedited on
Top Priority
ii) 2 or more Diesel Pumps are under maintenance
 If more than 1 Diesel Engine driven pump have broken down, apart from necessary
actions to expedite maintenance on Top Priority on all the broken down pumps in parallel,
the following action is recommended as an emergency measure:
 In-house Fire tenders & Firefighting personnel should be available in full strength
throughout the period of maintenance
 Hire / Organize additional Fire tenders during the period of maintenance to be in
readiness to fight contingencies

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3.8 Startup & Operation of Fire & Gas Detection System
There is no Operation involved in keeping the F&G System except to ensure that the System
and installations are Complete and Active, namely the following:
A. F&G Panels
 Control Room
 Repeater Panel at the Security Gate
 Ensure that F&G Panels in the Control room and Repeater panel at the Security gate are
powered ON
B. Terminal Area - Field installations (P&ID TCE 7410A-580-IN-026)
 Flame Detectors
 All the Flame detectors in the Storage tank area
 Point type Gas Detectors

 Storage Tank Areas of Dike I
 North & South Pump houses of Dike I
 Storage Tank Areas of Dike II

 North Pump house of Dike II
 Truck loading Area - One each Truck Loading Bay
 Open Path Gas Detectors
 Manifold Area of Dike I Piping & Pigging

 Manifold Area of Dike II Piping & Pigging
 Manual Call points & Hooters / Strobes

 Explosion Proof Manual Call points in Dike I Storage tank Area
 Explosion Proof Manual Call points in Dike II Storage tank Area
 Weather Proof Manual Call point in Truck Loading Bay Area

 Weather Proof Manual Call points in Utilities Station
 Weather Proof Manual Call point in Drum storage & Loading Bay
 All the above Manual Call points should be tested periodically and attended to if required, to
ensure that they remain active all the time
C. Building I – MCC & Control Room (P&ID TCE 7410A-IC-580-027)
 Heat Detectors
 Control Room (Cabinets Room)
 Battery Room
 H2 Detectors

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 Battery Room
 Multi-sensor Detectors (Smoke & Temperature)

 Control Room
 MCC
 Smoke Detectors above False ceiling with Response Indicator

 Control Room
 Manual Call Points & Hooters / Strobes

 Entrance to Control Room
D. Building II – Administrative Building (P&ID TCE 7410A-IC-580-028)
 Heat Detector
 Pantry
 Multi-sensor Detectors (Smoke & Temperature)

 Server Room
 Smoke Detectors
 Dining room
 Prayer room
 Corridor
 Storage
 Open Office
 Plant Manager
 Conference room
 Meeting room
 AC room
 Manual Call Points & Hooters / Strobes

 Entrance to Building
E. Building III – Utility Area (P&ID TCE 7410A-IC-580-029)
 Smoke Detectors
 Total Area coverage
 Manual Call Point & & Hooters / Strobes

 Entrance to the Building
3.8.1 Preventive maintenance of Fire & Gas Detection System
 It should be a matter of practice that all F&G Equipment are periodically tested and
corrective actions taken immediately wherever required

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 All the Equipment should be regularly tested by simulation / manual activation to confirm that
they are all in prime working condition
3.8.2 Breakdown & Shutdown maintenance of Fire & Gas Detection System
 There is no holiday for the Fire & Gas detection System from the time the first drop of
Hydrocarbon is taken into the Terminal for processing, considering the Safety of the
Terminal & the Personnel
 Hence there should be no room for total Breakdown of the System
 All the routine maintenance & replacements should be taken care as part of Preventive
maintenance
 Sufficient Spares & Replacement should always be available at site
 Absence of communication regarding F&G Detection can be limited only from the
Equipment / Components under Preventive maintenance which should be made up by
manual vigilance in the area/s during the period of maintenance

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3.9 Startup & Operation of Thermic Fluid System
Thermic Fluid System has to be put into Operation before the Intake of Bitumen in their Storage
Tanks
 Well before the berthing of the ship for unloading Bitumen / Truck unloading of Bitumen into the
Storage tank/s, the following should be ensured:
 Thermic Fluid circulation is established through the Heating coils of the Tank/s
 The Burner Management System (BMS) of the Thermic Fluid package is retested and
confirmed to be in order and ready to fire again, when Bitumen is taken into the tank
A. Thermic Fluid circulation Networks

(P&ID 7410A81G-MAX-ME-PI-1351 , TCE-7410A-300-PI-8653 & 8654)
 Thermic Fluid (Hot Oil) is distributed from the common 100 NB outlet line from the Thermic Fluid
Heaters E-TF-008A & E-TF-008B to the Heating coils of the Bitumen Storage Tanks T-BTM-001
& T-BTM-002
 Keep all the Hot Oil Supply & Return lines (4 each) on both the Tanks T-BTM-001 & T-BTM-
002 Open
 If the Hot oil Supply or Return lines to any of the above recipients is under maintenance,
the same should be kept isolated by keeping the isolation valves closed and with positive
isolation with blinds, if necessary
B. Thermic Fluid System (Generation) (P&ID P&ID 7410A81G-MAX-ME-PI-1351
 Hot Thermic Fluid is generated in the Thermic Fluid System by 2 Fuel oil (High Speed Diesel)
fired Furnaces E-TF-008A / B
 Keep the TF Circulation Pumps P-TF-006A&B Electrically Energized
(*Neither Jacket for the Circulation Pumps Casings Nor Cooling water supply for the
Casing Jackets for the Pumps Or Cooling water for the Pumps seals are not shown in
the P&ID. If they are provided in actual installations, the Cooling water lines should be
kept Open)
 Keep the Control Panel Powered ON

 Ensure that the Lubricant for the bearings of the Pump is filled up to the correct level
 Ensure high level of Thermic Fluid in the De-Aerator cum Expansion vessel
 Ensure level in the Storage / Dump vessel also for makeup of Thermic Fluid if required
 Ensure that the Fuel oil Service Tank is full
 System for Auto making up level of Fuel oil Service Tank on LSL-1351-02 with Supply
from the main Storage tank should be established
 Keep the 100 NB isolation valve on the Hot Thermic Fluid line to the Process Open
 Keep the 100 NB isolation valve on the Hot Thermic Fluid Return line from the Process Open
 Keep the Circulation Pumps discharge valve (80 NB) Inlet to the Selected Furnace (E-TF-
008A) and the Hot Fluid Outlet valve (80 NB) from the Furnace going to the Outlet line to the
Process Open
 Select Furnace E-TF-008A for Firing and E-TF-008B in Standby mode

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 Keep the Fuel oil Supply & Return valves of the Furnace (20 NB) Open
 Keep the De-Aeration Cum Expansion Tank outlet isolation valve and Pumps suction isolation
valves Open
 Keep the discharge damper on the Flue gas line Open (to pre-adjusted position for a stable Fire
during Operational Tests)
 Keep the Supply ON to the Control Panel
 Select Circulation Pump P-TF-006A
 Put the Rotary switch on Circulation position
 The Thermic Fluid circulation Pump P-TF-006A should start
 Slowly Open the discharge valve of P-TF-006A
 The discharge valve of P-TF-006B may also be kept open, since the NRV on the pump
discharge would prevent reverse flow
 With the above conditions, the circulation of Thermic fluid should be established in the entire
circuit as follows:
 De-Aerator Cum Expansion Tank – Circulation Pump (P-TF-006A) – Coil of Furnace (E-TF-
008A ) – 100 NB Outlet line to Process - Heating Coils of Bitumen Tanks T-BTM-001 & T-
BTM-002 – 100 NB Return line to De-Aerator Cum Expansion Tank
 Check the entire circuit for any leakage and corrective actions, if any required
 When a healthy circulation with steady pressure is established, the Furnace may be Test Fired to
reconfirm its readiness to Fire when required, to start generating Hot Thermic Fluid
 Turn the Rotary switch to Fire position
 Confirm the following cycle of operations on turning the Rotary switch to Fire position
 The Blower starts commencing “Pre-purging”
 After Pre-purging Sparking starts (within 15 seconds)
 Burner solenoid valve gets energized and Fuel oil is sprayed into the Combustion
chamber
 Flame is established on Low Flame
 Sparking Stops
 After 12 Seconds from the time the Flame is established, the Burner switches to High
Flame
 When the Burner Firing is established, the above process may be repeated a few times to
make sure that the Burner Management cycle is Consistent and Established
 When the Burner Firing is satisfactorily established, Put the Rotary switch on Circulation position
and keep the circulation going
 The Furnace may be Fired when the Intake of Bitumen into the Tank commences
 If there is going to be a huge time gap before Bitumen Intake to the Storage Tank, the circulation
of Thermic Fluid may kept stopped by keeping the Rotary Switch in OFF position in the Control
Panel
3.9.1 Preventive maintenance of Thermic Fluid system

i) TF Circulation Pumps High vibrations / Trip / Abnormal behavior
 In case any abnormality is observed on any of the TF circulation pumps, take the following
actions immediately

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 Start the Standby pump

 Stop the running / distressed Pump
 Handover the Pump for preventive checkup & maintenance by Mechanical and Electrical
maintenance
 Electrically isolate the Motor for the pump from the, before commencing any
 If the Pump needs to be opened / major overhaul, close the suction & discharge valves and drain
& collect the holdup Thermic Fluid in cans, before commencement of maintenance activities

 Close the drain, Open the Suction valve, Start the Pump that has been returned after
maintenance, run the Pump in Test position’ in parallel with the Pump in Operation and
observe the parameters
 If parameters are normal, it may be kept in regular operation for sustained observation and the
running Circulation pump may be stopped and kept as Standby
ii) Problems associated with the Furnace (Burner / Leakage in Coil etc.)
 In case of any problem associated with the Furnace (e.g. E-TF-008A), take the following actions:
 Stop the distressed Furnace by bringing the Rotary Switch to Circulation position
 Select the Standby Furnace on the Panel
 Fire the Furnace as per procedure explained above and keep the Furnace in line
 Before handing over the Furnace that has been stopped for maintenance carry out the following
activities:
 Keep the Circulation Pumps discharge valve (80 NB) Inlet to the Furnace (E-TF-008A) and the
Hot Fluid Outlet valve (80 NB) from the Furnace going to the Outlet line to the Process
Closed
 Close the Fuel Oil Supply & Return isolation valves to the Furnace
 In case Hot job is involved on the Coil of the Furnace / TF line/s, Fuel Oil line, take the following
additional actions:
 Drain the holdup liquid into cans the portion / line to be handed over for Hot job
 Carry out positive isolation of the line / segment with blinds
 Purge the line with N2 & test the line if it is free of Hydrocarbons / Inflammable materials
 Hand over for maintenance
3.9.2 Breakdown & Shutdown maintenance of Thermic Fluid System

(Both Furnaces/Circulation Pumps under maintenance, TF Not available / Common
lines leakage etc. )
 In case of Total Breakdown or Shutdown of the Thermic Fluid System, apart from
necessary actions to expedite the necessary actions / Maintenance on Top Priority on all
the Causes for Breakdown in parallel, the following actions are recommended, as an
emergency measure if the Shutdown is expected to be prolonged:
 Avoid further intake of Bitumen to their respective storage tanks to avoid the risk of
solidification

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 Maximize continuous recirculation of Bitumen in their storage tanks, as continuous

recirculation would impart heat to the Stored material and help to keep it fluid
 Monitor the Density of Bitumen in both the Bitumen Storage Tanks T-BTM-001 & 002
(DI 5301 & DI 5401)
 Monitor the Current drawn by the Bitumen Transfer Pumps P-BTM-001 & 002
 If ready offtake is available for Ship loading of Bitumen, take the opportunity to offload
the materials by offering preferential berth for the Tankers at the Ship Loading Arm
 Maximize preferred Truck loading of Bitumen
 If ready offtake of Drummed material is available, Drum filling of Bitumen is an added
avenue to lessen the stock
 Ensure that Electrical Tracing in all the lines is active; Maximize heating value, if
possible
 Expedite the maintenance activities to get the system back to normal

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3.10 Startup & Operation of SCADA / DCS
SCADA / DCS should have been Started and in Operation prior to the Pre-Commissioning &
Commissioning stage of the rest of the Terminal Systems, Packages and Equipment. Each
successful Startup Operation of the Terminal Systems and Unit Operations of the Terminal,
only enhances its credibility and vindicates its status as the Chief Coordinator & Captain of all
the Installations in the Terminal and Operations they cater to. To ensure that SCADA / DCS
Systems System and installations are complete and Active at all times is Sacrosanct.
 It should be ensured that the Power backup (UPS) for SCADA is in prime condition at all times
 The System and all the History records of SCADA should be ensured to be free of virus at
all times
 Periodical Retrieval and backup storage of all Records should be a noncompromising practice
Preventive maintenance of SCADA / DCS
 It should be a matter of practice that all the SCADA & Affiliated installations are
periodically tested and corrective actions taken immediately wherever required
Breakdown & Shutdown maintenance SCADA / DCS
 There is no holiday for SCADA / DCS System from the time it is Powered ON, Software
loaded & Pressed into service
 Hence there should be no room for total Breakdown of the System
 All the routine maintenance & replacements should be taken care as part of Preventive
maintenance
 Sufficient Spares & Replacement should always be available at site
 To the extent possible, preventive maintenance of the System should be carried by
selective isolation of the segment of maintenance, so that the rest of the Terminal
Operations can progress normally.
 The services of the SCADA System Supplier should be readily available at short notice
 Contact details of the key Service personnel – Both Software and Hardware - should be
readily available

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4. STARTUP & OPERATION - PRODUCTS INTAKE TO STORAGE TANKS
After the Startup & Operation of all the Support Systems, the Storage Tanks are ready to receive the
Operating Fluids in their respective Tanks. The Solvents / Products to be offloaded in the Storage
Tanks are received by 2 modes of transport from the origin viz. Ship and Road Tankers. Apart from
the above two modes of receiving Products to Storage Tanks, there also exists a provision for Inter-
Terminal Transfer of Products (except Bitumen), between the existing McGraw Terminal and this
New Terminal. All the 3 modes of receiving Products into the Storage Tanks are as follows:
 Unloading Products from the Ship
 Unloading Products sent by Road Tankers
 Inter-Terminal Transfer of Products

A brief of the facilities for the above 3 modes of receiving Products to Storage Tanks are given below.
Unloading Products from the Ship
The unloading of Solvents / Products transported by ship, are done by Unloading pumps of the Ship
from the Jetty to their respective Storage Tanks through 4 numbers of Piggable 10” lines, which are
allocated for Products based on the following criteria:
 1 No. of Electrically traced line (C.S.) dedicated for Bitumen service
 1 No. of SS 304 lines dedicated for Phenol, Glycols and other Products
 2 Nos. of C.S. line for all other Products except Bitumen, Phenol and Glycols
There are Pig Launchers & Receivers (PLR) 4 numbers each at the Jetty end and the Piping Manifold
end, to cater to the Pigging of lines allocated based on the above philosophy:
 PLR -001 (Jetty end) & PLR-002 (Piping Manifold end) of SS 304 for Phenol, Glycols and other
Products
 PLR-003 (Jetty end) & PLR-004 (Piping Manifold end) of C.S. for all other Products except
Bitumen, Phenol and Glycols
 PLR-005 (Jetty end) & PLR-006 (Piping Manifold end) of C.S. for all other Products except
Bitumen, Phenol and Glycols
 PLR-007 (Jetty end) & PLR-008 (Piping Manifold end) of C.S. with Electrical tracing exclusively
dedicated for Bitumen
 Flexibility is provided for all the Sending & Receiving PLRs except for PLRs 007 & 008,
to transfer the incoming Product to one of the Storage Tanks either in Dike I or Dike II
 The same Flexibility facilitates transfer from one of the Tanks of either Dike I or Dike II to
the Jetty for Ship Loading, for all the Products except Bitumen (Dike II), through the line
allocated based on Product properties mentioned above
 PLR-007 & 008 cane be used only for the Ship unloading of Bitumen to one of the
Bitumen Storage Tanks and for Ship Loading from one of the Bitumen Storage Tanks to the
Ship
The Operations involved in Ship Unloading to Storage Tanks and Ship Loading from Storage Tanks
to Ship are identical for all Products of Dike I & Dike II
 Only Caution needs to be exercised to ensure that the Product received from Ship is
routed through the Right line to the Right Tank, which involve manual Operations
Unloading Products from Road Tankers

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There are 3 numbers of Pumps provided for unloading Products from Road Tankers to their
respective Storage Tanks, with the Pumps & lines allocated based on the following philosophy:
 One Gear Pump P-SOL-007 with SS 3304 lines for viscous (except Bitumen) fluids like Base Oil
and Polyol for transfer to T-BOL-001-004 or Polyol to T-POL-001
 BOL and POL Tanks are located in Dike I. However, flexibility exists to divert the Product
unloaded from the Road Tanker to any of the Tanks either in Dike I or Dike II
 One Centrifugal Pump P-SOL-008 with SS 3304 lines for all other non-viscous products (except
Bitumen)
 Flexibility exists to divert the Product unloaded from the Road Tanker to any of the Tanks
either in Dike I or Dike II
 One Gear Pump P-BTM-005 with CS Electrically traced lines exclusively dedicated for
Bitumen
 The discharge line delivers to one of the Bitumen Storage Tanks T-BTM-001 or 002 located in
Dike II only
Inter Terminal Transfer of Products
 One No. SS 304 line is provided connecting the McGraw Terminal and this New Terminal through
one Piggable 10” line
There are Pig Launchers & Receivers (PLR) one each at the New Terminal Manifold end and the
McGraw Terminal end, to cater to the Pigging of line
 PLR-009 (New Terminal end) and PLR-010 (McGraw Terminal end) for Inter Terminal transfer of
all Products except Bitumen
The Procedure for Ship unloading, Tanker unloading and Inter Terminal Transfers for taking Products
into Storage Tanks are detailed in the following sections, highlighting the precautions to be taken
during each process.
Support Systems in Operation for Specific Products
The support Systems to be in Operation for the following Products when they are taken in to their
Storage Tanks and their Operational parameters are detailed in section 4.4
 VAM Chilled Water Package, CHW circulation & Polymerization Inhibitor

 Styrene Chilled Water Package, CHW circulation & Polymerization Inhibitor
 Bitumen Thermic Fluid System & Circulation through Coil
 Phenol Electric Heater – Part of Storage Tank installation

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4.1 Unloading Products from the Ship (Ref. P&ID TCE 7410A-300-PI-8652)
Unloading of Product should be preceded by posting Operators with assigned responsibilities

mentioned below for each position.
 Close coordination is required among Control Room Operator, Jetty end Operator, Manifold
Operator and the Field Operator (near the Storage Tanks).
 Since use of Mobile phones should be avoided in areas handling Hydrocarbons, all the
Operators should be equipped with Walkie-Talkies for communication & coordination.
 Please refer to the Marked up drawings with Stepwise procedure enclosed, depicting the Actions
and Responsibilities amongst the Operators involved in the Operation, for Transfer of Products
from Ships to the Storage Tanks in Dike I and Dike II followed by Pigging and N2 purge of the line,
which are detailed below
 The marked up drawing should be read in conjunction with the details given below, to
note the finer points brought out in both
a) Control Room Operator
 Responsibilities include the following:
 Coordinate & Reconfirm with the Jetty end Operator, Manifold Operator and the Field
Operator as to the Product to be transferred and the Location of the Tank to which the
Product is to be transferred is in Dike I or Dike II
 Confirm that all the Flame and Gas detectors in the Tank Dike area, Pumping area and Open
path area are healthy and there are no High Level Alarms from any of them
 Select the Correct Product Tank into which the Product is to be received on the screen
in the Control Room
 Select “RECEIPT – JETTY”
 Ensure that the Actuated valves on the Tank are in Remote Auto mode
 Once the *Remote Auto” mode is selected, on selection of “RECEIPT – JETTY” for the Tank
on the HMI screen, confirm that the Actuated Inlet valve Opens and Actuated Outlet valve
Closes.
 Confirm the following depending on the Product Tank:
 Dike I Tank - If the Product Tank is T-C09-001 , T-C10-001 Tank, Confirm that Actuated
Inlet valves from C-001 and C-002 of Process Block remain Closed in Remote Auto
mode
 Dike II Tank (Except Bitumen) - If the Product Tank is T-NPTL-001, T-NPTL-002, T-
NPTL-003, T-MEG-001, T-XYL-001, Confirm that Actuated Inlet valves from C-001 and
C-002 of Process Block remain Closed in Remote Auto mode
 Bitumen Tank (Dike II) – If the Product Tank is T-BTM-001 / 002, Confirm that the
Actuated valves to TLF (XV 5304 / XV 5404) remains closed
 If the above conditions are fulfilled, the Tank is ready to receive the Solvent from the
Jetty
 Coordinate with the Jetty end Operator, the Manifold Operator and the Field Operator
to Start Pumping the Product, when all of them are ready

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 After the Pumping is started, monitor the Level of the Product Tank which has been selected
on Screen and confirm that there is increase in Level
 Receive information from the Jetty end Operator, Manifold Operator and Field Operator
regarding the Status at the three ends and coordinate the necessary actions.
b) Operator at the Jetty end

 Pre-unloading Check of the PLR at the Jetty end viz.
 Pig signaler is mounted
 Check the Quick Opening Closure (QOC) for the following:
 Leak proof seating with proper seating of Seal
 Integral Pressure Alert valve (PAV) in place
 Small removable ring of the Swing door locks with the PAV to prevent accidental opening of
the door with pressure in the system
 Oversee the Connection of the Vessel’s Pump discharge to the Unloading Arm
 Coordinate & Reconfirm with the Control Room Operator and the Manifold Operator as
to the Product to be transferred and the Location of the Tank to which the Product is to
be transferred is in Dike I or Dike II
 Connect the Unloading Arm’s outlet to the Barred Tee of the Correct PLR, taking care to
maintain the allocation of Lines (connected to PLRs) for different Products considering their
properties viz. the following:
 Line connected to PLR -001 of SS 304 for Phenol & Glycols; Optional for other
Products except Bitumen, in case of requirement
 Lines connected to PLR-003 Or PLR-005 of C.S., based on availability, for all other
Products except Bitumen, Phenol and Glycols
 Line connected to PLR-007 of C.S. with Electrical tracing exclusively dedicated for
Bitumen
 Close the PLR isolation valve downstream of the PLR

 Open the Inlet / Outlet Isolation valve on the Barred Tee
 Confirm that all Utility connections are kept Closed and the PG isolation valve is Open
 Oversee the Pumping facility in the Vessel and ensure that viscous fluids like Base Oil
and Polyol are connected to Gear Pumps for Pumping the Product
 Coordinate with the Control room Operator, Manifold Operator and the Field Operator
before commencement of Pumping from the Vessel
 Give Clearance to the Vessel Captain to Start the Pump
 Coordinate with the Control Room Operator, Piping Manifold Operator & the Field
Operator (near the Storage Tank) if there is no leakage and all is well
 If leakages are observed near the Jetty or reported from the Manifold or in the
Field, coordinate with the Ship’s Captain to Stop pumping immediately
 Get the corrective actions for leakage carried out coordinate with the other Operators and
give clearance to the Ship’s Captain to Restart Pumping
 After completion of Pumping, under coordination with the Manifold Operator and
Control Room, carry out the following
 Coordinate with the Ship’s Captain to Stop the Pump

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 If provision exists, connect Utility N2 to flush the Ship Pumps discharge line with N2
 Disconnect the Unloading Arm outline line to the Inlet of the Barred Tee
 Close the Inlet / Outlet Isolation valve on the Barred Tee
 Coordinate with the other Operators viz. Control Room, Manifold and Field to start
Pigging
 Run the Pig from the Jetty end to the Manifold end as per Supplier’s Procedure, to
make sure that the line is fully cleared of the material pumped and the line is ready to
receive the next Product without any fear of contamination
 After the Pig reaches the Manifold end and Retraction of Pig, coordinate with the other
Operators to commence N2 Purging of line
 Open the Inlet / Outlet Isolation valve on the Barred Tee
 Make the Utility connection on the PLR of the line
 Start N2 purging of the line
 Regulate the opening of Utility valve to ensure that there is not a vigorous agitation in
the Storage Tank, if flushed back to the Tank
 Purge the line till the line is dry and free of liquid as checked from the Drain
points on the Manifold and near the Storage Tank by the respective Operators
 Stop N2 Purging
c) Operator at the Manifold

 Pre-unloading Check of the PLR at the Manifold end viz.
 Coordinate & Reconfirm with the Control Room Operator, the Jetty end Operator and
the Field Operator as to the Product to be transferred and the Location of the Tank to
which the Product is to be transferred is in Dike I or Dike II
 Check & keep the isolation valves position around the PLR at the Manifold end as per
the following criterion:
Product is to be transferred to a Storage Tank in Dike I
 Close 100% the Inlet / Outlet Isolation valve on the Barred Tee towards the Jetty
 Open the Isolation valve between the two Barred Tees
 Ensure that the isolation valve of the Utility connection above the Barred Tee through which
the Product is to be delivered is fully Closed
 Close the Receiving PLR Outlet Valve on the line

 Open the Barred Tee outlet valve towards the Manifold end
 Open the Isolation valves (2 Nos.) from the Barred Tee Inlet / Outlet line to the hose
connection

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Product is to be transferred to a Storage Tank in Dike II (Except Bitumen):
 Open the Inlet / Outlet Isolation valve on the Barred Tee towards the Jetty
the Product is to be delivered is fully Closed
 Close the Receiving PLR Outlet Valve on the line

 Close the Isolation valve between the two Barred Tees
 Close the Barred Tee Inlet / Outlet valve towards the Manifold end
 Open the Isolation valves (2 Nos.) from the Barred Tee Inlet / Outlet line to the hose
connection
Bitumen is to be transferred to Storage Tank T-BTM-001 or T-BTM-002 (Dike II)
 There is only One Barred Tee to which an outline (Electrically traced C.S. line) is connected
 Keep the Inlet / Outlet valve of the Barred Tee Open
 Ensure that the isolation valve of the Utility connection above the Barred Tee
Is fully closed
Hose Connection from the discharge of Barred Tee to the Manifold (Except Bitumen)
 Connect one end of a hose with QRC to the Open end of the discharge line from the Barred
Tee adjoining the two isolation valves
 Connect the QRC at the other end of the hose to the QRC adjoining the Isolation valves
of the Correct Product line Connected to the Correct Manifold
 Open the two isolation valves connected to the Manifold discharging to the Correct
Storage Tank
Discharge line of Barred Tee to Bitumen Storage Tanks
 There is a permanent Electrically traced line connecting the Barred Tee to the Manifold
connecting the lines leading to the Bitumen Storage Tanks T-BTM-001 and T-BTM-002
 Open the Barred Tee Outlet valve
 Open the common isolation valve on the line from the Barred Tee
 Close the isolation valve meant for Dispatch to Ship / Tanker Unloading
 Open the isolation valve on the line discharging to the Correct Bitumen Tank BTM-001
or T-BTM-002
 Close the Isolation on the line leading to the Tank to which Bitumen is Not to be sent
(Please note Caution below)
 Close the isolation valve on the Line from the Product transfer Pump P-BTM-003 near
the Manifold (Please note Caution below)
 Close the isolation valve Close the isolation valve on the Line from the Truck
Unloading Pump P-BTM-005 near the Manifold (Please note Caution below)
Caution
 When Ship Unloading of Bitumen is Progress, Truck Unloading cannot take place

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 It is strongly recommended to take the following course of actions before

commencement of Ship Unloading to avoid serious accidents due to manual error
during Ship Unloading Operations
 After Closing the isolation valves at the above mentioned positions, Tag the Isolation
valves “DO NOT OPERATE”. For additional Safety, Put slip plate / blind on the
upstream flange of the isolation valves. It is mandatory to put slip plate on the
upstream flange, in case any maintenance work is in progress on the line
 Bitumen Transfer Pump P-BTM-003 should be Electrically Isolated and Tagged
 Bitumen Truck Unloading Pump P-BTM-005 should be Electrically Isolated and
Tagged
 Give Clearance to the Jetty end Operator & Control Room to Start the Pump
 Coordinate with the Control Room Operator, Jetty end Operator and the Field Operator (near
the Storage Tank) if there is no leakage and all is well
 If leakages are observed near the Manifold end, coordinate with the Jetty end Operator
and Control Room Operator to Stop pumping immediately
 Carry out the corrective actions for leakage and give clearance to the Jetty end Operator and
Control Room Operator to Restart Pumping
 After completion of Pumping, coordinate with the Jetty end Operator and Control
Room, for Pigging the Pig from the Jetty end to the Manifold followed by N2 Purge of
the lines, to make sure that the line is fully cleared of the material pumped and the line
is ready to receive the next Product without any fear of contamination
 N2 Purge from the Manifold to the Storage Tanks of Dike I & Dike II Products might not
be required after every Unloading of Product from Ship, since the lines from the
Storage Tank up to the up to the Manifold are dedicated lines and there is no fear of
Contamination - Except Heat sensitive materials VAM & Phenol (Dike I) and Bitumen &
Styrene (Dike II)
 Act in coordination with the Jetty and other Operators to ensure that the line is N2 purged free
of liquid
d) Field Operator (near the Storage Tanks)
 Coordinate & Reconfirm with the Control Room Operator, Jetty end Operator and the
Manifold Operator as to the Product to be transferred and the Location of the Tank to
which the Product is to be transferred is in Dike I or Dike II
 Confirm that the Actuated Inlet valve of the selected Product Tank is Open in the field
 Confirm that the Actuated valve on the Tank Outlet is Closed in the field
Inlet valves from C-001 and C-002 of Process Block are Closed in the field
C-002 of Process Block are Closed in the field

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 Bitumen Tank (Dike II) – If the Product Tank is T-BTM-001 /002, Confirm that the
Actuated valve to TLF (XV 5304 / XV 5404) is Closed in the field
 Any Tank selected – TLF Transfer Pump is Stopped and its Suction & Discharge
valves are Closed
 Give Clearance to the Control Room, Jetty end Operator and the Manifold Operator to Start
the Pump
 Coordinate with the Control Room Operator, Jetty end Operator and Manifold Operator if
there is no leakage and all is well
 If leakages are observed near the Storage Tank, coordinate with the Jetty end Operator,
Manifold Operator and Control Room Operator to Stop pumping immediately
 Carry out the corrective actions for leakage and give clearance to the Jetty end Operator,
Manifold Operator and Control Room Operator to Restart Pumping
 After the Pumping is started, monitor the Level of the Product Tank and confirm that there is
increase in Level on the Level Indicator
 Act in coordination with the Jetty and other Operators to ensure that the line is Pigged and N2
purged free of liquid
 Coordinate with the Other Operators to get the N2 pressure regulated, to ensure vigorous
agitation does not take place in the Tank during N2 purge
4.1.1 Preventive maintenance during Unloading Products from the Ship

i) Line leakages involving Cold jobs (from Flanges, Valves etc)
 Leakages in the line during pumping are dealt with as part of the Process above and individual
responsibilities are mentioned
 All leakages should be coordinated through the Jetty end Operator who in turn coordinate with
the Ship’s Captain to temporarily Stop Pumping and get the Pumping restarted after the
Leakages are attended
ii) Transfer Line is blocked / Quantity Pumped is less

A. Identification of Choked portion of the line
 If the Quantity pumped is Less / Nil, the Jetty end Operator should get the Pump checked through
the Ship’s Captain and request for Changeover of the Pump in service
 If there is no problem with the Pump, then the line from the Jetty to the Manifold or from the
Manifold to the Storage Tank may be choked
 First step is to ascertain where the Choke is under coordination amongst Operators as follows
 Please refer to the Marked up drawing enclosed, depicting the actions in the Field and
responsibilities for Pigging & N2 Purge after Ship Unloading
The jetty end Operator
 Get the Pump stopped in coordination with the Ship’s Captain

 Prepare for Pigging the Line from the Jetty to the Manifold
 In coordination with the other Operators Start Pigging from the Jetty to the Manifold as
explained above
Manifold Operator

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 Confirm & Inform other Operators if the Pig has reached the Manifold end
 If the Pig reaches the Manifold end, it confirms that the line from the Jetty up to the
Manifold end is Clear
 After the Pig reaches the Manifold end, inform Jetty end Operator in coordination with
the other Operators to Start N2 Purging of the line as explained above and depicted in
the enclosed Marked Up drawing
 After N2 purging for about 15 minutes, Check & Confirm if the N2 comes out with Pressure
from the drain point
 The Operator should wear Safety gears like Helmet, Coverall, Face Shield and
Goggles to avoid injury due to liquid splashing out with N2 pressure
 If N2 comes out from the drain points near the Manifold , it confirms that the line from
the Jetty up to the Manifold is Clear
Field Operator
 Check the drain point near the Storage Tank

 If the N2 comes with Pressure from the drain point near the Storage Tank, the line from
the Jetty upto Storage Tank is clear
 Coordinate with the other Operators to get the Pump restarted
 If Choke is identified in any of the segments viz. - Line from the Jetty up to the Receiving PLR at
the Manifold end or/and Line from the receiving end PLR up to the Manifold or/and Line from the
Manifold up to the Storage Tank - hammer gently with wooden mallet on the line in the identified
segment of Choke especially near the bends & elbows to relieve the Choke in line
 If the line is heavily choked and relieving the Choke is time consuming (unlikely for Products
other than Bitumen), the following options may be resorted to save time & demurrages, if any
applicable, due to delay in Unloading the Product
B. Corrective Actions - Line from Jetty to Manifold is Choked
 Under coordination with the Other Operators Change over the line to the next available
line for pumping – this option is applicable for Products Other than Bitumen, Phenol
and Glycols only
Manifold Operator
 Do the necessary adjustment to the isolation valves connected to the Inlet / Outlet line of the
Barred Tee
 Connect hose to the Open end of the line from the Barred Tee to be taken in line to the
appropriate line on the Manifold as explained above
 Coordinate with the Jetty end and other Operators to resume Pumping and confirm if all is
well
 After the Pumping through the alternative line is completed, continue efforts to clear
the Choke in the first line and keep it purged with N2 ready for lining up, when required
 If the Choked line is SS (Phenol or Glycols), or dedicated line for Bitumen, there is no other
alternative than to Clear the Choke before restarting Pumping

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C. Corrective Actions - Line from Manifold to Storage Tank is Choked
Manifold & Field Operator
 If alternate Storage Tank is available divert the Product, under coordination with the
other Operators, divert the Product with appropriate connection of the hose to the
alternative Tank
 Otherwise the only option is to suspend the Pumping Operation until the Choke is
cleared
4.1.2 Breakdown maintenance during Unloading Products from the Ship

Transfer Line Leaks heavily involving Hot jobs
 Carry out the necessary activities mentioned below for handing over the line for the Hot job
Jetty Operator
 Get the Pump stopped in coordination with the Ship’s Captain

 Prepare for Pigging the Line from the Jetty to the Manifold
 In coordination with the other Operators Start Pigging from the Jetty to the Manifold followed
by N2 purging as explained above
 After N2 purging for about 1 hour, Check & Confirm if the line is Dry, N2 comes out with
Pressure from the drain point & no liquid is present
 Continue purging with N2, with periodical checks if the gas outlet of the drains is free of
HC / Inflammable material
 When the line is free of HC / Inflammable material, handover the appropriate segment
of the line for maintenance and necessary actions
 Alternative Options available to save time to avoid delay in Unloading the Ship due to
the maintenance on the line, are the same as above for Preventive maintenance
 After the Pumping through the alternative line is completed, continue with N2
Purging in the first line until free of HC / Inflammable material, handover the line for
maintenance and necessary actions

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277
2 3
Step wise Procedure for 4Ship Unloading to5 Dike I Tank .e.g. T-PHL-001 12
ZS9B-ld-OO£-VOl tn:H ~Nl~rnd ~ NOl1n81~USIO

OH""'° Dnam:1d ~O.:l rn~d
15
A 7 16 A
2
12
.. 3
8
5 10
4 6
14 11
1 9 lmES
13 1. PROUCT TRAHSf£R LINE FROM JETIY TO BE MANUALLY CONNECTE
B
1. Close the PLR Outlet valve (Jetty end) WITH HOSE CONNECTION TO INDMDUAL TANK flLUNC LINES BY
HOSE & QRC.
2. Connect Unloading Arm Outlet to to the Barred Tee (Jetty end) 2. COPPER JUMPERS TO BE PROVIDED OVER AU. FlANGES TD
MAINTAIN ELECTRICAL CONTINUITY.
3. INTERTANK TRANSf'ER TO BE CARRIED OUT BY CONNECTING
3. Close the Inlet / Outlet valve of the 2nd Barred Tee from the Manifold end DISCHARGE LINE OF SOLVENT TRANSf£R PUMPS TO RESPECTM
TANK f1U..JNG LINES.
4. ORC TO BE EQUIPPED WITH DRY-BREAK SYSTEMS TO AIJ.IYlf SPI
4. Close the PLR Outlet valve (Manifold end) 5.
FREE DISCONNECTION.
FlANGE Cl.JAROS TO BE PROVIDED FOR AU. FLANGE JOINTS.
5. Connect Hose from Barred Tee Inlet / Outlet line to line leading to the Correct Tank of Dike I 6.
7.
"' INDICATES MINIMUM DISTANCE.
VENT SHAU. BE PROVIDED WITH CHICAGO COUPLING.
8. DRAIN SHALL BE PRO'lllDED WITH CAMLOCK COUPLING.
6. Open isolation valves leading to the Tank 9. llllLITY STATION HAVING CONNECTION FOR COMPRESSED AIR,
NITROGEN AND SERVICE WATER SHAU BE CONNECTED WITH HOSE
CONNECTION.
c 7. Open valves on the Barred Tee Inlet / Outlet line to hose connection 10. AU. P1C SIGNALERS SHALL ME MECHANICAL TYPE WITH LOCAL c
8. Open the Inlet / Outlet valve of the 1st Barred Tee from the Manifold end 11. llllLITY STATION IS PROVIDED FOR P!CClNG MANIFOLD AT JETlY.
12. llllLITY STATION IS PROVIDED FOR PIGGING MANIFOLD AT DIKE-II.
13. llllLITY STATION IS PROVIDED FOR PIGGING MANIFOLD AT DIKE- I.
9. Open the valve between the two Barred Tees (Manifold end)
10. Clearance for Pumping from Control Room & Field Operators
11. Clearance for Pumping from the Manifold Operator
Legend
12. Open the Barred Tee Inlet / Outlet valve (Jetty end)
13. Clearance for Pumping from the Jetty Operator Valve Open
D 14. Communication to Ship's Captain to Start Pump Valve Closed D
15. Pump started on Ship and Product starts flowing T -1
16. Product flows to the Product Tank 'IY?E OF LINE NO.

FlLIID ALLOTED LINE NO. DELETED LINE NO.
Step wise Procedure for Ship Unloading to Dike II Tank e.g. To Naphtha Tank T-NPT-001
15 2
3 UTl.IJlES 52301-52800 52lCU-S231 $231'1 52319
E
12 8 E
.!:!.Q1.Q.S
1. DELETED.
2. NO. OF FLAME & CAS DETECTORS SHAU BE ANAUSED AFTER
14 11 LAYOUT flNAUSATlON BY HAFV..
10
1 9 4
13
J-JV'V-C
1. Close the PLR Outlet valve (Jetty end) NOTE-3,4
P-2»-c>.2-lh-52023-T
r 2. Connect Unloading Arm Outlet to to the Barred Tee (Jetty end) F
3. Close the Inlet / Outlet valve of the 1st Barred Tee from the Manifold end
4. Close the PLR Outlet valve (Manifold end) 6
7
5. Connect Hose from Barred Tee Inlet / Outlet line to line leading to the Correct Tank of Dike II
6. Open isolation valves leading to the Tank
7. Open valves on the Barred Tee Inlet / Outlet line to hose connection 16
8. Open the Inlet / Outlet valve of the 2nd Barred Tee from the Manifold end 5 DO NOT SCALE
c
Nfl'ROCEH
9. Close the valveNITROCEH
IG-:!O-CA1--~:Sll
between the two Barred Tees (Manifold end)
IG-50-<A1-fl-t111t
NITROOEH
-50-a.1--91149 HAZEL INTERNATIONAL FZE c
OlMICM. TERllH.ll. AT HAMRIYAH fR[£ ZM. ~ UAE
COIU'RCSSID NR r'"""=<......
10. Clearance
="-'~=1,.1,.1»._ _ _.,
for Pumping from Control RoomPf-8611
PHHtl
CA-50-CA1--1:tl29
& Field Operators
c:A>--'°""CA1--1!1DI
CXlMf'R£SS(]) . . .
Pl-1012 11. Clearance for Pumping from the Manifold Operator

"-1012 Pt-1012 ~~~·-·~T-AL-~, CAPITAL ENGINEERING CONSULTANCY
l_e. -.- -- -::-. P.O.BOX : 6825J, Shorjoh - U.AE.
WAW!
12. Open the Barred Pt-Be92 Tee Inlet / Outlet valve (Jetty
SE:RYICE W.\TER SDMC(
Pl-8&92 end) P&ID FOR PRODUCT
13. Clearance for Pumping NOT[-•
N<m:-•
NO'Tt-11
from the Jetty Operator
NOTt-12
NOTt-• NOTt-13
DISTRIBUTION & PIGGING
14. Communication
UTILITY STATION
to Ship's Captain to Start Pump
UTILITY STATION G TATA CONSULTING ENGINEERS LIMITED
FOR RO ISSUE ONLY 15. Pump started on Ship and Product starts flowing CL£AREll TATA MUMBAI
REVISIONS ORN
H
16. Product flows to the Product Tank H
278
2 3 4 9 10
Step wise Procedure for Ship Unloading to Dike I Tank .e.g. T-PHL-001
Legend
Valve Open
1 Valve Closed
2
3
1. Ensure that the Activated valve on the Inlet line is Open

2. Ensure that the Activated valve on the Outlet line is Closed
3. Product flows to Tank
279
Step wise Procedure for Ship Unloading to Dike II Tank .e.g. T-NPT-001
2
5

3. Ensure that the Activated valve on the line from C001 is Closed
5. Product Flows to Tank
280
2 3 4 5 12
Step ~Nl~rnd
wise Procedure for Pigging & N2 Purge after Ship Unloading to Dike I Tank e.g. T-PHL-001
ZS9B-ld-OO£-VOl tn:H ~ NOl1n81~USIO
OH""'° Dnam:1d ~O.:l rn~d
2 4
A
15 A
13
.. 3 5
14
8 11
6
1 12 7
9 10 lmES B
1. PROUCT TRAHSf£R LINE FROM JETIY TO BE MANUALLY CONNECTE
WITH HOSE CONNECTION TO INDMDUAL TANK flLUNC LINES BY
1. Message From & To Ship's Captain - 'Pumping completed Stop Pump' 2.
HOSE & QRC.
COPPER JUMPERS TO BE PROVIDED OVER AU. FlANGES TD
2. *Pumping Stopped & Line hold up to Unloading Arm N2 pushed for Safety 3. INTERTANK TRANSf'ER TO BE CARRIED OUT BY CONNECTING
DISCHARGE LINE OF SOLVENT TRANSf£R PUMPS TO RESPECTM
(*Feasibility to be worked out at the Ship & the Jetty based on facilities) 4.
ORC TO BE EQUIPPED WITH DRY-BREAK SYSTEMS TO AIJ.IYlf SPI
FREE DISCONNECTION.
3. Close the Inlet / Outlet valve of the Barred Tee (Jetty end) 5.
6.
7. VENT SHAU. BE PROVIDED WITH CHICAGO COUPLING.
4. Disconnect Unloading Arm Outlet (& Inlet from Ship) and clearance for Ship to sail 8.
9.
DRAIN SHALL BE PRO'lllDED WITH CAMLOCK COUPLING.
llllLITY STATION HAVING CONNECTION FOR COMPRESSED AIR,
5. Open the PLR Outlet valve (Manifold end) NITROGEN AND SERVICE WATER SHAU BE CONNECTED WITH HOSE
CONNECTION.
c 10. AU. P1C SIGNALERS SHALL ME MECHANICAL TYPE WITH LOCAL c
6. Clearance for Pigging & N2 Purge from Control Room & Field Operators 11. llllLITY STATION IS PROVIDED FOR P!CClNG MANIFOLD AT JETlY.
7. Clearance for Pigging from Manifold Operator 12. llllLITY STATION IS PROVIDED FOR PIGGING MANIFOLD AT DIKE-II.
13. llllLITY STATION IS PROVIDED FOR PIGGING MANIFOLD AT DIKE- I.
8. Prepare for Pigging (Jetty end)

9. Open the PLR Outlet valve (Jetty end)
10. Pigging from Jetty end to Manifold end Started Legend
11. Hold up liquid in the line pushed to the Tank
Valve Open
D
12. Check Pig receipt & Clearance for N2 Purge (Manifold end)
D
13. Connect Utility hose & Open N2 (Jetty end) T -1 Valve Closed
14. N2 Purge from Jetty end Started 'IY?E OF LINE NO.
LINE NO. DELETED LINE NO.
15. N2 Purge towards the Tank in progress FlLIID ALLOTED
Step wise Procedure for Pigging & N2 Purge after Ship Unloading to Dike II Tank e.g. To Naphtha Tank T-NPT-001
14 2 4 UTl.IJlES 52301-52800 52lCU-S231 $231'1 52319
3
E 9 15 .!:!.Q1.Q.S
E
8 7 1. DELETED.
LAYOUT flNAUSATlON BY HAFV..
1
11 13
10 6 5
J-JV'V-C
1. Message From & To Ship's Captain - 'Pumping completed Stop Pump' NOTE-3,4
r 2. *Pumping Stopped & Line hold up to Unloading Arm N2 pushed for Safety P-2»-c>.2-lh-52023-T
F
(*Feasibility to be worked out at the Ship & the Jetty based on facilities) 6. Clearance for Pigging &
16 N2 Purge from Control
3. Close the Inlet / Outlet valve of the Barred Tee (Jetty end)
4. Disconnect Unloading Arm Outlet (& Inlet from Ship) and clearance for Ship to sail Room & Field Operators
5. Open the PLR Outlet valve (Manifold end)
6. Open the isolation valves between the two Barred Tees (Manifold end) 12
7. Clearance for Pigging & N2 Purge from Control Room & Field Operators DO NOT SCALE
c
Nfl'ROCEH IG-:!O-CA1--~:Sll
8. ClearanceNITROCEH
for Pigging from Manifold Operator
IG-50-<A1-fl-t111t
NITROOEH
-50-a.1--91149 HAZEL INTERNATIONAL FZE c
9. Prepare forPHHtl Pigging (Jetty end) Pf-8611 OlMICM. TERllH.ll. AT HAMRIYAH fR[£ ZM. ~ UAE
COIU'RCSSID NR r'"""=<...... _ _.,
="-'~=1,.1,.1»._ CA-50-CA1--1:tl29 CXlMf'R£SS(]) . . .
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Pl-1012 10. Open the PLR Outlet valve (Jetty end)

"-1012 Pt-1012 ~~~·-·~T-AL-~, CAPITAL ENGINEERING CONSULTANCY
11. PiggingSE:RYICE
from Jetty end to Manifold end Started
W.\TER
Pt-Be92
WAW! SDMC(
Pl-8&92 P&ID FOR PRODUCT
N<m:-• 12. Hold up liquid in the
NO'Tt-11
NOT[-•line pushed to the Tank NOTt-•
NOTt-12 NOTt-13
UTILITY STATION UTILITY STATION
14. Connect Utility hose & Open N2 (Jetty end) CL£AREll
G TATA CONSULTING ENGINEERS LIMITED
FOR RO ISSUE ONLY TATA MUMBAI
ORN
H
15. N2 Purge fromREVISIONS Jetty end Started H
16. N2 Purge towards the Tank in progress

281
2 3 4 9 10
Step wise Procedure for Pigging & N2 Purge after Ship Unloading to Dike I Tank e.g. T-PHL-001
Legend
Valve Open
1 2 Valve Closed
1. N2 Purge of Product line from Jetty

2. Coordinate with Jetty & Manifold Operators to regulate N2
Pressure to avoid vigorous agitation in the Tank
282
Step wise Procedure for Pigging & N2 Purge after Ship Unloading to Dike II Tank e.g. To Naphtha Tank T-NPT-001
2
1
1. N2 Purge of Product line from Jetty

2. Coordinate with Jetty & Manifold Operators to regulate N2
Pressure to avoid vigorous agitation in the Tank
283
Step wise Procedure for Typical Ship Unloading Bitumen e.g. To T-BTM-001 (Dike II)
1. Close the PLR Outlet valve (Jetty end)

2. Connect Unloading Arm to the Barred Tee (Jetty end)
3. Close the PLR Outlet valve (Manifold end)
4. Close the valve for Dispatch to ship, Blind & Tag for Safety
5. Close the valve leading to the Tank Not selected for receiving Bitumen, Blind & Tag for Safety
6. Open the valve leading to the Tank Selected for receiving Bitumen
7. Close the valve on the discharge line of T-BTM-003 near Manifold, Blind & Tag for Safety
8. Close the valve on the discharge line of T-BTM-005 near Manifold, Blind & Tag for Safety
9. Open the isolation on the Inlet / Outlet line of the Barred Tee (Manifold end)
10. Open the Barred Tee Inlet / Outlet valve (Manifold end)
11. Clearance for Pumping from the Control Room & Field Operators
14. Clearance for Pumping from the Jetty Operator
15. Clearance for Pumping to the Ship's Captain
16. Pump Started on the Ship and Bitumen starts flowing
17. Bitmen to Tank T-BTM-001
16 2
13 5 Tag & Blind for Safety
Legend
10
Valve Open
15 Valve Closed
6
1 3 17
14
9
284
Step wise Procedure for Typical Ship Unloading Bitumen e.g. To T-BTM-001 (Dike II)
5 6
10
3
4

8
3. P-BTM-001 is Stopped
4. P-BTM-001 Suction valve is Closed 9
5. Activated valve on the Recycle line is Closed
6. Activated valve for TLF is Closed
7. Inter connecting valves between Suctions of P-TM-001 & P-TM-002 Closed
8. Drum Filling is not in Progress during this period
(P-BTM-004 is Stopped & valve to suction Closed)
9. Dispatch to Ship is not in progress during this period
(P-BTM-003 is Stopped & valve to Suction Closed)
10. Bitumen flows to Tank 285
Step wise Procedure for for Pigging & N2 Purge after Ship Unloading Bitumen e.g. To T-BTM-001 (Dike II)
Required for maintenance jobs on the line & extended Shut downs
1. Message From & To Ship's Captain - 'Pumping completed Stop Pump'

2. *Pumping Stopped & Line hold up to Unloading Arm N2 pushed for Safety
(*Feasibility to be worked out at the Ship & the Jetty based on facilities)
3. Close the Inlet / Outlet valve of the Barred Tee (Jetty end)
4. Disconnect Unloading Arm Outlet (& Inlet from Ship) and clearance for Ship to sail
5. Open the PLR Outlet valve (Manifold end)
6. Clearance for Pigging & N2 Purge from Control Room & Field Operators
7. Clearance for Pigging from Manifold Operator
8. Prepare for Pigging (Jetty end)
10. Pigging from Jetty end to Manifold end Started
11. Hold up Bitumen in the line pushed to the Tank
13. Connect Utility hose & Open N2 (Jetty end)
14. N2 Purge from Jetty end Started
15. N2 Purge towards the Tank in progress
4
13 2
8 14
3 Legend
Valve Open
15
1 Valve Closed
5 6
9 12
10
7 11
286
Step wise Procedure for for Pigging & N2 Purge after Ship Unloading Bitumen e.g. To T-BTM-001 (Dike II)
Required for maintenance jobs on the line & extended Shut downs
Legend
Valve Open
Valve Closed
Pump Running
Pump Stopped
1. Confirm that all valves remain as for Ship Unloading

2. N2 purge of the line in Progress to T-BTM-001
3. Monitor & coordinate with the Manifold & Jetty Operators to regulate N2 pressure to ensure that 3
vigorous agitation does not take place in the Tank
287
4.2 Unloading Products from Road Tankers

(P&ID TCE.7410A-300-PI-8685, -PI-8681, -PI-8682, -PI-8652)
Tankers can be Unloaded to the Storage Tanks or may be taken directly for Drum filling. Procedures
for both the Operations are detailed below under titles 4.2.1 and 4.2.2.
Unloading of Product should be preceded by posting Operators with assigned responsibilities

mentioned below for each position.
 Close coordination is required among Control Room Operator, Tanker Unloading Operator,
Manifold & Field Operator (near the Storage Tanks) / Drum Filling Operator.
4.2.1 Tanker Unloading to Storage Tanks
 Please refer to the Marked up drawings with Stepwise procedure enclosed, depicting the Actions
and Responsibilities amongst the Operators involved in the Operation, for Transfer of Products
from the Tankers to the Storage Tanks in Dike I and Dike II followed by N2 purge of the line, which
are detailed below
 The marked up drawings should be read in conjunction with the details given below, to
 Ensure that all the Flame and Gas detectors in the Tank Dike area, Pumping area and Open
in the Control Room
 Select “UNLOADING - TT” on the HMI
 Once the “Remote Auto” mode is selected, on selection of “UNLOADING - TT” for the Tank
on the HMI screen, confirm that the Inlet Actuated valve Opens Tank Outlet Actuated valve
Closes
Inlet valves from C-001 and C-002 of Process Block remain Closed in Remote Auto
mode
Actuated valves to TLF (XV 5304 / XV 5404) remains closed
 If the above conditions are fulfilled, the Tank shall be ready to receive the Solvent from
the Tanker
 Coordinate with the Tanker Unloading Operator, the Manifold Operator and the Field
Operator to Start Pumping the Product, when all of them are ready

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288
on Screen and confirm that there is increase in Level
 Receive information from the Tanker Unloading Operator, Manifold Operator and the
Field Operator regarding the Status at their respective ends and coordinate the
necessary actions.
b) Tanker Unloading Operator

to the Product to be transferred and the Location of the Tank to which the Product is to
be transferred is in Dike I or Dike II (and not for Direct Drum Filling)
 Make the necessary hose connections from the Tanker to the Suction of the requisite
Unloading Pump and the discharge line hose connections based on the following criterion:
 Base Oil (BOL) or Polyol (POL) – P-SOL-007 (Gear Pump) - Suction hose to the
Tanker Outlet and Discharge hose to Manifold for Dike I where BOL and POL Tanks are
located
 All other Products except Bitumen - P-SOL-008 (Centrifugal Pump) – Suction hose to
the Tanker Outlet. Discharge hose to the Piping Manifold of Dike I or Dike II, where the
Storage Tank is located
 Bitumen – P-BTM-005 (Gear Pump) - Suction hose to the Tanker Outlet.

Pump discharge line is a permanent electrically traced line leading to Piping Manifold for
Dike II, where the Bitumen Tanks are located and requires no hose connection
 Coordinate with the Control room, Manifold and Field Operators before Starting the
Pump
 Coordinate with the Control Room Operator, Manifold Operator & the Field Operator
(near the Storage Tank) if there is no leakage and all is well
 If leakages are observed near the Pump or in the Manifold or in the Field, Stop the
pump immediately
Restart Pumping
 After completion of Pumping, under coordination with the Control Room and other
Operators, carry out the N2 purging of the lines as depicted in the Marked up
drawings enclosed and explained below for the following 3 cases:
 Products Pump Centrifugal Pump P-SOL-008
 Products Pump Gear Pump P-SOL-007
 Bitumen Pump Gear Pump P-BTM-005
a) N2 Purging For Products Pumped to Tank through Centrifugal Pump P-SOL-008
 Stop the Pump

 Close the Suction & Discharge valves of the Pump that was in service
 Connect Utility hose connection to the connection point on the discharge line of the Pump
P-SOL-008
 Close the Pump Suction & Discharge valves for P-SOL-008 & and Open the

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289
Recirculation valve
 Coordinate with the Manifold Operator to Close the Tanker Unloading Pump
discharge vale leading to the Manifold
 Open Utility N2 valve and Crack open (around 10%) the Utility connection isolation
valve to ensure that N2 does not flow back to the Tanker with pressure but only
gently pushes the holdup volume in the Suction hose back to the Tanker, to ensure
Safety (of the Tanker Unloading Operator) while disconnecting the Suction hose from
the Tanker Outlet
 Close the Tanker Outlet valve
 Close the isolation valve on the Tanker discharge header
 Disconnect the Connection hose from the Tanker, taking care not to spill the small holdup
liquid in the hose, if any, on to the body or face
Goggles to avoid injury to self
 Coordinate with the Control room Operator and Manifold Operator, before starting N2
Purging of the Pump discharge line to get the line free of hold up volume of Product
and get it ready for discharging other Products through the same line without
contamination
 Coordinate with the Manifold Operator to Open the Tanker Unloading Pump
discharge valve leading to the Manifold
 Keep the Suction & Discharge valves of the Pump Closed
 Open the Utility connection valve and N2 valve to Start N2 purging of the line
 When N2 purging is complete, close the Utility connection valve and the N2 valve
b) For Products Pumped by Gear Pumps P-SOL-007 & T-BTM-005 (Bitumen)
 Stop the Pump

 Close the Suction & Discharge valves of the Pump
 Connect Utility hose for N2 to the drain valve for N2 Purge of Tanker Unloading line
 Crack open (10-15%) the N2 Utility valve first and then Open the drain valve to prevent
Bitumen backing into the hose
 Open the Suction valve (10-15%)
 Open the Tanker Outlet valve (10-15%) to back flush the line hold up of Bitumen to the
Tanker
 Caution: Monitor pressure of N2 prevent vigorous agitation & spill of the Product
from the top of the Tanker with mandatory Safety gears
 Close the Tanker discharge header valve (Not applicable for Bitumen since there is No
discharge header valve for Bitumen)
 Disconnect the Connection hose from the Tanker, taking care not to spill the small
holdup liquid in the hose, if any, on to the body or face
 The Operator should wear Safety gears like Helmet, Coverall, Face shield and
Goggles to avoid injury to self
 Release the Tanker
 Connect Utility hose connection to the connection point on the discharge line of the Pump

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290
 For Bitumen, there is no risk of contaminating other Products. Hence there is no need
to flush the discharge line of P-BTM-005 each time after Tanker Unloading, if the time
span between two transfers is not long, since the lines are electrically traced to keep
the holdup Bitumen warm. However for extended shut downs and Hot maintenance
job on the line, N2 purge of the discharge line is required.
 However for Other Products pumped through P-SOL-007, it is desirable to N2 Purging
of the discharge line after Pumping each Product to prevent contamination as
follows:
 Coordinate with the Control room Operator and Manifold Operator, before starting N2
Purging of the Pump discharge line to get the line free of hold up volume
 Coordinate with the Manifold Operator to keep Open the Tanker Unloading Pump
discharge vale leading to the Manifold
 Keep the Suction & Discharge valves of the Pump Closed
 Open the Utility connection valve and N2 valve to Start N2 purging of the line
 For carrying out Hot maintenance job on either the Suction or Discharge line of the
Pump, the respective line should be N2 purged for sufficient length of time to fully
displace the liquid from the line and until the gas samples at different drain points on
the line confirm that the line is free of HC / Inflammable material
 When N2 purging is complete, close the Utility connection valve and the N2 valve
c) Manifold Operator
 Coordinate & Reconfirm with the Control Room Operator and the Tanker Unloading
Product is to be transferred is in Dike I or Dike II Or for Direct Drum Filling
 If the Product is diverted to Storage Tank (all Products except Bitumen), connect a hose
to the QRC of the line from the discharge of the Tanker Unloading Pump in Dike I or Dike II
Manifold as applicable
 Connect the QRC on the other end of the hose to the QRC on the line leading to the Storage
Tank of the Product
 Confirm that the two ends of the hose are correctly connected to avoid pressurizing
the wrong Product line / Discharge to the wrong Tank
 Open the isolation valves on the line from the discharge of Tanker Unloading Pump and the
line leading to the Correct Storage Tank
 Coordinate with the Control Room Operator and the Tanker Unloading Operator and give
clearance for Starting the pump
 Coordinate with the Control Room Operator, Tanker Unloading Operator & the Field
Operator (near the Storage Tank) if there is no leakage and all is well
 If leakages are observed near the Jetty or reported from the Manifold or in the Field,
coordinate with the Tanker Unloading Operator to Stop pumping immediately
give clearance to the Ship’s Captain to Restart Pumping

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291
 If the Product is Bitumen, it should be directed to Bitumen Storage Tank

 Coordinate and confirm from the Control Room Operator if the product is to be sent to
T-BTM- 001 or 002
 Close the Ship Unloading valves both on the Barred Tee and after Barred Tee (Please
note the Caution below)
 Close Bitumen Transfer Pump P-BTM-003 discharge valve near the Manifold (Please
note the Caution below)
 Close the isolation valve that is Not the intended Tank for transfer (Please note the
Caution below)
 Open the Isolation valve Tanker Unloading Pump T-BTM-005 discharge near the
Manifold
 Open the isolation valve to the Correct Tank T-BTM-001 or T-BTM-002 to which
Bitumen is to be transferred
 Open the Common discharge valve for Tanks
 Give clearance for Starting the Pump
Caution
 Tanker Unloading cannot take place when Ship Unloading / Dispatch to Ship is in
Progress
commencement of Truck Unloading to avoid serious accidents due to manual error
during Truck Unloading Operations
 Bitumen Transfer Pump P-BTM-003 should be Electrically Isolated and Tagged
 After completion of pumping, Coordinate with the Control room Operator, and the
Tanker Unloading Operator, for starting N2 Purging of the Pump discharge line to get
the line free of hold up volume of Product
d) Drum Filling Operator
 Responsibilities:
 No responsibilities in Transfer of Tanker Unloaded Product to Storage Tanks
e) Field Operator (near the Storage Tanks)
 Coordinate & Reconfirm with the Control Room Operator and the Tanker Unloading
Product is to be transferred is in Dike I or Dike II (and not for for Drum Filling)
 If the Product is sent to the Storage Tank, confirm that the Actuated Inlet valve of the selected
Product Tank is Open in the field
 Other Actuated valves viz. Tank Outlet, for TLF and for Drum Filling are Closed in the field.

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292
 Dike II Tank (Except Bitumen) - If the Product Tank is T-NPT-001, T-NPT-002, T-NPT-
003, T-MEG-001, T-XYL-001, Confirm that Actuated Inlet valves from C-001 and C-002
of Process Block are Closed in the field
Actuated valve to TLF (XV 5304 / XV 5404) is Closed in the field
 TLF Transfer Pump - Stopped and its Suction & Discharge valves are Closed
 Coordinate with the Control Room, Tanker Unloading Operator and the Manifold Operator and
give clearance to Start the Pump
 Coordinate with the other Operators mentioned above if there is no leakage and all is well
 If leakages are observed near the Storage Tank, coordinate with the Tanker Unloading
Operator, Manifold and Control Room Operator to Stop pumping immediately
 Carry out the corrective actions for leakage and give clearance to the Tanker Unloading
Operator, Manifold and Control Room Operator to Restart Pumping
 After the Pumping is started, monitor the Level of the Product Tank and confirm that there is
increase in Level on the Level Indicator
 Act in coordination with the Control Room, Tanker Unloading and Manifold Operators to
ensure that the line is N2 purged free of liquid
4.2.2 Tanker Unloading for Drum Filling
 Ensure that all the Flame and Gas detectors in the Tank Dike area, Pumping area and Open
 Select “UNLOADING – TT - DRUM”
 Once the “Remote Auto” mode is selected, on selection of “UNLOADING – TT - DRUM” for
the Tank on the HMI screen,
 Coordinate with the Field Operator & Drum Filling Operator and when they are ready, Open
the Actuated valve at the Inlet of Drum Filling Unit XV 8201 (Bitumen) / XV 8202 (Other
Products)
 If the above conditions are fulfilled, the Drum Filling Unit shall be ready start receiving
the Solvent from the Tanker for Drum Filling.
 Coordinate with the Tanker Unloading Operator and the Drum Filling Operator to Start
Pumping the Product, when all of them are ready
 Receive information from the Tanker Unloading Operator and the Drum Filling Operator
regarding the Status at their respective ends and coordinate the necessary actions.
b) Tanker Unloading Operator

 Responsibilities are basically the same as above for Tanker Unloading to Storage Tanks,
except the Transfer Pump discharge line connections and coordination with the Drum

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Filling Operator instead of the Manifold & Field Operators, which alone are mentioned
below, other responsibilities being the same
 Make the necessary hose connections from the Tanker to the Suction of the requisite
Unloading Pump and the discharge line hose connections based on the following criterion:
 Base Oil (BOL) or Polyol (POL) – P-SOL-007 (Gear Pump) - Suction hose to the
Tanker Outlet and Discharge hose to the Drum Filling Unit
 All other Products except Bitumen - P-SOL-008 (Centrifugal Pump) – Suction hose to the
Tanker Outlet and Discharge hose to the Drum Filling Unit
 Bitumen – P-BTM-005 (Gear Pump) – Can only be diverted to Storage Tanks as

mentioned above and cannot be sent for Drum Filling
 Coordinate with the Control Room Operator and the Drum Filling Operator for the
following purposes
 If there is no leakage and all is well
 Before starting N2 Purging of the Pump discharge line
c) Manifold Operator
 No specific responsibilities for the Manifold Operator in Drum Filling of Tanker

Unloaded Product
d) Drum Filling Operator
 Coordinate with the Field Operator & Control Room Operator Confirm that Actuated
valve from Drum filling - XV 8201 (Bitumen) / XV 8202 (Other Products)
is Opened
 Place the Drum/s of the correct Grade near the filling nozzle and align the nozzle to the Drum
Filling Opening
 Confirm that all the isolation valves on the header for Drum Filling of Solvents are kept Closed
 Crack Open (around 20%), the isolation valve on the line from the discharge of Tanker
Unloading Pump
 Coordinate with the Control Room Operator and the Tanker Unloading Operator and give
clearance for Starting the pump
 Once flow starts coming from the Drum filling nozzle, adjust the opening of the isolation valve
on the header to convenient level as required
 After Pumping and Drum Filling completion, Coordinate with the Control room and
Tanker Unloading Operator for N2 Purging of the Pump discharge line and fill the
holdup volume in Drums to get the line free of hold up volume of Product and get it
ready for discharging other Products through the same line without contamination
 For Bitumen to prevent solidification & choking of line during long shut downs

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 It is important that the Drum Filling Operator wears Protective gears like Helmet,
Coverall, Face shield & Goggles before commencement of N2 purging to avoid
splashing of the liquid onto the face in case of excess N2 Pressure
 Keep the isolation valve on the header throttled (about 15% Open) prior to
commencement of N2 purging
 When the line is fully purged and Dry N2 starts coming out from the filling nozzle, coordinate
with the Control Room and Tanker Unloading Operator and get the N2 purging stopped
 If there are partly filled Drums left at the end of Filling directly from the Tanker and N2
Purging, keep the Drums closed and segregated, so that they can be filled with the same
material at opportune time
e) Field Operator (near the Storage Tanks)
 No specific responsibilities for the Field Operator in Drum Filling of Tanker Unloaded
Product
4.2.3 Preventive maintenance during Tanker Unloading

i) Pump (P-SOL-007 (Polyol & Base Oil) / P-SOL-008 (Bitumen) trips on
Starting
 The Field Operator should Check the Pump for any abnormalities
 If there is no problem with the Pump, then check for one of the probabilities
 One of the isolation valves might not have been opened
 Pump might have got decoupled
 In the above two cases, the Pump might be tripping due to No Flow and Activation of PS
(for Gear Pumps) on the Pump discharge line
 In case the problem is identified to be one of the above, the solution to the problem is
known
 The problem should be attended to resume Operations
ii) Discharge line of the Transfer Pump is Choked or other Cold jobs
 If there is no problem on account of reasons mentioned above under i), the line may be choked
 If so Stop the Pump
 Try to ascertain the segment of choke viz. Pump discharge to the Manifold or Manifold to the
Storage tank or Pump discharge to the Drum filling unit, by opening the drain points and checking
 Under coordination with all the other Operators, (Tanker unloading Operator) start N2 purging of
the line as detailed above and depicted in the enclosed Marked up drawing with stepwise
procedure
 Tap the line at different places with a wooden mallet and check the drain points with throttled
opening (10-15%)
 Safety gears like Helmet, Coverall, Face shield and Goggles are mandatory
requirements to safeguard against the Product splashing onto the face and body
 If the choke cannot be identified or cleared, get the Tanker Unloading Pump electrically
isolated and open flanges at different segments and clear the line segment by segment

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 Carry out any other Cold job like Instrumentation problems etc.
 Restart Pumping after reinstatement of the System to original positions
4.2.4 Breakdown maintenance during Unloading of Tanker

i) Transfer Line Leaks heavily involving Hot jobs
 Stop Pump stopped in coordination with all the Operators

 Start N2 Purging of the line as explained above
 After N2 purging for about 1 hour, Check & Confirm if the line is Dry, N2 comes out with
 Continue purging with N2, with periodical checks if the gas outlet of the drains is free of
 When the line is free of HC / Inflammable material, handover the line for
 Restart Tanker Unloading after reinstatement of the System to original conditions

 Transfer of Other Product/s through Other Pump/s and Line/s may be scheduled during this
period
ii) Tanker Unloading Pump breakdown
 Since there is only one pump of each category and no Standby pump is available, there is no other
alternative than to suspend Tanker Unloading through that specific Pump until the Pump is
rectified / replaced
 Close the Pump Suction & Discharge valves
 Isolate the Pump electrically
 If the Tanker has to be released without Unloading / Partial Unloading, carry out the N2 purge
of the Suction line as detailed above & disconnect the Pump suction hose taking care not to spill
the holdup liquid in the hose on to the body or face
 The Operator should wear Safety gears like Coverall, Face shield and Goggles to
safeguard against injury to self
 Close the Tanker Outlet valve and Release the Tanker
 Purge the discharge line of the Pump with N2 as explained above

 Handover the Pump for Maintenance / Replacement
 Transfer of Other Product/s through Other Pumps may be scheduled during this period
 Tanker Unloading with the same Pump (handed over to maintenance) may be restarted after
the Pump is returned after maintenance and the lines & valves are reinstated to original
position

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Marked up drawing for Typical Tanker Unloading to Dike I & II Tanks
i) Case 1- T-BOL-001(Dike I), ii) Case 2- T-NPT-001(Dike II)
Case 1
1. Tanker at Bay for P-SOL-007

2. Connect hose
3. Refer next sheet
Legend
4. Refer next sheet
5. Refer next sheet Valve Open
6. Open the valve on the Tanker discharge header
7. Open Tanker Outlet valve Valve Closed
1
6
7
1 2 Case 2
1. Tanker at Bay for P-SOL-008
6 2. Connect hose
5
3. Refer next sheet
4. Refer next sheet
5. Open the valve on the Tanker discharge header
6. Open Tanker Outlet valve 297
Case 1
1. Ref. Previous sheet
3. Connect hose
4. Open the Suction valve
5. Open the discharge valve
Legend
8. Clearance from Manifold Operator
9. Start the Pump Valve Open
10
10. Close the Recirculation valve
5 Valve Closed
3 11. Product to Dike I Manifold
4
11
Pump Running
9
8
10
9
Case 2 11
3
7
4
8
3. Connect hose
4. Open the Suction valve
7. Clearance from Manifold Operator
8. Start the Pump
11. Product to Dike II Manifold
298
Legend
Valve Open
Valve Closed
5
Case 1
2 4
1. Connect hose 1
2. Open the Destination Tank valves near Manifold
3. Open the discharge valves of Tanker Unloading Pump (P-SOL-007)
4. Clearance to Tanker Unloading & Control Room Operators to Start Pump
3
5. Product to Destination Tank (T-BOL-001)
Case 2
1. Connect hose 2
2. Open the Destination Tank valves near Manifold
3. Open the discharge valves of Tanker Unloading Pump (P-SOL-007)
1 3
4. Clearance to Tanker Unloading & Control Room Operators to Start Pump 4
5. Product to Destination Tank (T-NPT-001)
299
Case 1
Legend
Valve Open
Valve Closed
Pump Running
Pump Stopped
3 1

300
Case 2
Legend
Valve Open
Valve Closed
Pump Running
Pump Stopped
2
5

301
Procedure for N2 Purging - After Tanker Unloading & For Maintenance
Case 1
1. Refer the next sheet
2. Close Tanker Outlet valve
3 to 7. Refer Next sheet
8. Open the Tanker Outlet valve (10-15%) to back flush the line hold up of
Bitumen to the Tanker Legend
Caution:
Monitor pressure of N2 to prevent vigorous agitation & spill of the Product Valve Open
Valve Closed
9. Close the Tanker Outlet valve
12 10. Close the Tanker discharge header valve
11 11. Disconnect hose to Tanker & Release Tanker with mandatory Safety gears
12. Release Tanker
10
8&9
11 Case 2
1 to 7. Refer next sheet
8
8. After N2 Push of holdup liquid to Tanker, Close Tanker Outlet valve
10 9 9. Close the Tanker discharge header valve
10. Disconnect hose to Tanker with mandatory Safety gears
11. Release the Tanker
302
1. Stop Pump
2. Refer to Previous sheet Procedure for N2 Purging - After Tanker Unloading & For Maintenance
3. Close the Suction valve i) Case 1- T-BOL-001(Dike I), ii) Case 2- T-NPT-001(Dike II)
4. Close the Discharge valve Case 1
5. Connect Utility hose for N2 to the drain valve for N2 Purge of Tanker Unloading line
6. Crack open (10-15%) the N2 Utility valve first and then Open the drain valve
to prevent Bitumen backing into the hose Discharge line purging
7. Open the Suction valve (10-15%) 15. Connect Utility hose for N2 on the Pump discharge line connection
8 to 12. Refer previous sheet 16. Inform Control Room, Field & Manifold Operators about Start N2 purge of discharge line 16
13. Close the drain valve first and the Close the Utility N2 valve 17. Crack Open (10-15%) Utility N2 first & then Open the Utility valve
14. Remove the Utility hose connection to the drain & Open the drain valve (10%) to 18. N2 purge in progress to Dike I Manifold
depressurize the Pump Suction line of N2 pressure with Safety precautions Legend
Valve Open
15
Valve Closed
17
7
18
6
3 1 4
5 13
14 Case 2
5
15
6
1 7
1. Close the Discharge valve

2. Stop the Pump
3. Close the Suction valve
4. Coordinate with Manifold Operator to Close Pump P-SOL-008 discharge valve near Manifold
5. Connect Utility hose for N2 purge of Suction line 4
6. Open N2 & Crack Open Inlet valve (10-15%)
7. Open the Recirculation valve
2 8 to 11. Refer the previous sheet
3 12. Keep N2 valve Closed until Start of Discharge line purging
Discharge line purging

13. Coordinate with Manifold Operator to Open Pump discharge valve near Manifold for N2 Purge 13&14
14. Inform Control Room, Field & Manifold Operators of N2 Purge of discharge line & Open N2 valve
15. N2 purge in progress to Dike I Manifold
303
Legend
Valve Open
Valve Closed

Case 1
1. When informed by Manifold Operator Confirm Unloading Pump discharge 1

valve Open for N2 purge of line up to Tank
2. N2 purge to T-BOL-001
Case 2
1. When informed by Manifold Operator Close Unloading Pump discharge valve

2. When informed by Manifold Operator Open Unloading Pump discharge valve for N2 purge of line up to Tank 1&2 3
3. N2 purge to T-NPT-001
304
Case 1
Legend
Valve Open
Valve Closed
Pump Running
Pump Stopped
1. When informed by Unloading Operator Confirm that all valves remain as for Tanker Unloading
2. N2 purge of the line in Progress to T-BOL-001 1
3. Monitor & coordinate with the Tanker Unloading Operator to regulate N2 pressure to ensure that
vigorous agitation does not take place in the Tank 3
305
Case 2
Legend
Valve Open
Valve Closed
3 Pump Running
2
Pump Stopped
1. When informed by Unloading Operator Confirm that all valves remain as for Tanker Unloading 1
2. N2 purge of the line in Progress to T-NPT-001
3. Monitor & coordinate with the Tanker Unloading Operator to regulate N2 pressure to ensure that 3
306
Marked up drawing for Typical Tanker Unloading Bitumen to T-BTM-001 (Dike II)
Legend
1. Bitumen Tanker at Bay

2. Connect hose
3. Refer next sheet
4. Refer next sheet
5. Open Tanker Outlet valve
1
2
307
Legend
Valve Open
Valve Closed
Pump Running
Pump Stopped
1. Refer previous sheet

3. Open Suction valve
4. Open discharge valve
6. Clearance for Pumping from the Manifold Operator 6
7. Start the Pump
8. Bitumen to Manifold
7 4 8
3
308
Legend
Valve Open
Marked up drawing for Typical Tanker Unloading Bitumen to T-BTM-001 (Dike II) Valve Closed
1. Close the valve Not for Transfer (T-BTM-002) , Blind & Tag for Safety Blind
2. Open the valve leading to the Destination Tank
3. Open the common isolation valve leading to the Tanks Valve Tag for Safety
4. Close the valve on Barred Tee Inlet / Outlet line, Blind & Tag for Safety
5. Close Transfer Pump P-BTM-003 discharge valve near the manifold , Blind & Tag for Safety
6. Open Tanker Unloading Pump P-BTM-005 discharge valve near manifold
7. Clearance to Start the Pump
8. Bitumen to T-BTM-001
1
3
8
2
4 5
309
5 6
1
Legend
Valve Open
Valve Closed
Pump Running
10
Pump Stopped
3
4

8
3. P-BTM-001 is Stopped
4. P-BTM-001 Suction valve is Closed 9
5. Activated valve on the Recycle line is Closed
6. Activated valve for TLF is Closed
7. Inter connecting valves between Suctions of P-TM-001 & P-TM-002 Closed
8. Drum Filling is not in Progress during this period
(P-BTM-004 is Stopped & valve to suction Closed)
9. Dispatch to Ship is not in progress during this period
(P-BTM-003 is Stopped & valve to Suction Closed)
10. Bitumen flows to Tank 310
Procedure for N2 Purging After Tanker Unloading & For Maintenance - Bitumen to T-BTM-001 (Dike II)
1. Refer Next sheet

2. Close Tanker Outlet valve
3. Refer Next sheet
4. Refer Next sheet
5. Refer Next sheet
6. Refer Next sheet
7. Refer Next sheet
8. Open the Tanker Outlet valve (10-15%) to back flush the line hold up of
Bitumen to the Tanker
Caution:
Monitor pressure of N2 to prevent vigorous agitation & spill of Bitumen
9. Close the Tanker Outlet valve
10. Refer Next sheet
13 11. Refer Next sheet
12. Disconnect hose to Tanker & Release Tanker with mandatory Safety gears
2 13. Release Tanker
12
8&9
311
Procedure for N2 Purging After Tanker Unloading & For Maintenance - Bitumen to T-BTM-001 (Dike II)
1. Stop Pump
3. Close the Suction valve
4. Close the Discharge valve
5. Connect Utility hose for N2 to the drain valve for N2 Purge of Tanker Unloading line
6. Crack open (10-15%) the N2 Utility valve first and then Open the drain valve
to prevent Bitumen backing into the hose
7. Open the Suction valve (10-15%)
9. Refer Previous sheet
10. Close the drain valve first and the Close the Utility N2 valve
11. Remove the Utility hose connection to the drain & Open the drain valve (10%) to
depressurize the Pump Suction line of N2 pressure with Safety precautions
Discharge line flushing required Only for Hot maintenance job on the line / Extended Shut down
14. Connect Utility hose for N2 on the Pump discharge line connection
15. Inform Control Room, Field and Manifold Operators about Starting N2 purge of discharge line
16. Crack Open (10-15%) Utility N2 first & then Open the Utility valve
14
7 3 15
4
16
6 1
10
5
11
312
Legend
Valve Open
Valve Closed
Blind
Procedure for N2 Purging of Tanker Unloading line & For Maintenance & Extended Shut downs - Bitumen to T-BTM-001 (Dike II)
Valve Tag for Safety
1. When informed by Unloading Operator Confirm that all valves remain as for Tanker Unloading 1
2. N2 purge of the line in Started from the Tanker Unloading Pump T-BTM-005 discharge
3. N2 Purge to T-BTM-001
313
Procedure for N2 Purging of Tanker Unloading line & For Maintenance & Extended Shut downs - Bitumen to T-BTM-001 (Dike II)
Legend
Valve Open
Valve Closed
Pump Running
2
Pump Stopped
1. When informed by Unloading Operator Confirm that all valves remain as for Tanker Unloading
2. N2 purge of the line in Progress to T-BTM-001 1
3. Monitor & coordinate with the Tanker Unloading Operator to regulate N2 pressure to ensure that 3
314
4.3 Inter-Terminal Transfer of Products

(P&ID TCE.7410A-300-PI-8686, -PI-8652)
One No. SS 304 line is provided connecting the McGraw Terminal and this New Terminal through a
10” line. PLR-009 (New Terminal end) and PLR-010 (McGraw Terminal end) are provided for Pigging
of the line.
The Procedures for Inter Terminal transfer of Products is similar to the transfer of Products from
Product Transfer from the Ship to the Terminal and vice versa. Given below are the Salient features:
 Since the line is SS 304, the same line can be used for all Products meant to be in Stored in
Storage Tanks of Dike I and Dike II including Polyols and Glycols but Except Bitumen
 Since the PLRs PLR-009 and PLR-0010 are bi-directional, they serve for Pigging of lines both
ways between the two Terminals viz. The New Terminal and the McGraw Terminal
4.3.1 Transfer from the McGraw Terminal to the New Terminal
 Procedure for the Transfer from the McGraw Terminal to the New Terminal is the same as
described above for explained above under 4.1 Unloading Products from the Ship
 The differences are only in the designation of the Origin and the mode of connection of
the Product to the sending PLR viz. PLR-010
 The Origin of Supply in this case is the McGraw Terminal instead of the Ship
 The Supply to the Barred Tee of the Supply PLR-010 is through a permanent SS
304 line, instead of a temporary connection to the Barred Tee of the Supply PLR at
the Jetty from the Unloading Arm
The assignment of responsibilities for the Operators are basically the same as mentioned for
Unloading Products from Ship, with the basic differences mentioned below:
 Close coordination is required among Control Room Operator, McGraw Terminal Operator,
Manifold & Field Operator (near the Storage Tanks) / Drum Filling Operator.
 The Selection of Tank and the Function may be the same as for Ship Unloading viz.
in the Control Room
 “RECEIPT – JETTY” on the HMI Screen
 However, it should be ensured that No Ship Unloaded Product is routed to the selected
Tank during this period
 Other Functions are the same as for Ship Unloading, except that the Co-ordination is
with the McGraw Terminal end Operator
b) McGraw Terminal end Operator (of the New Terminal)
 The Operator of the New Terminal assigned for transfer of Product from the McGraw
Terminal shall coordinate with his counterparts / designated person of the McGraw
Terminal for all matters including - Starting & Stopping of Transfer Pump, Pigging from
the McGraw Terminal end, N2 Purging etc.

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 Responsibilities remain the same as for Ship Unloading, excepting that the
coordination has to be with the McGraw Terminal end Operator instead of the Jetty end
Operator
d) Field Operator (near the Storage Tanks)
 Responsibilities remain the same as for Ship Unloading, excepting that the
coordination has to be with the McGraw Terminal end Operator instead of the Jetty end
Operator
4.3.2 Transfer from the New Terminal to the McGraw Terminal
 Procedure for the Transfer from the New Terminal to the McGraw Terminal is the same as
described in the subsequent section Dispatch to Ship of Products from Storage Tanks
 The differences would only be the designated Operator at the McGraw Terminal instead
of the Jetty and the Coordination of all the assigned Operators with the McGraw
Terminal end Operator (instead of the Jetty end Operator)
4.3.3 Preventive maintenance during Inter Terminal Transfer of Products

 Procedure for Preventive maintenance is the same as described above for Unloading
Products from the Ship, the only difference being the McGraw Terminal end replacing the
Jetty end
4.3.4 Breakdown maintenance during Terminal Transfer of Products

 Procedure for Breakdown maintenance is the same as described above for Unloading
Products from the Ship, the only difference being the McGraw Terminal end replacing the
Jetty end

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4.4 Support Systems in Operation & Parameters for Specific Products
Some Products detailed in the following paragraphs require controlled parameters to retain their
properties, which are critical for further Operations and their Salability. The Startup and Operation of
all the Support Systems have been covered in the preceding Chapter/s and given in the following
sections are only the vital parameters to be maintained.
4.4.1 Thermic Fluid System for Bitumen Storage Tanks T-BTM-001 & 002
 Bitumen should be stored at 120 deg. C in their Storage Tanks, to prevent Solidification, keep it
molten in liquid state and maintain its properties
 Towards achieving the above objective the following should be ensured
Thermic Fluid System
 The Startup & Operation of the Thermic Fluid System is detailed under Chapter 3 and paragraph
3.9
 Before the expected intake of Bitumen into the Storage Tanks, Reconfirm that System and all the
Equipment that are part of the System are in perfect working condition
 Establish circulation Thermic Fluid through one of the circulation pumps e.g. PTF 006A
through one of the Furnaces e.g. E-TF-008A through the Coils of E-BTM-001 & E-BTM-002
with return back to the Deaerator cum Expansion Tank
 Fire Furnace E-TF-008A and reconfirm that the Burner Management System is alright
 Repeat the above with circulation pump PTF 006B and inline E-TF-008B and confirm that the
entire System is alright
 The above check of the Total System would ensure that Unit taken into Operation and the
Standby Unit are both available
 In case of maintenance or breakdown of the Operating Unit, the Standby Unit is ready
to go into Operation
 Once the Total Check of the System consisting of all the Units is done as mentioned above, Select
any one of the circulation Pumps e.g. PTF 006A and any one of the Furnaces e.g. E-TF-008A
 Fire the Furnace just before intake of Bitumen into the Storage Tanks
 Further Settings and Operations are from the Storage Tank end as given below
Bitumen Storage Tanks T-BTM-001 & T-BTM-002
 Monitor the Level of the Bitumen Storage Tank T-BTM-001 / T-BTM-002 into which Bitumen is
being taken either through Ship Unloading or through Tanker Unloading as detailed above
 Keep the initial setting of Three Port Valve of TPV 5301 / TPV 5401 at around 80 deg. C until the
Bitumen starts flowing into the tank and there is level increase in the Tank
 When level increase is noted, slowly increase the TPV 5301 / TPV 5401 settings in Steps of 10
deg. C to avoid overheating of coils without material in the Tank
 When the Low Low Alarm goes off, keep the TPV setting at 120 deg. C and maintain the
same setting
 After the transfer to the Tank is complete and no further transfer is there from any source, carry
out the following

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 Select “RECIRCULATION” on the HMI Screen of the Selected Tank

 Confirm that Actuated valves XV 5301 (Tank Outlet) and XV 5303 are Open and all other
valves are Closed
 Confirm that the NO Recirculation valve of the Tank is Open
 Start the Pump P-BTM-001 / P-BTM-002 into which Bitumen has been taken
 Keep Bitumen on Recirculation until need arises for any other Unit Operation
connected to the Tank viz. Dispatch to Ship / Truck Loading / Drum Filling / Transfer
one from One Bitumen Tank to the Other
4.4.2 Electric Heater for Phenol Storage Tank T-PHL-001
 Monitor the Level of the Phenol Storage Tank T-PHL-001 into which Phenol is being taken either
through Ship Unloading or through Tanker Unloading as detailed above
 Monitor the Level increase in the Tank
 Keep the Setting of the Electric Heater provided in the Tank at 50 deg. C and maintain the same
set point and Temperature
 The temperature of Phenol should be maintained above 40 deg. C to prevent Crystallization
4.4.3 Chilled Water System for Styrene & VAM Storage Tanks
T-STY-001 & T-VAM-001
 Styrene and VAM should be stored at 20 deg. C in their respective Storage Tanks to prevent their
Polymerization at higher temperatures (above 55 deg. C)
 Polymerization inhibitor dozing Systems are also installed for both the Storage Tanks to
prevent their Polymerization and maintain their properties
 The Chilled Water System is installed to maintain the Temperatures of Styrene and VAM at 20
deg. C
Chilled Water System
 The Startup & Operation of the Chilled Water System is detailed under Chapter 3 and paragraph
3.4
 Before the expected intake of Styrene / VAM into their Storage Tanks, Reconfirm that System and
all the Equipment that are part of the System are in perfect working condition
 Confirm that the Chilled Water Inlet & Outlet valves of the Exchanger E-STY-001 / E-VAM -
001 are kept Open
 Establish circulation in the Chilled Water Loop - From the Chilled Water Package through
VAM & Styrene Heat Exchangers and back to the Package - by running one of the Primary
Pumps (Suction from Hot Well) PM-5040A / PM-5040B and any of three of the Secondary
Pumps (Suction from Cold Well) PM-5045A / PM-5045B/ PM-5045C / PM-5045D
 Circulation of Chilled water through the Steam Condensers of Columns C001 and
C002 of the Process Block may be kept isolated by keeping the Inlet and Outlet
valves of the above Condensers Closed (with Positive Isolation with blinds, if
necessary) till such time the Process Block is Started Up and the Condensers are
ready to receive the Chilled Water circulation through them
 Start the Process Chilled Water Package and Confirm that the entire System is alright
 Maintain a LWT (Low Water Temperature) set point of the Chilled water package at around 25
deg. C (below the Atmospheric temperature)
 When material intake to VAM and Styrene tanks take place / When the Process Block is
started up, the LWT of the Chilled water package can be lowered as desired (20 deg. C)

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 Start the Standby Primary Pump and Standby Secondary Pump and Stop the running Primary
Pump and One of the running Secondary Pumps
 Confirm that the Standby Pumps are also in Order
 The above check of the Total System would ensure that the Chilled water Package, Pumps
taken into Operation and the Standby Pumps are all available
 In case of maintenance or breakdown of the running Pump, the Standby Pump is ready
to go into service
 When steady state is established and if there is intake of Product into only one of the Storage
Tanks T-STY-001 / T-VAM-001 and if the Process Block is not in Operation, the Chilled water Inlet
& Outlet valves of the Chilled Water Exchanger of Empty Storage Tank E-STY-001 / E-VAM-001
may be kept Closed and One of the three running Secondary Chilled water Pumps may be kept
stopped to conserve Energy and avoid unnecessary wear & tear of the Pump
 Once the Total Check of the System consisting of all the Equipment of the System is done as
mentioned above, further Settings and Operations are from the Storage Tanks end as given below
T-STY-001
 Monitor the Level of the Storage Tank T-STY-001 into which Styrene is being taken either through
Ship Unloading or through Tanker Unloading as detailed above
 When the LL Alarm goes off, Open the Tank Outlet Actuated valve XV 6301 from the HMI
 Start the Recirculation Pump P-STY-002 and Open the discharge valve to Recirculate Styrene
from the Tank through the Heat Exchanger E-STY-001 back to the Tank
 Maintain a LWT (Low Water Temperature) set point of the Chilled water package at 20 deg. C
(below the Atmospheric temperature)
 Monitor the Temperature of circulating Fluid outlet of the Exchanger through TIT 6303
 The Temperature should come down gradually, if the initial Temperature was higher than the
LWT set Point of 20 deg. C in the Chilled Water Package
 When a steady state equilibrium is reached TIT 6303 and LWT set point of Chilled Water
Package (20 deg. C) should match
 If there is a marginal lag between the Chilled Water Temperature and the circulating fluid,
Lower / Control LWT so that the circulating fluid temperature is maintained at 20 deg. C
 Confirm that the Polymerization Inhibitor Vessel V-TBC-001 is full and also the Inhibitor dozing
Pump P-TBC-001 is connected to the Polymerization Inhibitor Barrels
 Confirm that the Dozing Pump suction valve from the Barrel, AODD Dozing Pump P-TBC-001
discharge valves to the Injection Quill and Spill back valve back to V-TBC-001 are all Open
 Open the Instrument Air to the AODD Dozing Pump P-TBC-001 and keep the Pump running
 Confirm that the Injection Quill picks up the Inhibitor from the discharge of the Dozing Pump
by slow drop in level of the Barrel and V-TBC-001 (LT 6304)
 Maintain dozing of Inhibitor Chemicals as per System requirement and based on analysis of
circulating Styrene
 Provision is kept for N2 Blanketing of the Product in the Storage Tank
 Open the isolation valve upstream of PCV 6301
 Maintain a N2 pressure of 50mm WC downstream of PCV 6301 just to maintain a positive
pressure of N2 in the Storage Tank
T-VAM-001

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 Monitor the Level of the Storage Tank T-VAM-001 into which VAM is being taken either through
Ship Unloading or through Tanker Unloading as detailed above
 When the LL Alarm goes off, Open the Tank Outlet Actuated valve XV 7001 from the HMI
 Start the Recirculation Pump P-VAM-002 and Open the discharge valve to Recirculate VAM from
the Tank through the Heat Exchanger E-VAM-001 back to the Tank
 Maintain a LWT (Low Water Temperature) set point of the Chilled water package at 20 deg. C
(below the Atmospheric temperature)
 Monitor the Temperature of circulating Fluid outlet of the Exchanger through TIT 7003
 The Temperature should come down gradually, if the initial Temperature was higher than the
LWT set Point of 20 deg. C in the Chilled Water Package
 When a steady state equilibrium is reached TIT 7003 and LWT set point of Chilled Water
Package (20 deg. C) should match
 If there is a marginal lag between the Chilled Water Temperature and the circulating fluid,
Lower / Control LWT so that the circulating fluid temperature is maintained at 20 deg. C
 Confirm that the Polymerization Inhibitor Vessel V-HQ-001 is full and also the Inhibitor dozing
Pump P-HQ-001 is connected to the Polymerization Inhibitor Barrels
 Confirm that the Dozing Pump suction valve from the Barrel, AODD Dozing Pump P-HQ-001
discharge valves to the Injection Quill and Spill back valve back to V-HQ-001 are all Open
 Open the Instrument Air to the AODD Dozing Pump P-HQ-001 and keep the Pump running
 Confirm that the Injection Quill picks up the Inhibitor from the discharge of the Dozing Pump
by slow drop in level of the Barrel and V-HQ-001 (LT 6004)
 Maintain dozing of Inhibitor Chemicals as per System requirement and based on analysis of
circulating VAM
 Provision is kept for N2 Blanketing of the Product in the Storage Tank

4.4.4 N2 Blanketing of Storage Tank Products
 Provision is kept for N2 Blanketing of the Products in the following Tanks

 T-STY-001
 T-VAM-001
 T-MEG-001
 Maintenance of N2 Blanketing is explained under Styrene and VAM Storage Tanks above
 Similar N2 Blanketing for the other Tanks should be maintained in the Storage Tanks wherever
provision is kept for N2 Blanketing, after the Product has been taken into the Storage Tank and LL
Alarm goes off
 N2 Blanketing of MEG Storage Tank T-MEG-001 should be maintained as follow:


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5 TERMINAL OPERATIONS
After the Products are taken into the Storage Tanks begin the main Unit Operations of the Terminal,
which is what the Terminal & Installations are meant to cater to. The following are the main Terminal
Operations:
 Dispatch of Products to Ship for Export

 Tanker loading of Products for Road Transportation of Products to the required
destinations
 Drum filling of Products to be dispatched in Drums to the required Destinations
 Blending of different Products received in Storage Tanks to produce desired and
marketable blend of Products
 Transfer of Product from one Storage Tank to another based on necessity
 Process the received Product to produce other marketable products (Process Block)
The above Terminal Operations except the Process Block Operations are detailed serially in this
Chapter. Process Block Operations are detailed separately under Process Block.

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5.1 Dispatch to Ship (Ref. P&ID TCE 7410A-300-PI-8682, PI-8652)
The first Unit Operation detailed below is the Dispatch of Stored Products by Ship for Exports.
Transfer Pumps are provided for transfer of Products from the Storage Tanks to the Manifold and
further onto the Ship based on Product characteristics and classified as follows:
 P-MTL-003A & P-MTL-003B (CF Pumps) are dedicated for Methanol transfer to Ship. The
Suction lines of Carbon Steel for these Pumps are permanent lines not requiring any hose
connections, to prevent contamination with traces of other Products and maintain purity. Provision
also exists to divert transfer of Methanol through the Solvent Transfer Pump P-SOL-009, in case
of pressing requirements. P-MTL-003A & P-MTL-003B discharge line of C.S. discharges to the
Manifold for Dike I from where it can be directly taken to the Barred Tee of the line connected to
PLR 002, 004 or 006 through permanent C.S. lines, without need for any hose connections.
 Provision also exists in Manifold Piping to transfer Methanol from One Tank to the Other viz.
T-MTL-001 to T-MTL-002 or vice versa, through dedicated lines not requiring any hose
connections.
 P-SOL-009 (CF Pump) is meant for pumping the Products mentioned below. Suction line of this
Pump is permanent C.S. line not requiring any hose connection. The Product lines from different
Tanks are joined into a common Suction header for the Pump which discharges through a C.S.
line to the Manifold for Dike I to an Open end with coupling connection. With appropriate hose
connections through couplings, the Product can be diverted to the Barred Tee of the available and
desirable line for onward transportation and loading the Ship. The Products in Storage Tanks of
Dike I to which this Pump caters to export are the following:
 C09
 White Spirit
 Toluene
 Styrene
 Gasoline
 Ethanol
 Provision also exists for Methanol to be diverted to this Pump in case of an emergency
 P-SOL-001 (CF Pump) is meant for pumping the Products mentioned below. The Product lines
from different Tanks up to the Suction of the Pump are Open ended with coupling connections at
the ends. Of the Products mentioned, Phenol and Glycols lines are of SS 304 and the others are
of Carbon Steel. The Product from the Tank meant to be transported is connected from the Open
ended Coupling to the Suction of the Pump through a hose connection. The Pump discharges
through an S.S. line to the Manifold for Dike I to an Open end with coupling connection. With
appropriate hose connections through couplings, the Product can be diverted to the Barred Tee of
the available and desirable line for onward transportation and loading the Ship.
 It should be noted that Phenol and Glycols can be diverted to the Barred Tee of line
connected to PLR-002 only, which alone is made SS304
 The Products in Storage Tanks of Dike I to which this Pump caters to export are the following:
 Phenol
 DEG
 C10
 C09
 MPG

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 Ethyl Acetate
 P-SOL-002 (Gear Pump) is meant for pumping the viscous Products mentioned below. The
Product lines from different Tanks of C.S. are Open ended with coupling connections at the ends.
The Product from the Tank meant to be transported is connected from the Open ended Coupling
to the Suction of the Pump through a hose connection. The Pump discharges through a C.S. line
to the Manifold for Dike I to an Open end with coupling connection. With appropriate hose
connections through couplings, the Product can be diverted to the Barred Tee of the available and
desirable line for onward transportation and loading the Ship.
 The Products in Storage Tanks of Dike I to which this Pump caters to export are the following:
 Polyol
 Base Oil
 P-SOL-003A & P-SOL-003B (CF Pumps) are meant for all Products of Storage Tanks of Dike II
except Bitumen. Suction line of this Pump is permanent C.S. line not requiring any hose
connection. The Product lines from different Tanks are joined into two headers made of SS 304 –
One header feeding P-SOL-003A and the other header feeding P-SOL-003B. Pumps Suction
lines are of SS 304 which discharge through a SS304 lines to the Manifold for Dike II to open ends
with coupling connections. With appropriate hose connections through couplings, the Product can
be diverted to the Barred Tee of the available and desirable line for onward transportation and
loading the Ship. The Products in Storage Tanks of Dike II to which this Pump caters to export are
the following:
 VAM
 Xylene
 Butyl Acetate
 MEG
 Naphtha
 P-BTM-003 (Gear Pump) is exclusively dedicated for Bitumen from Bitumen Storage Tanks
located in Dike II. C.S. electrically traced lines from the Bitumen Tanks are joined into a common
suction header feeding the Suction of the Pump. The discharge line of the Pump C.S. electrically
traced line feeds the Barred Tee of the electrically traced line attached to PLR 008, also
exclusively dedicated for Bitumen.
Loading the Product to Ship
Loading of Product to a Vessel for export, should be preceded by posting Operators with assigned
responsibilities mentioned below for each position.
 Close coordination is required among Control Room Operator, Manifold Operator, Jetty end
Operator, and the Field Operator (near the Storage Tanks).
responsibilities for Transfer of Product from the Storage Tank in Dike I or Dike II to the Ship,
followed by Pigging & N2 Purge, which are detailed below

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 Coordinate & Reconfirm with the Jetty end Operator, Manifold Operator and the Field
Operator as to the Product to be transferred and the Location of the Tank from which
the Product is to be transferred is in Dike I or Dike II
 Select the Correct Product Tank into which the Product is to be transferred on the
screen in the Control Room
 Select “DISP-SHIP”
 Ensure that the Actuated valves on the selected Tank are in Remote Auto mode
 Once the “Remote Auto” mode is selected, on selection of “DISP-SHIP” for the Tank on the
HMI screen, confirm that the Actuated Inlet valve Closes and the Outlet valve Opens.
 Dike I Tank - If the Product Tank is T-C09-001 , T-C10-001 Tank, Confirm that
Actuated Inlet valves from C-001 and C-002 of Process Block remain Closed in
Remote Auto mode
Actuated valve to TLF (XV 5304 / XV 5404) is Closed in Remote Auto mode
 If the above conditions are fulfilled, the Tank is ready to Dispatch Solvent from the
Tank to the Jetty
 Coordinate with the Jetty end Operator, the Manifold Operator and the Field Operator
to Start Pumping the Product, when all of them are ready
on Screen and confirm that there is gradual decrease in Level
 Receive information from the Jetty end Operator, Manifold Operator and Field Operator
b) Field Operator
 Coordinate & Reconfirm with the Control Room Operator, Manifold Operator and the
Jetty end Operator as to the Product to be transferred and the Location of the Tank
from which the Product is to be transferred is in Dike I or Dike II
 Confirm that the Actuated Inlet valve of the selected Product Tank is Closed in the field
 Confirm that the Actuated Outlet valve of the selected Product Tank is Open in the field

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Actuated valves to TLF is Closed in the field
 Get the correct Pump ready for Pumping as follows:

 Go to the Right Pump location based on the Location of the Tank from which the Product is to
be Pumped from Dike I or Dike II and the Product to be Pumped based on the allocation of
Pumps for various Products / Solvents mentioned above
Products of Dike I
Methanol:
 Chose P-MTL-003A Or P-MTL-003B depending on availability
 Only in case of an Emergency or Non availability of both the Pumps P-MTL-003A & B,
P-SOL-009 can be taken in line for Methanol Export, after making sure that P-
SOL-009 discharge line is flushed clean of previously pumped Product through this
Pump, to ensure the Purity of Methanol at the destination
 Open the isolation valve on the selected Tank (T-MTL-001 OR T-MTL-002) Outlet line
feeding the Suction header of the Pump selected Pump
 Close the isolation valve on the Outlet line of the other Tank (Not selected) leading to the
Suction header of the Pump
 Open the Suction isolation valve of the selected Pump P-MTL-003A Or P-MTL-003B
 Keep the Suction & Discharge isolation valves of the other Pump (Not selected) Closed
 Coordinate with the other Operators before Starting the Pump
 Open the discharge valve after Starting the Pump
 Confirm that the PG on the discharge line indicates the Operating Pressure
C09, White Spirit, Toluene, Styrene, Gasoline, Ethanol:

 The Pump for any of these Products is P-SOL-009
 Ensure that the isolation valves from the Methanol Tanks (T-MTL-001 & T-MTL-002)
Outlet lines joining the Suction header of P-SOL-009 are kept fully Closed
 Close the Isolation valves on the Outlet lines of all the Other Tanks and keep only the Outlet
line of the Tank whose Product is to be exported Open
 Open the Suction isolation valve of the Pump
Phenol, DEG, C10, C09, MPG, Ethyl Acetate

 Keep both the open ended valves on the Outlet lines of all the Tanks Closed initially viz.
T-PHL-001, T-DEG-001, T-C10-001, C-09-001,T-MPG-001, T-ETA-001 should be kept
Closed
 Connect a hose through couplings from the Outlet line of the Tank whose Product is to be
exported to the Suction line of the Pump
 Open only the Tank Outlet valve whose Product is to be exported
 Open the Suction valve of the Pump and confirm that there is no leakage

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Polyol, Base Oil

 The Pump for any of these Products is Gear Pump P-SOL-002
T-POL-001, T-BOL-001,002,003,004 should be kept Closed
 Open the Suction & Discharge valves of the Pump and confirm that there is no leakage
Products of Dike II
VAM, Xylene, Butyl Acetate, MEG, Naphtha (All except Bitumen)
 The Pumps for any of these Products is P-SOL-003A OR P-SOL-003B, depending on

availability
 Close the Isolation valves on the Outlet lines of all the Other Tanks to the Suction headers of
both the Pumps and Open Only the Outlet line of the Tank whose Product is to be
exported Only to the Suction header of the selected Pump P-SOL-003A OR
P-SOL-003B
 Keep the isolation valve on the selected Tank Outlet line to the Suction header of the
Pump Not selected Closed

 Applicable for all the above cases of Pumping - If leakages are observed near the Pump,
coordinate with the Other Operators and Stop the pump immediately
 Carry out the corrective actions for leakage and restart the Pump after coordination with the
Other Operators
 At the end of the Pumping operation, carry out N2 Purging of the Suction and discharge
lines in coordination with the Other Operators, if required and for Hot jobs on the line.
 N2 Purging, if required to be carried out, should be done segment wise, viz. Tank to
Pump, Pump to Jetty & Ship
 Please refer the Marked up drawing for N2 Purging
 N2 Purge from the Storage Tank to the Transfer Pump for Dike I & Dike II Products
might not be required after every Dispatch to Ship, since the lines up to the Transfer
Pump are dedicated lines and there is no fear of Contamination - Except Heat sensitive
materials VAM & Phenol (Dike I) and Bitumen & Styrene (Dike II)
 Pre-unloading Check of the PLR at the Manifold end viz.


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 Coordinate & Reconfirm with the Control Room Operator, the Jetty end Operator and
the Field Operator as to the Product to be transferred and the Location of the Tank
from which the Product is to be Loaded to Ship is in Dike I or Dike II
 Check & keep the isolation valves position around the PLR at the Manifold end as per
the following criterion:
Product is to be Dispatched to Ship from a Storage Tank in Dike I
 Close 100% the isolation valve Inlet / Outlet of the Barred Tee towards the Jetty
the Product is to be loaded is fully Closed
 Close the Sending PLR (towards the Manifold) Outlet Valve on the line
 Open the Barred Tee Inlet / Outlet valve towards the Manifold end
Product is to Dispatched to Ship from a Storage Tank in Dike II (Except Bitumen):
 Open the isolation valve Inlet / Outlet of the Barred Tee towards the Jetty
the Product is to be pumped is fully Closed
 Close the Sending PLR Outlet Valve on the line

 Close the Isolation valve between the two Barred Tees
 Close the Barred Tee Inlet / Outlet valve towards the Manifold end
Bitumen is to be Dispatched to Ship from Storage Tank T-BTM-001 or T-BTM-002
 There is only One Barred Tee to which an outline (Electrically traced C.S. line) is connected
 Keep the Inlet / Outlet valve of the Barred Tee Open
 Ensure that the isolation valve of the Utility connection above the Barred Tee is fully closed
Hose Connection between the Barred Tee and the Manifold (Except Bitumen)
 Line up the available line for Ship dispatch taking care to maintain the allocation of Lines
(connected to PLRs) for different Products considering their properties viz. the following:
 Lines connected to PLR-004 C.S. Or PLR-006, based on availability, for all other
 Line connected to PLR-008 C.S. with Electrical tracing exclusively dedicated for
Bitumen
 Connect one end of a hose with QRC to the Open end of the Barred Tee Inlet line that has
been taken in line (Barred Tee Inlet / Outlet valve Open)

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 Connect the QRC at the other end of the hose to the QRC connected to the Isolation valves of
the Correct Product line Connected to the Correct Manifold
 Open the two isolation valves connected to the hose feeding the Barred Tee
 Open the two isolation valves connecting the hose to the discharge line of Correct Transfer
Pump for Ship Loading
Discharge line of Barred Tee to Bitumen Storage Tanks
 There is a permanent Electrically traced line connecting the Barred Tee to the Manifold
connecting the lines leading to the entry of Bitumen Storage Tanks T-BTM-001 and T-BTM-
002
 Open the Barred Tee Inlet / Outlet valve
 Open the isolation valve Feeding the Barred Tee
 Open the common isolation valve leading to the Tanks
 Close the isolation valves leading to the Inlet Bitumen Tanks BTM-001 and T-BTM-002
 Close the Bitumen Tanker Unloading Pump P-BTM-005 discharge valve near the
Manifold (Please note the Caution mentioned below)
 Open the isolation valves for the Line from the Product transfer Pump P-BTM-003
coming to the Manifold for Ship loading
Caution
 When Ship Loading of Bitumen is Progress, Tanker Unloading cannot take place
commencement of Ship Loading to avoid serious accidents due to manual error during
Truck Unloading Operations
 Truck Unloading Pump P-BTM-005 should be Electrically Isolated and Tagged
 Give Clearance to the Jetty end Operator & Control Room to Start the Pump
 Coordinate with the Control Room Operator, Jetty end Operator and the Field Operator (near
 If leakages are observed near the Manifold end, coordinate with the Field Operator and
Control Room Operator to Stop pumping immediately
 Carry out the corrective actions for leakage and give clearance to the Field Operator and
 After completion of Pumping, coordinate with the Jetty end Operator and Control
Room, and run the Pig from the Manifold end to the Jetty end as per Supplier’s
Procedure, to make sure that the line is fully cleared of the material pumped and the
line is ready to receive the next Product - Without any fear of contamination (products
other than Bitumen) / Line is free of clogging (Bitumen)
 Coordinate with other Operators and give clearance to the Field Operator to Start N2 purging
from the Transfer Pump to the Jetty end & Up to the Ship to ensure that the line is free of
liquid from the Transfer Pump up to the Jetty end

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 Disconnect the hose connection from the Manifold end to the Loading end (Not
applicable for Bitumen)
Goggles to safeguard against injury by the spill of any remnant liquid in the hose on
to self
d) Operator at the Jetty end
 Pre-unloading Check of the PLR at the Jetty end viz.

 Oversee the Connection of the Loading Arm to the Ship

to the Product to be transferred and the Location of the Tank from which the Product is
to be Loaded is in Dike I or Dike II
 Connect the Loading Arm’s Inlet to the Barred Tee of the Correct PLR, through which the
Product is to be dispatched for different Products considering their properties viz. the
following:
 Lines connected to PLR-003 C.S. Or PLR-005, based on availability, for all other
 Line connected to PLR-007 C.S. with Electrical tracing exclusively dedicated for
Bitumen
 Close the PLR Outlet valve

 Open the Inlet / Outlet Isolation valve of the Barred Tee
 Confirm that all Utility connections are kept Closed and the PG isolation valve is Open
 Oversee the facilities onboard the Ship, if permitted and required, to confirm that the
Vessel is adequately equipped to handle & ship the Product
 Coordinate with the Vessel Captain before commencement of Pumping
 Coordinate with the Control room Operator, Manifold Operator and the Field Operator
to Start Pumping to the Vessel
 Coordinate with the Control Room Operator, Piping Manifold Operator & the Field Operator if
there is no leakage and all is well
 If leakages are observed near the Jetty Coordinate with the Field & Other Operators
to Stop pumping immediately
give clearance to all the Operators to Restart Pumping
 Coordinate with the Ship’s Captain & other Operators viz. Manifold , Control Room, and
Field Operators to start Pigging from the Manifold end to the Jetty end as depicted in
the Marked up drawing with Stepwise Procedure

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 After the Pig reaches the Jetty end and Retraction of Pig, coordinate with the Ship’s Captain &
Other Operators and give clearance for N2 Purging of the line from the Transfer Pump
discharge up to the Ship
 Coordinate with Field & other Operators to regulate the Utility N2 isolation valve to avoid
nuisance on the Ship due to excess N2 pressure
 When the discharge to the Ship is dry and free of liquid, Inform the Field & Other Operators to
Stop N2 Purging
 Disconnect the Loading Arm Inlet line from the Barred Tee
to self
 Coordinate with the Ship’s Captain to disconnect the Loading end to the Ship for
onward clearance of the Vessel to sail with the cargo
Preventive maintenance during Dispatch to Ship
The procedure for Preventive maintenance is similar to Ship Loading. However detailed below
is the procedure with changes as applicable for Dispatch to Ship
responsibilities for Pigging & N2 Purge after Dispatch to ship
 marked up drawing should be read in conjunction with the details given below, to note
the finer points brought out in both
5.1.1 Preventive maintenance during Dispatch to Ship

 All leakages should be coordinated through the Field Operator who in turn temporarily Stop
Pumping and restart the Pump after the Leakages are attended
ii) Pump trips on Starting
 In the above two cases, the Pump might be tripping due to No Flow and Activation of FS
(for Centrifugal Pumps) / PS (for Gear Pumps) on the Pump discharge line
known
iii) Transfer Line is blocked / Quantity Pumped is less
A. Identification of Problem / Choked portion of the line
 If there is no problem with the Pump, then the line from the Storage Tank to the Transfer Pump or
from the Transfer Pump to the Manifold or from the Manifold to the Jetty up to the Ship may be
choked

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 First step is to ascertain where the Choke is under coordination amongst Operators as follows:
responsibilities for Pigging & N2 Purge after Dispatch to ship, which are detailed below
 Coordinate with the Manifold Operator to start Pigging the line from the Manifold to the Jetty
end
 Confirm & Inform other Operators if the Pig has reached the Jetty end
 If the Pig reaches the Jetty end, the line from the Manifold to the Jetty is clear
 If the Pig does not reach the Jetty end, then the line from the Manifold to the Jetty is
blocked and communicate the same to the Manifold and other Operators to proceed
with remedial actions as explained below
Manifold Operator
 Get the Pump stopped in coordination with the Field Operator

 Prepare for Pigging the Line from the Manifold to the Jetty
 Coordinate with the Jetty Operator to Start Pigging from the Manifold end to the Jetty end as
explained above
 If the receipt of Pig is acknowledged by the Jetty Operator, it confirms that the line
from the Manifold to the Jetty is clear
 If the Pig does not reach the Jetty end, then the line from the Manifold to the Jetty is
blocked and hence proceed with remedial actions as explained below
 After confirming the status of the line from the Manifold end to the Jetty end – whether
the line is clear or blocked, proceed with further investigations to ascertain the status
from the Transfer Pump to the Manifold
 Coordinate with the Field Operator to start N2 purge of the line from the Transfer Pump, as
depicted in the enclosed Marked up drawing with Stepwise procedure
 On starting of N2 Purge from the Transfer Pump as confirmed by the Field Operator, check
from the drain points, near the Manifold , if the liquid comes out with N2 Pressure
Goggles to avoid injury due to liquid splashing out
 If the Product comes out with N2 pressure from the drains, then the line from the
Transfer Pump up to the Manifold is clear, Otherwise the line is choked / blocked
somewhere in between
Field Operator
 Check from the drain points of the Tank Outlet line up to the Transfer Pump, if the Product
comes out normally from the drains(with the Tank Outlet valve Open) , confirming that the line
from the Tank up to the Transfer Pump is clear

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 Whether or not the line from the Tank up to the Storage Tank is clear or not, proceed
with further investigations to ascertain the status from the Transfer Pump to the
Manifold
 Make arrangements for N2 Purge of the line from the Transfer Pump discharge as depicted in
the enclosed Marked up drawing with Step wise Procedure
 Get feedback from the Manifold Operator regarding the Status of the line from the Transfer
Pump up to the Manifold for necessary corrective actions
B. Corrective Actions - Line from Manifold to Jetty is Choked
 If Choke is identified in any of the segments viz. - Line from the Manifold up to the Receiving PLR
at the Jetty end or/and Line from the receiving end PLR up to the Manifold or/and Line from the
Transfer Pump up to the Manifold or/and lien from the Storage Tank up to the Transfer Pump -
hammer gently with wooden mallet on the line in the identified segment of Choke especially
near the bends & elbows to relieve the Choke in line
 If the line is heavily choked and relieving the Choke is time consuming (unlikely for
Products other than Bitumen), the following options may be resorted to save time &
demurrages, if any applicable, due to delay in Dispatching the Product to the Ship
 Coordinate with the Manifold Operator if the line is being changed over to the other
available options
 If confirmed by the Manifold Operator of the Changeover of line, Do the necessary
adjustment to the isolation valves connected to the Inlet / Outlet line of the Barred Tee and
Loading Arm Outlet as applicable and depicted in the Marked up drawing, to proceed with
Dispatch to Ship through the alternative line
Manifold Operator
 Under coordination with the Other Operators Change over the line to the next available
line for pumping – this option is applicable for Products Other than Bitumen, Phenol
and Glycols only
 Do the necessary adjustment to the isolation valves connected to the Inlet / Outlet line of the
Barred Tee
 Connect hose to the Open end of the line from the Barred Tee to be taken in line to the
appropriate line on the Manifold
 Coordinate with the Jetty end and other Operators to resume Pumping and confirm if all is
well
 After the Pumping through the alternative line is completed, continue efforts to clear
the Choke in the first line and keep it purged with N2 ready for lining up, when required
 If the Choked line is SS (Phenol or Glycols), or dedicated line for Bitumen, there is no other
alternative than to Clear the Choke before restarting Pumping
C. Corrective Actions - Line from the Transfer Pump up to the Manifold is

Choked

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332
 If alternate Transfer Pump is available, as per allocation mentioned above based on the
Product characteristics, under coordination with the other Operators, line up the
alternative Pump to commence Ship Dispatch with appropriate connection of the hose
to the alternative pump
cleared
5.1.2 Breakdown maintenance during Dispatch to Ship

Jetty Operator
 Get the Pump stopped in coordination with the Field Operator

 In coordination with Manifold & the other Operators get the Pigging started from the Manifold
end up to the Jetty end
 Coordinate with the Field and other Operators to get the N2 purging done from the Transfer
Pump up to the Ship as depicted in the Marked up drawing
 Check & Confirm if the line is Dry, N2 comes out with Pressure from the drain point & no liquid
is present
 If the leakage is in the line from the Manifold to the Jetty, Continue purging with N2,
with periodical checks if the gas outlet of the drains is free of HC / Inflammable material
Manifold Operator
 Under coordination with the Jetty Operator Run the Pig from the Manifold end to the Jetty end
 After Pigging is completed, coordinate with the Jetty & Field Operator to start N2 purging from
the Transfer Pump up to the Ship
 If the leaky segment is from the Transfer Pump up to the Manifold, isolate the line from
the Manifold to the Jetty, by disconnecting the hose / positive isolation with Blind / Slip
plate, if connected by a permanent line up to the Barred Tee (Methanol & Bitumen)
 After N2 purging for about 1 hour up to the Manifold, Check & Confirm if the line is Dry, N2
comes out with Pressure from the drain point & no liquid is present
Field Operator
 If the leaky segment is from the Storage Tank up to the Transfer Pump, Close all the
isolation valves from the leaky area and the discharge line of the Transfer Pump, with positive
isolation with Blind / Slip plate, on the discharge line flange of the Transfer Pump
 Insert Blinds / Slip plates as required for positive isolation of the Storage Tank for
carrying out the Hot job
 Start N2 purging of the line from the Storage Tank up to Transfer Pump as depicted in the
Marked up drawing

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333
 If the leaky segment is between the Transfer Pump and the Jetty, under coordination with
Manifold and Jetty Operators, make preparations and start N2 purging from the Transfer
Pump up to the Ship, as depicted in the enclosed Marked up drawing
 Continue N2 Purging until the line is free of HC / Inflammable material, as confirmed by tests
in the appropriate segment
 When the line is free of HC / Inflammable material, handover the appropriate segment of the
line for maintenance and necessary actions
 Alternative Options available to save time to avoid delay in Dispatching to Ship due to the
maintenance on the line, are the same as above for Preventive maintenance
 After the Pumping through the alternative line / alternative Tank is completed, continue
with N2 Purging in the first line until free of HC / Inflammable material, handover the

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334
3
2
Step wise Procedure
4
for Dispatch
5
to Ship of Dike I Tank e.g. T-PHL-001 12

OH""'° Dnam:1d ~O.:l rn~d Case 1
A
16 2. 9 A
3 4
.. 11 7 8
14
12. 1 6 5 13 lmES B
1. PROUCT TRAHSf£R LINE FROM JETIY TO BE MANUALLY CONNECTE
1. Close PLR Outlet valve (Jetty end) 2.
HOSE & QRC.
COPPER JUMPERS TO BE PROVIDED OVER AU. FlANGES TD
2. Connect Loading Arm to Ship 3. INTERTANK TRANSf'ER TO BE CARRIED OUT BY CONNECTING
DISCHARGE LINE OF SOLVENT TRANSf£R PUMPS TO RESPECTM
3. Open Barred Tee Inlet / Outlet valve (Jetty end) 4. ORC TO BE EQUIPPED WITH DRY-BREAK SYSTEMS TO AIJ.IYlf SPI
FREE DISCONNECTION.
4. Close Barred Tee Inlet / Outlet valve (2nd from the Manifold end) 5.
6.
7. VENT SHAU. BE PROVIDED WITH CHICAGO COUPLING.
5. Close PLR Outlet valve (Manifold end) 8.
9.
c
6. Open the valve between the two Barred Tees (Manifold end) NITROGEN AND SERVICE WATER SHAU BE CONNECTED WITH HOSE
CONNECTION.
10. AU. P1C SIGNALERS SHALL ME MECHANICAL TYPE WITH LOCAL c
7. Open the Barred Tee Inlet / Outlet valve (1st from the Manifold end) 11. llllLITY STATION IS PROVIDED FOR P!CClNG MANIFOLD AT JETlY.
8. Connect hose from Transfer Pump discharge line to line feeding the Barred Tee 13. llllLITY STATION IS PROVIDED FOR PIGGING MANIFOLD AT DIKE- I.
9. Open the isolation valves feeding the Barred Tee

10. Open isolation valves on the transfer pump discharge line near the manifold
11. Clearance for Pumping Ship's Captain Legend
12. Clearance for Pumping Jetty Operator
13. Clearance for Pumping Manifold Operator Valve Open
D D
14. Communication of Clearance for Pumping to C.R. & Field Operators T -1
Valve Closed
15. Product entry to the line to the Jetty 'IY?E OF LINE NO.
LINE NO. DELETED LINE NO.
16. Product to Ship 10 FlLIID ALLOTED
Step wise Procedure for Dispatch to Ship of Dike II Tank e.g. Naphtha Tank T-NPT-001 15
16 2.
4 Case 2 UTl.IJlES 52301-52800 52lCU-S231 $231'1 52319
E 3 7 .!:!.Q1.Q.S
E
11 1. DELETED.
1 6 5 14
12. 13 J-JV'V-C
NOTE-3,4
P-2»-c>.2-lh-52023-T
r F
1. Close PLR Outlet valve (Jetty end)

9
2. Connect Loading Arm to Ship
3. Open Barred Tee Inlet / Outlet valve (Jetty end)
4. Close Barred Tee Inlet / Outlet valve (1st from the Manifold end)
5. Close PLR Outlet valve (Manifold end)
6. Close the valve between the two Barred Tees (Manifold end) DO NOT SCALE
c 7. Open the Barred Tee Inlet / Outlet valve (2nd from the Manifold end)
IG-:!O-CA1--~:Sll IG-50-<A1-fl-t111t -50-a.1--91149
8 HAZEL INTERNATIONAL FZE c
Nfl'ROCEH NITROCEH NITROOEH
8. Connect hose from PHHtl Transfer Pump discharge line to line feeding the Barred Tee
Pf-8611 OlMICM. TERllH.ll. AT HAMRIYAH fR[£ ZM. ~ UAE
COIU'RCSSID NR r'"""=<...... _ _.,
="-'~=1,.1,.1»._ CA-50-CA1--1:tl29 c:A>--'°""CA1--1!1DI
10 15
Pl-1012 9. Open the isolation valves feeding the Barred Tee
"-1012
CXlMf'R£SS(]) . . .
Pt-1012 ~~~·-·~T-AL-~, CAPITAL ENGINEERING CONSULTANCY

10. Open isolationSE:RYICE
valves
W.\TER
Pt-Be92
on the transfer pump discharge WAW!
SDMC(
Pl-8&92
line near the manifold P&ID FOR PRODUCT
11. N<m:-•
Clearance for Pumping Ship's
NO'Tt-11
NOT[-•
NOTt-12
Captain NOTt-• NOTt-13
12. Clearance for Pumping Jetty Operator
UTILITY STATION
13. Clearance for Pumping Manifold Operator
FOR RO ISSUE ONLY CL£AREll TATA MUMBAI
H 14. Communication of Clearance REVISIONS
for Pumping toORNC.R. & Field Operators H
15. Product entry to the line to the Jetty

16. Product to Ship
335
2 3 4 9 10
Legend
Valve Open
Step wise Procedure for Dispatch to Ship of Dike I Tank e.g. Phenol Valve Closed
7 9 Case I Pump Running
3
1 1. Keep all Tank Outlet valves Closed
2. Connect a hose from the Correct Tank Outlet to the Pump Suction line
2 3. Open the Correct Tank Outlet valve & Confirm No leak
4. Open the Pump Suction valve
5. Coordinate with Control Room, Manifold & Jetty Operators before Starting the Pump 5
6. Start the Pump
4 6 7. Open the discharge valve
8. Confirm all well from all Operators & No leakage 8
9. Product to Dike I Manfold
9
7 Step wise Procedure for Dispatch to Ship of Dike II Tank e.g. Naphtha Tank T-NPT-001
Case 2
1. Keep all Tank Outlet valves to the Suction headers of Pumps Closed
1 2. Ensure the Tank Outlet isolation valve of the Selected Tank to the Suction header of Pump Not selected
(P-SOL-003B) Closed
3. Open the Tank Outlet valve of the Selected Tank only to the Suction header of selected Pump (P-SOL-003A)
4 6 5. Coordinate with Control Room, Manifold & Jetty Operators before Starting the Pump
6. Start the Pump 5
3
2 7. Open the discharge valve
336
N2 Purge I leg - Step 2wise Procedure for 3 Pigging & N2 Purge
4 after Dispatch
5 to Ship of Dike I Tank .e.g. T-PHL-001 12

OH""'° Dnam:1d ~O.:l rn~d Case I
A 13 A
13 15
.. 10
3 13 5
2, 4, 11& 14 8 6
12
9 7
1. Message from Field & Control Room Operators - 'Pumping completed & Pump Stopped ' 1 lmES B
2. Message from & to Ship's Captain & Jetty Operator - 'Pumping completed ' 1. PROUCT TRAHSf£R LINE FROM JETIY TO BE MANUALLY CONNECTE
HOSE & QRC.
3. Open the PLR Outlet valve (Jetty end) 2. COPPER JUMPERS TO BE PROVIDED OVER AU. FlANGES TD
3. INTERTANK TRANSf'ER TO BE CARRIED OUT BY CONNECTING
4. Clearance for Pigging from Ship's Captain & Jetty Operator DISCHARGE LINE OF SOLVENT TRANSf£R PUMPS TO RESPECTM
5. Close Barred Tee Inlet / Outlet valve (Manifold end) 4. ORC TO BE EQUIPPED WITH DRY-BREAK SYSTEMS TO AIJ.IYlf SPI
FREE DISCONNECTION.
5. FlANGE Cl.JAROS TO BE PROVIDED FOR AU. FLANGE JOINTS.
6. Open PLR Outlet valve 6.
7.
VENT SHAU. BE PROVIDED WITH CHICAGO COUPLING.
7. Prepare for Pigging 8.
9.
NITROGEN AND SERVICE WATER SHAU BE CONNECTED WITH HOSE
c 8. Pigging in progress 10.
CONNECTION.
AU. P1C SIGNALERS SHALL ME MECHANICAL TYPE WITH LOCAL c
9. Check Pig receipt & give clearance for N2 Purge (Jetty end Operator) 11. llllLITY STATION IS PROVIDED FOR P!CClNG MANIFOLD AT JETlY.
10. Open the Barred Tee Inlet / Outlet valve (Manifold end) 13. llllLITY STATION IS PROVIDED FOR PIGGING MANIFOLD AT DIKE- I.
11. Clearance from the Ship's Captain and the Jetty Operator for N2 purge
12. Clearance to Field Operator to Start N2 purge
13. N2 purge in progress Legend
14. Check from drains if liquid is displaced & Message to Field Operator to Stop N2 purge Valve Open
D 15. Disconnect Loading Arm & Clearance for Ship to sail (Jetty end Operator) D
16. Restore conditions back to normal T -1

Valve Closed
14
N2 Purge I leg - Step wise Procedure for Pigging & N2 Purge after Dispatch to Ship of Dike II Tank .e.g. T-NPT-001 'IY?E OF LINE NO.
FlLIID ALLOTED LINE NO. DELETED LINE NO.
Case 2 13
13 15 10 13 UTl.IJlES 52301-52800 52lCU-S231 $231'1 52319
E
3 8 13 5 .!:!.Q1.Q.S
E
2, 4, 11 9 12 1. DELETED.
6
7 1
1. Message from Field & Control Room Operators - 'Pumping completed & Pump Stopped '
J-JV'V-C
2. Message from & to Ship's Captain & Jetty Operator - 'Pumping completed ' NOTE-3,4
r 3. Open the PLR Outlet valve (Jetty end) P-2»-c>.2-lh-52023-T

F
4. Clearance for Pigging from Ship's Captain & Jetty Operator

5. Close Barred Tee Inlet / Outlet valve (Manifold end)
6. Open PLR Outlet valve & the valve between two Barred Tees
7. Prepare for Pigging
8. Pigging in progress 13
9. Check Pig receipt & give clearance for N2 Purge (Jetty Operator) DO NOT SCALE
c 10. Open the Barred Tee Inlet / Outlet valve
IG-:!O-CA1--~:Sll IG-50-<A1-fl-t111t -50-a.1--91149 HAZEL INTERNATIONAL FZE c
Nfl'ROCEH NITROCEH NITROOEH
11. Clearance from thePHHtl Ship's Captain and the JettyPf-8611
Operator for N2 purge OlMICM. TERllH.ll. AT HAMRIYAH fR[£ ZM. ~ UAE
COIU'RCSSID NR r'"""=<......
="-'~=1,.1,.1»._ _ _., CA-50-CA1--1:tl29
12. Clearance to Field Operator to Start N2 purge CXlMf'R£SS(]) . . .
c:A>--'°""CA1--1!1DI 14
Pl-1012 "-1012 Pt-1012 ~~~·-·~T-AL-~, CAPITAL ENGINEERING CONSULTANCY
13. N2 purge in progress SE:RYICE W.\TER WAW!
SDMC(
Pt-Be92 Pl-8&92 P&ID FOR PRODUCT
14. Check N<m:-• from drains if liquid isNOT[-•
displaced & Message to Field NOTt-• Operator to Stop N2 purge
NOTt-13
NO'Tt-11 NOTt-12
15. Disconnect Loading Arm & Clearance for Ship to sail (Jetty end Operator)
UTILITY STATION
16. Restore conditions back to normal
FOR RO ISSUE ONLY CL£AREll TATA MUMBAI
REVISIONS ORN
H H
337
2 3 4 9 10
N2 Purge I leg - Step wise Procedure for Pigging & N2 Purge after Dispatch to Ship of Dike I Tank .e.g. T-PHL-001
Case 1 Legend
1 Valve Open
1. Coordinate with Control Room, Manifold & Jetty Operators regarding completion of Quantity to be Dispatched
2. Close Pump discharge valve Valve Closed
3. Stop the Pump
Pump Running
4. Close the Pump Suction & Tank Outlet valves
5. Insert a Slip plate (blind) on the discharge of Pump 7 Pump Stopped
6. Connect a hose to the Utility connection
7. Clearance from Manifold & Jetty Operators to commence N2 purge
8. Open N2 & the Utility valve
10. N2 purge to the Ship in progress
11. Message from Jetty & Manifold Operators 'N2 Purge Complete - Stop N2' 11
12. Close N2 Utility valve
13. Close Pump discharge valve
N2 Purge II leg - Optional but Mandatory for Hot jobs & Heat Sensitive materials
14. Insert a Slip plate (blind) on the Suction of Pump
21 9 10 20
19 16. Place a Drum of the Product, insert the hose & secure the hose
2 17. Open the drain valve
8 13 18. Open the Pump Suction valve
19. Open Tank Outlet valves
14 12 6 22
20. Coordinate & give clearance for N2 Purge
4
21. N2 Purge from the Tank started (II leg)
22. Fill the purged Product in drums with Safety gears
5 23. Shift the filled Drums to Storage Area
18 17 Case 2
15 3
N2 Purge I leg - Step wise Procedure for Pigging & N2 Purge after Dispatch to Ship of Dike II Tank e.g. Naphtha Tank T-NPT-001
16 1 1. Coordinate with Control Room, Manifold & Jetty Operators regarding completion of Quantity to be Dispatched
23 2. Close Pump discharge valve
3. Stop the Pump
10 7
9 5. Insert a Slip plate (blind) on the discharge of Pump
13 7. Clearance from Manifold & Jetty Operators to commence N2 purge
2 8. Open N2 & the Utility valve
12 9. Open the Pump discharge valve
8 6
11. Message from Jetty & Manifold Operators 'N2 Purge Complete - Stop N2' 11
5 12. Close N2 Utility valve
3 N2 Purge II leg - Optional but Mandatory for Hot jobs & Heat Sensitive materials
4
17 15. Place a Drum of the Product, insert the hose i& secure the hose 18
19 16
14 17. Open the Tank Outlet valve
21 18. Coordinate & give clearance for N2 Purge
21. Shift the filled Drums to Storage Area
After the above activities are completed, restore normal positions 20
338
Case 1
N2 Purge II leg - Step wise Procedure for N2 Purge after Dispatch to Ship of Dike II Tank .e.g. T-PHL-001
Optional but Mandatory for Hot jobs & Heat Sensitive materials
Legend
Valve Open
Valve Closed
Pump Running
Pump Stopped
2
4
1. Close all the valves

2. Connect Utility hose to on the Tank Outlet line
3. Coordinate with other Operators before starting N2 Purge 3
4. Open the Utility valve and N2
5. N2 Purge the desired destination end
5
339
Case 2
N2 Purge II leg - Step wise Procedure for N2 Purge after Dispatch to Ship of Dike II Tank .e.g. Naphtha Tank T-NPT-001
Optional but Mandatory for Hot jobs & Heat Sensitive materials
Legend
Valve Open
Valve Closed
1
Pump Running
Pump Stopped
2
4

4. Open the Utility valve and N2 5
340
Step wise Procedure for Dispatch to Ship of Bitumen e.g. from T-BTM-001 (Dike II)
1. Close the PLR Outlet valve (Jetty end)

2. Connect Loading Arm to Ship
4. Close the PLR Outlet valve (Manifold end)
6. Open the valve feeding the Barred Tee (Manifold end)
7. Open the common isolation valve leading to the Tanks
8. Close the valve going to T-BTM-01 from the Manifold, Blind & Tag for Safety
9. Close the valve going to T-BTM-02 from the Manifold, Blind & Tag for Safety
10. Close the valve near the manifold on P-BTM-005 discharge line, Blind & Tag for Safety
11. Open the valve near the manifold on P-BTM-003 discharge line
12. Clearance for Pumping from the Ship's Captain
13. Clearance for Pumping from the Jetty Operator
15. Clearance for Pumping to Control Room & Field Operator
16. Transfer Pump P-BTM-003 Started & Bitumen starts flowing for Ship Dispatch
17. Bitumen to Ship
2
17
Legend
12 3 Valve Open
5
Valve Closed
9
1 4
8
14
11 16. Bitumen Transfer Pump discharge
13 15 6 7
10
341
Step wise Procedure for Dispatch to Ship of Bitumen .e.g. from T-BTM-001 (Dike II)
1. Close the valve from Tank Not for export (T-BTM-002)

2. Open valve from Tank for export (T-BTM-001)
4. Open the Pump Discharge valve 5
5. Coordinate with Control Room, Manifold & Jetty Operators before Starting Pump
6. Start the Pump
Legend
Valve Open
4 Valve Closed
Pump Running
NRV
2
3 6
1
342
N2 Purge I leg - Step wise Procedure for Pigging & N2 Purge after Dispatch to Ship of Bitumen .e.g. from T-BTM-001 (Dike II)
1. Message from Field & Control Room Operators - 'Pumping completed & Pump Stopped '
2. Message from & to Ship's Captain & Jetty Operator - 'Pumping completed '
4. Clearance for Pigging from Ship's Captain & Jetty Operator
5. Close Barred Tee Inlet / Outlet valve (Manifold end)
6. Open PLR Outlet valve
7. Prepare for Pigging
8. Pigging in progress
9. Check Pig receipt & give clearance for N2 Purge (Jetty end Operator)
11. Clearance from the Ship's Captain and the Jetty Operator for N2 purge
12. Clearance to Field Operator to Start N2 purge
13. N2 purge in progress
14. Check from drains if liquid is displaced & Message to Field Operator to Stop N2 purge
15. Disconnect Loading Arm & Clearance for Ship to sail (Jetty end Operator)
16. Restore conditions back to normal
13
15
9 Legend
11
3 Valve Open
13
5 Valve Closed
6 7
2,4,11 8
12 13
1
14
343
N2 Purge I leg - Step wise Procedure for Pigging & N2 Purge after Dispatch to Ship of Bitumen .e.g. from T-BTM-001 (Dike II)
1. Coordinate with Control Room, Manifold & Jetty Operators regarding completion of Quantity to be Dispatched 1
2. Stop the Pump
5. Insert a Slip plate (blind) on the discharge of Pump
7. Clearance from Manifold & Jetty Operators to commence N2 purge
11. Message from Jetty & Manifold Operators 'N2 Purge Complete - Stop N2'
N2 Purge II leg - Step wise Procedure for Pigging & N2 Purge after Dispatch to Ship of Bitumen .e.g. from T-BTM-001 (Dike II)

15. Place a Drum of the Product, insert the hose i& secure the hose
16. Open the drain valve
17. Open the Tank Outlet valve
After the above activities are completed, restore normal positions 20
10 Legend
Valve Open
13 Valve Closed
3
7
Pump Running
9
4 5
19 8 12 6
11
2
16 17
18
14
15 21 344
N2 Purge II leg - Step wise Procedure for Pigging & N2 Purge after Dispatch to Ship of Bitumen .e.g. from T-BTM-001 (Dike II)
2
Legend
4 Valve Open
Valve Closed
Pump Running
Pump Stopped

5
4. Open the Utility valve and N2
345
5.2 Tanker Loading of Products
The Tanker Loading has 5 Bays for Loading the Products to the Tankers. Each Bay has loading
Arm/s provided for Loading of Products on to the Tankers
 Loading Bay 1 has 2 Loading Arms - One exclusively dedicated for Bitumen and the Other
for all other Products
 Bay 2 to Bay 5 have one Loading Arm each, which can be utilized for any of the Products in the
Terminal Except Bitumen
 There are dedicated Batch Controllers for each Product line
 Of the Products to be loaded in Tankers, Only Bitumen is Loaded from the Top
 All the Other Products are Loaded from the Bottom
 Close coordination is required among the following personnel for carrying out Tanker Loading
Operations:
 Control Room Operator
 Field Operator
 Tanker loading Supervisor
 Operators at the Loading Bays
 Security staff at the Tankers Entry & Exit gates who monitor the movements of Empty &
Filled Tankers
 Since use of Mobile phones should be avoided in areas handling Hydrocarbons, it is important that
proper internal communication facilities are functional
 Field Operators, who might not have ready access for internal communication facilities, as
a bare minimum, should be provided with a Walky-Talky and another provided in the
Control Room who in turn will coordinate with the others through internal communication
facilities
responsibilities for Transfer of Product from the Storage Tank in Dike I or Dike II to the Tanker
(TLF), which are detailed below.
Control Room Operator
 View on the Terminal Manager User Interface (TMUI) Coordinate & Reconfirm with the
Tanker Loading Supervisor and the Field Operators the following details:
 Product to be Loaded in the Tanker
 Location of the Tank from which the Product is to be transferred is in Dike I / Dike II
 Quantity to be Loaded
 Bay allocated for Tanker Loading
 Readiness of the Tanker for Loading

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346
 Select the Correct Product Tank from which the Product is to be Dispatched on the
 Select “DISP-TLF”
 Ensure that the Actuated valves of the selected Tank are in Remote Auto mode
 Once the “Remote Auto” mode is selected, on selection of “DISP-TLF” for the Tank on the
Remote Auto mode
Actuated valve for TLF (XV 5304 / XV 5404) Opens
 If the above conditions are fulfilled, the Tank is ready to Dispatch Solvent from the
Tank for Tanker Loading
 Coordinate with the Tanker Loading Supervisor, the and the Field Operator and when
all are ready Open the Digital Control valve of the selected Bay for the Product - DCV
8102/03/04/05/06 for all other Products except Bitumen / DCV 8101 – (Bay 1) for
Bitumen
 Ensure that no other Product Tank is selected for TLF from the same Bay
 Set the Quantity to be filled

 Coordinate with the Tanker Loading Supervisor, the and the Field Operator to monitor
Pumping the Product (Started in Remote Auto mode)
 Confirm that the Pump Stops in Remote Auto mode, when the Preset Quantity is filled
 Coordinate N2 Purging of the Line, if required, for Hot Jobs / maintenance on the
Tanker Loading Transfer line
 N2 Purging of the Transfer line is Not required after every transfer of Product from
any Tank for Tanker Loading, since the lines are dedicated and permanent lines from
the TLF transfer Pump up to the 5 Loading Bays & hence no fear of contamination of
Products
 Receive information from the Tanker Loading Supervisor and the Field Operator
regarding the Status and coordinate the necessary actions.
Security Entry Gate
 Check the relevant Papers presented by the Driver for getting the Tanker filled with the
requisite material
 Inform the Tanker Loading Supervisor about the arrival of Tanker with details for filling the
specified Product

[email protected]
347
 Look for details on the Terminal Manager User Interface (TMUI) to Print Filling Advisory Note
(FAN)
 Confirm that the Shipment is authorized by the Supervisor on TMUI with the following details:
 Compartment wise Product to be loaded

 Information about Driver & Vehicle
 Quantity to be Loaded
 Customer & Destination
 Print the Filling Advisory Note (FAN) and hand over to the Driver for Tare weighing of the
Tanker
Field Operator near the Weigh Bridge / Tanker Driver
 Present the valid FAN at the Weigh bridge and get the Tare weight printed with details of Bay
allocated for proceeding to get the Tanker filled
 After the Tanker is filled, Present the FAN for Gross Weighing
 If the Filled Quantity is more than the Tanker Capacity Or Less than the Specified Quantity
confirm that Decant Or Top UP is printed on the FAN and Guide the Driver for proceeding to
the Bay for appropriate actions (by the Loading Operator)
 If the Quantity filled is Correct, then Guide the Driver to the Exit Gate for collecting the Bill of
Lading (BOL)
Tanker Loading Supervisor
 Check the validity of the FAN brought by the Driver with the following details:
 Shipment Number & Details of Shipment

 Product to be filled
 Quantity to be filled
 Bay allocated for filling
 Compartment number in the Tanker to be filled
 Guide the Driver to the correct Bay for Loading
 Inform the Control Room Operator Field Operator about the Tanker and Details of Shipment
to be viewed on TMUI, for Opening the DCV downstream of the Flow meter to the correct Bay
and to Start the Pump
Field Operator (Pumps)

[email protected]
348
Actuated Inlet valves from C-001 and C-002 of Process Block are Closed in the field
Actuated valves to TLF (XV 5304 / XV 5404) is Opened in the field
 Get confirmation and Coordinate with the Control Room Operator, the Loading Supervisor
and the Loading Operator at the mentioned Bay before Starting the TLF Pump
 On confirmation from Control Room that the DCV for the correct Product and the correct Bay
has been Opened, Coordinate the Start of TLF Pump in Remote Auto mode
 Confirm that the FS on the Pump discharge is healthy, confirming that Pumping is in progress
 Inform Control Room, the Loading Supervisor & Loading Operator that the Pump has been
Started
 Coordinate & carry out N2 Purging of the Line, if required, for Hot Jobs / maintenance
on the Tanker Loading Transfer line
 N2 Purging of the Transfer line is Not required after every transfer of Product from
any Tank for Tanker Loading, since the lines are dedicated and permanent lines from
the TLF transfer Pump up to the 5 Loading Bays & hence no fear of contamination of
Products
 Please refer the Marked up drawing for N2 Purging, if require to be carried out
Tanker Loading Operator
 Check the authorized FAN details

 Confirm that the System displays the Correct Quantity and Arm Number
 Authorize the Name & Quantity of Product to be loaded
 Authorize the Compartment Number of the Tanker to be Loaded
 Connects the Loading Arm to the Correct Compartment of the Tanker
 Completes the Grounding (Earthing) to the Truck
 Confirm that “Press Start to Start Loading” is indicated on the Batch Controller Unit (BCU)
 Press the Button & Start Loading the Tanker
 Confirm that the Pump stops when the Preset Quantity is filled & Filling Stops
 Disconnect the Loading Arm and the Grounding to the Tanker
 Guide the Driver to proceed for Gross weighing
Dispatch Section (at the Security Gate)
Responsibilities include the following:
 Close the Shipment Status in the Terminal Manager User Interface (TMUI)
 Print the Bill of Lading (BOL) and hand over to the Driver
Security Exit Gate

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 Check the BOL, carry out final inspection of the vehicle and allow the vehicle to Exit the
Terminal
5.2.1 Preventive maintenance during Tanker Loading

 All leakages should be coordinated through the Control Room & Field Operators who in turn
temporarily Stop Pumping and restart the Pump after the Leakages are attended
 DCV for Tanker Loading may be Closed in the field resulting
on the Pump discharge line
known
 The problem should be attended to before Truck Loading can be done from the selected
Tank
 Line from the Storage Tank to the TLF may be blocked

Identification of Problem / Choked portion of the line
 Try to ascertain the segment of choke, by opening the drain points and checking
 Under coordination with all the other Operators, Tap the line at different places with a wooden
mallet and check the drain points with throttled opening (10-15%)
 If the choke cannot be identified or cleared, get the TLF transfer Pump electrically isolated
and open flanges at different segments and clear the line segment by segment

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5.2.2 Breakdown maintenance during Tanker Loading

 Stop Pump in coordination with all the Operators

 Start N2 Purging of the line as explained above
 After N2 purging for about 1 hour, Check & Confirm if the line is Dry, N2 comes out with Pressure
from the drain point & no liquid is present
 When the line is free of HC / Inflammable material, handover the line for maintenance
and necessary actions
 Restart Tanker Loading after reinstatement of the System to original conditions

 Tanker Loading from the Other Tank (if available) / Other Products may be scheduled
during this period
ii) Tanker Loading Pump breakdown
 Since there is only one pump of each Tank and no Standby pump is available, there is no other
alternative than to suspend Tanker Loading from that Particular Tank until the Pump is rectified /
replaced
 Close the Pump Suction & Discharge valves
 Isolate the Pump electrically
 Purge the discharge line of the Pump with N2 as explained above

 Handover the Pump for Maintenance / Replacement
 Tanker Loading from the Other Tank (if available) / Other Products may be scheduled
during this period
 Tanker Loading from the same Tank with the same Pump (handed over to maintenance)
may be restarted after the Pump is returned after maintenance and the lines & valves are
reinstated to original position

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Typical Step wise Procedure for Tanker Loading from .e.g. Naphtha Tank T-NPT-001
Legend
Valve Open
Valve Closed
4
Pump Running
1 Pump Stopped
5
2
11
9
3
10
8
1. Confirm Tank Inlet Activated valve is Closed
2. Confirm Tank Outlet Activated valve is Open
3. Confirm that the Activated valves from the Process Block are Closed
4. Close all other valves as shown
5. Open the Tank Outlet Manual isolation valve (Optional)
7. Coordinate with Control room to Open DCV to TLF (Ref. next sheet)
8. Coordinate with Control room to Start Pump on 'Remote Auto' 7&8
9. Open the Discharge valve
10. Confirm good pressure on PG & FS is healthy
11. Product to TLF
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Typical Step wise Procedure for Tanker Loading from .e.g. Naphtha Tank T-NPT-001
1. Tanker at Allocate Bay (e.g. Bay 3) after Tare weighing with valid FAN
2. Check & Confirm FAN details in TMUI
2
3. Coordinate with Control Room to Open the DCV of allotted Bay (3)
4. Connect the Loading Arm Outlet to Tanker Legend
5. Connect Earthing to Tanker
6. Open Only the manual isolation valve for the Product on the distribution header Valve Open
7. Ensure that Isolation valves for all Other Products on the allotted Bay are Closed Valve Closed
8. Coordinate with Control Room & Field Operator to Start Pump
9. Product flows to the allotted Bay (3)
10. Open the Filling valve, Press "Start Filling" Button and Start Filling the Tanker 3,8 & 12
11. When Preset Quantity is filled, Confirm that the Flow Stops
12. Coordinate with Control Room & Confirm that DCV is Closed
14. Close the Filling valve
15. Disconnect Loading Arm connection to the Tanker
16. Disconnect Earthing to the Tanker
17. Guide Tanker Driver for Final Weighing
9
6
7
12
1
4
10 5 Earthing
14 16
15
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Typical Step wise Procedure for N2 Purging of TLF line .e.g. Naphtha Tank T-NPT-001
Required Only for Hot jobs on the line / Maintenance
Legend
Valve Open
Valve Closed
Pump Running
4 5 Pump Stopped
3 8
6 9
1. Ensure the Pump is Stopped & Electrically isolated

2. Keep the Pump Suction & Discharge valves fully Closed
3. Confirm that the Tank Outlet Activated valve is Closed (and also all Other Activated valves)
4. Keep the manual isolation valve on the Tank Outlet Closed
5. Connect Utility N2 hose on the Utility connection
6. Open the Pump Recirculation valve
7
7. Coordinate with Control Room, Tanker Loading Supervisor & Operator before starting N2
8. Open Utility N2 valve and then the Utility connection valve on the Tank Outlet line
9. N2 Purging Started towards TLF
354
Typical Step wise Procedure for N2 Purging of TLF line .e.g. Naphtha Tank T-NPT-001
1. Open Only the manual isolation valve for the Product on the distribution header
2. Ensure that Isolation valves for all Other Products of the Bay (3) are Closed
3. Ensure that No Tanker is allocated for the Bay
4. Connect a hose to the drain of the header
5. Place a Drum of the Product, insert the hose & secure the hose
6. Cordon off the Area with Sign board "Entry Prohibited"
7. Only the Operator filling the Drum should be inside the cordon with mandatory Safety gears
8. Coordinate with Control Room & Confirm that DCV to the Bay (3) is Closed
Legend
9. Coordinate with Control Room & Field Operator to Start N2 purge 7
10. Crack Open the Drain valve (10-15%) & regulate the Opening to avoid Spray & Spill from the Drum due to excess Pressure
11. After the liquid is fully displaced and only N2 starts coming, continue for some more time to purge the line free of HC Valve Open
12. Coordinate with Control Room & Field Operator to Stop N2 purging Valve Closed
8,9 &12,21
13. Close the manual valve of the Product on the distribution header
14. Cloe the drain valve & shift the Utility hose to the next Bay
16,17,18,19. Repeat the above Steps for all the other 4 Bays for the Product line from that Tank, One at a time,
cordoning off each Bay to purge out the Product completely from the line
20. After the above steps, loosen the end flange of the main distribution header for the Product from that Tank
21. Coordinate with Control Room & Field Operator to Restart N2 Purge
22
22. Continue Purging with periodic checks until the gas outlet of the line is free of HC / Inflammable material
N2 Purge - Check for
23. Hand over the line for Hot job
HC /,Inflammables
9 14
1
20
10
2
Entry Prohibited 14
6 Entry Prohibited
4
5
15
8
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5.3 Drum Filling of Products
There are two Drum Filling Units (DFU) Installed in the Terminal.
DFU-00I is exclusively dedicated Bitumen and it is a Palletized Drum Filling Unit with 4 Drums loaded
on the Pallet. It has capacity to fill 30 Drums per hour. One Working Unit and One Standby are
provided.
DFU-002 can be used for all other Products except Bitumen. It is a single Drum Filling Unit. The
wetted parts are SS 304 material and hence the DFU is compatible for all the materials in the
Terminal including Phenol and Glycols. One Working Unit and One Standby are provided.
Operations:
 Field Operator
 Drum Filling Supervisor / Operator
facilities
responsibilities for Transfer of Product from the Storage Tank in Dike I or Dike II to the Drum Filling
Unit.
 View on the Terminal Manager User Interface (TMUI) Coordinate & Reconfirm with the Drum
Filling Supervisor / Operator and the Field Operators the following details:
 Product to be Filled in Drums
 Location of the Tank from which the Product is to be transferred is in Dike I / Dike II
 Readiness of the Drum Filling Unit to commence Operations
 Select the Correct Product Tank from which the Product is to be Filled in Drums on the
 Select “DISP-DRUM”
 Ensure that the Actuated valves of the selected Tank and the Drum Filling Pump are in
Remote Auto mode
 Once the “Remote Auto” mode is selected, on selection of “DISP-DRUM” for the Tank on the

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 Only One Bitumen Tank and only One Product Tank other than Bitumen can be
selected on the TMUI screen for Drum Filling
Remote Auto mode
 Bitumen Tank (Dike II) – If the selection for Drum Filling is Bitumen Tank T-BTM-001 /
002, Confirm that the Actuated valve for TLF (XV 5304 / XV 5404) is Closed Remote
Auto mode
 If the above conditions are fulfilled, the Tank is ready to Dispatch Product from the
Tank for Drum Filling
 Coordinate with the Drum Filling Supervisor / Operator and Open the Activated valve feeding
the Drum Filling Unit as follows:
 If the Product selected for Drum Filling is Bitumen, Open the Actuated valve for Drum
Filling T-BTM-001 / T-BTM-002, XV 8201
 For Other Products, Open the Actuated valve for Drum Filling XV 8202
 Coordinate with the Drum Filling Supervisor / Operator, the and the Field Operator to
monitor Pumping the Product, when all of them are ready
 Coordinate N2 Purging of the Line, if required, for Hot Jobs / maintenance on the
Tanker Loading Transfer line
 N2 Purging of the line from the Tank up to the Drum Filling Transfer Pump is Not
required after every transfer of Product from any Tank for Drum Filling, since the
lines are dedicated permanent lines from the Tank up to the Transfer Pump & hence
no fear of contamination of Products
 N2 Purging of the line from the Tank up to the Drum Filling Transfer Pump may be
carried out during long duration only for Heat sensitive materials
 However, for all the Products, it is desirable to Flush the line from the Transfer Pump
discharge up to the nozzle of the Drum Filling Unit with N2, to clear the holdup of
previous material with the next Product lined up for Drum Filling in DFU- 002
 Receive information from the Tanker Loading Supervisor and the Field Operator
regarding the Status and coordinate the necessary actions.
Drum Filling Supervisor / Operator

Bitumen (DFU 001)
 Power ON the Controller
 Switch ON the VFD conveyor
 Chose the Recipe & Set values

 Point the Cursor1 to Screen Button & Press OK
 Move Cursor to Recipe2 Button

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 Point the cursor to the Recipe Number3 Button & press OK

 Move the cursor to the Edit Button4 & Press OK
1
Cursor can be moved by Up /Down /Right / Left Buttons
2
For DFU 1 there should be only One Recipe “Bitumen” – to be confirmed at site
3
For DFU 1 there should be only 1 Recipe Number – to be confirmed at site
4
This is a provision to change the Batch weight, Semi course, Course Wt., In flight Wt.
& Drum Tare Wt. – This should normally be undisturbed and best carried out by
experienced persons – Please Refer definitions below
Definitions:
Batch Wt. : Wt. of Material to be filled
Coarse Wt. : At this Wt. in Kgs the Actuator Ball valve partially closes
Semi Coarse Wt. : At this Wt. in Kgs the Actuator Ball valve fully closes
In flight Wt. : Wt. of Material that will fall into the Drum after valve closes
Tare Wt. : Wt. in Kgs of Empty Drum
*For all Wt. & Time values the last 2 digits Decimals
 Ensure that the Weight Reading on display is 0, initially

 Load the Pallet with the number of Empty Drums (Normally 4) as set in the Recipe
 Place the Pallet with Empty Drums on the Feed Conveyor
 Release the Emergency Stop Push Button, if pressed
 Put the System on Auto mode
 Press the in-feed Forward Button momentarily – The Pallet with Drums will move forward and
Stop on the Weighing Platform (by Limit switch activation)
 Use nozzle Forward & nozzle Reverse Push Buttons and align nozzle to the bung opening of
the Drum
 Coordinate with the Control Room Operator (& Field Operator) to get the Drum Filling
Transfer Pump (P-BTM-004) Started
 Coordinate with Control Room & ensure that the Activated valve for DFU XV 8201 (for
Bitumen) is Open
 Ensure that the pressure is 4 Kg / cm2 inlet to the DFU as read on the pressure gauge
 Press Start Button, after which the following actions should take place:
 The Controller checks the Tare weight & its correctness as per Software formula
(*If the Tare weight is not in line with Software formula Error will be displayed and the
Process Stopped)
 The Drum Tare weight will be displayed and the drip tray will be retracted back
 The nozzle is taken down at the pre-set time in the Controller for Head down time
 If the nozzle touches the Drum & align error will be displayed and nozzle retracts
back; if so realign the bung opening of the Drum to nozzle to proceed further
 After the pre-set Head down time on the Controller, the limit switch should sense the nozzle
down position
 The nozzle should Open & after the preset prefill delay in the Controller, the ball valve
should Open fully
 Material starts flowing into the Drum & Material Flow timer will be started
 *The controller checks the Material weight to confirm that the weight of the Material in
the Drum is equal to or above the material flow weight for the set time. If the weight is
less than the above, “Material Flow Error” will be displayed and nozzle would be
retracted back.
If so, it is an indication of blockage in the line for Insufficient / No flow, for corrective
actions before proceeding further

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 When the weight in the Drum crosses the coarse set point, the ball valve partially closes
 When the weight in the Drum crosses the semi coarse set point, the ball valve fully closes
 The dripping timer is started, the nozzle Closes after the preset dripping time in the
Controller, the nozzle is pulled up & the drip tray comes forward for the preset Head up
time in the Controller
 Before the end of the Preset Head up time, align the next Drum bung hole on the
Pallet to the nozzle as explained above
 Repeat the above for the balance 2 Drums on the Pallet (Total 4 Drums on the Pallet)
 When all the Drums on the Pallet as programed are filled, the Process Stops
 When all the Drums on the Pallet are filled, press Outfeed Button to move the Pallet out
of the weighing platform
 Repeat the above procedure for Filling the next Pallet of Drums as explained above
 Continue Drumming the Product for the Target number of Drums / Target duration
 At the end of Drumming operations, Coordinate with the Control Room and get the
Drum Filling Transfer Pump stopped
 Push the holdup material in the Transfer Pump discharge line up to the nozzle with N2
and collect the pushed material in a Drum – this is not a set program of the Controller
but manual operation, to ensure that the line and the nozzle are free of material &
hence probable choke up during the Shutdown period
 Coordinate with the Control Room and get the Activated valve for Drum Filling Closed
All Products Except Bitumen (DFU 002)
 Power ON the Controller
 Chose the Recipe & Set values
 Point the Cursor1 to Screen Button & Press OK
 Move Cursor to Recipe2 Button
 Point the cursor to the Recipe Number3 Button & press OK
 Move the cursor to the Edit Button4 & Press OK
1
Cursor can be moved by Up /Down /Right / Left Buttons
2
For DFU 2 Products Other than Bitumen would be listed with their Recipe Numbers
3
For DFU 2 the selected Product to be filled in Drums with its Recipe Number will be
displayed
4
This is a provision to change the Batch weight, Semi course, Course Wt., In flight Wt.
& Drum Tare Wt. – This should normally be undisturbed and best carried out by
experienced persons – Please Refer definitions below
Definitions:
Batch Wt. : Wt. of Material to be filled
Coarse Wt. : At this Wt. in Kgs the Actuator Ball valve partially closes
Semi Coarse Wt. : At this Wt. in Kgs the Actuator Ball valve fully closes
In flight Wt. : Wt. of Material that will fall into the Drum after valve closes
Tare Wt. : Wt. in Kgs of Empty Drum
*For all Wt. & Time values the last 2 digits Decimals

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 Ensure that the Weight Reading on display is 0, initially

 Load the Empty Drum on the Platform
 Release the Emergency Stop Push Button, if pressed
 Put the System on Auto mode
 Align nozzle to the bung opening of the Drum
 Confirm that the Instrument Air Pressure is available at minimum 6 Kg / cm2 inlet to the
AODD Pump
 Coordinate with Control Room & ensure that the Activated valve for DFU XV 8202 (for
Products other than Bitumen) is Open
 Open the AODD Pump Discharge valve
 Open the Air Inlet valve to the Pump
 Operate the Pump as per vendor procedure
 Confirm that the pressure of the Product being filled is minimum 4 Kg / cm2 inlet to the DFU
as read on the pressure gauge
 Press Start Button (of the DFU), after which the following actions should take place:
 The Controller checks the Tare weight & its correctness as per Software formula
(*If the Tare weight is not in line with Software formula Error will be displayed and the
Process Stopped)
 The Drum Tare weight will be displayed
 The nozzle is taken down at the pre-set time in the Controller for Head down time
 If the nozzle touches the Drum & align error will be displayed and nozzle retracts
back; if so realign the bung opening of the Drum to nozzle to proceed further
 After the pre-set Head down time on the Controller, the limit switch should sense the nozzle
down position
 The nozzle should Open & after the preset prefill delay in the Controller, the ball valve
should Open fully
 Material starts flowing into the Drum & Material Flow timer will be started
 *The controller checks the Material weight to confirm that the weight of the Material in
the Drum is equal to or above the material flow weight for the set time. If the weight is
less than the above, “Material Flow Error” will be displayed and nozzle would be
retracted back.
If so, it is an indication of blockage in the line for Insufficient / No flow, for corrective
actions before proceeding further
 When the weight in the Drum crosses the coarse set point, the ball valve partially closes
 When the weight in the Drum crosses the semi coarse set point, the ball valve fully closes
 The dripping timer is started, the nozzle Closes and after the preset dripping time in the
Controller, the nozzle is pulled up for the preset Head up time in the Controller
 Remove the Filled up Drum from the Platform

 Load the next empty Drum on the platform and align the bung hole to the nozzle as
explained above
 Repeat the above procedure for Filling the Drum as explained above
 Continue Drumming the Product for the Target number of Drums / Target duration
 At the end of Drumming operations, Coordinate with the Control Room and get the
Drum Filling Transfer Pump stopped

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 Push the holdup material in the Transfer Pump discharge line up to the nozzle with N2
and collect the pushed material in a Drum – this is Not a set program of the Controller
but manual operation, to ensure that the line and the nozzle are free of material &
hence probable choke up during the Shutdown period
 Coordinate with the Control Room and get the Activated valve for Drum Filling Closed
5.3.1 Preventive maintenance - Drum Filling

i) Product Weight inaccurate / Weight without Material / Drum is < or > 0
 If the Final weight of the Filled Drum is not as programmed or if the Empty weight is not equal to 0,
it is a clear indication that the machine needs to be calibrated
 The Weighing machine needs to be calibrated with Standard weights as per vendor
procedure.
 Calibration should be desirably carried out by experience (Instrumentation) personnel
and should not be tampered with by unauthorized persons
 Standby DFU may be lined up during the calibration of one DFU
ii) Line leakages involving Cold jobs (from Flanges, Valves etc
 In case of line leakages involving Cold jobs like Flange leakage etc., Coordinate with Control
Room & Field Operator and get the Transfer Pump for Drum Filling stopped
 Get the leakage attended and Restart operations
iii) Drum Filling Transfer Pump under maintenance
 Products Except Bitumen (DFU 002) - There is flexibility to take the alternative pump for Drum
Filling by changing over the hose connection with QRC coupling from the Tank Outlet line to the
Suction of the alternative Pump
 Bitumen (DFU 001) – DFU transfer Pump P-BTM-004 is dedicated for Bitumen and there is no
Standby available
 Hence the only option is to expedite the maintenance of the Pump. If this is going to be
time consuming, get the Pump replaced by Warehouse Spare pump to commence
Drum Filling of Bitumen
iv) Transfer is blocked / Quantity Pumped is less

Identification of Problem / Choked portion of the line

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 If the choke cannot be identified or cleared, get the TLF transfer Pump isolated and open
flanges at different segments and clear the line segment by segment
5.3.2 Breakdown maintenance - Drum Filling

 Stop Pump in coordination with Control Room Operator

 Start N2 Purging of the line as depicted in the enclosed Marked up Drawing
 After N2 purging for about 1 hour, Check & Confirm if the line is Dry, N2 comes out with Pressure
from the drain point & no liquid is present
 When the line is free of HC / Inflammable material, handover the line for maintenance
and necessary actions
 Restart Drum Filling Operations after reinstatement of the System to original conditions

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Typical Step wise Procedure for Drum Filling from .e.g. Naphtha Tank T-NPT-001
Legend
Valve Open
Valve Closed
4
Pump Running
1 Pump Stopped
5
2

363
Legend
Valve Open
Valve Closed
Pump Running
Typical Step wise Procedure for Drum Filling from .e.g. Naphtha Tank T-NPT-001
Pump Stopped
1. Select the available Pump (P-SOL-004A)

2. Connect a hose from selected Tank Outlet to Pump
3. Open Tank Outlet & Pump Suction valves
4. Load the Drum on DFU Platform
5. Align Filling nozzle to the bung opening of the Drum
6. Coordinate with Control Room to Open the Actuated valve 7 3
7. Open Instrument Air to the AODD Pump
8. Put the DFU System on Auto mode, Start the Pump & Start Filling in the Drum
9. When Filling is Completed, Offload the Drum from Platform, Close & Seal Openings 1
10. Shift Drum to Storage Area
2
5
8
4 9
10
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Legend
Valve Open
Valve Closed
Pump Running
N2 Purge Leg I - Typical Step wise Procedure for N2 Purge after Drum Filling from .e.g. Naphtha Tank T-NPT-001 Pump Stopped
1. Close Tank Outlet & Pump Suction valves
2. Connect Utility N2 hose on the Pump Suction line
3. Load the Drum on DFU Platform
4. Align Filling nozzle to the bung opening of the Drum
5. Coordinate with Control Room to Open the Actuated valve 5
6. Open Instrument Air to the AODD Pump
7. Open Utility N2 & Utility connection drain valve
8. Operate Pump & Start Filling N2 Purged Product in Drum with Safety gears to safeguard
against liquid splashing
9. Shift the Drum when N2 Purge is Completed
N2 Purge Leg II- Typical Step wise Procedure for N2 Purge after Drum Filling from .e.g. Naphtha Tank T-NPT-001

10. Close the Utility connection drain valve
11. Load the Drum on DFU Platform 6 7
8 & 18
12. Align Filling nozzle to the bung opening of the Drum 10
13. Coordinate with Control Room to Open the Actuated valve
14. Open the Tank Outlet & Pump Suction valves 17 21
15. Coordinate with Control Room & Field Operator and give clearance for N2 Purge
16. N2 Purge II leg is in progress (Pl Refer next sheet)
17. Open Instrument Air to the AODD Pump 2
18. Operate Pump & Start Filling N2 Purged Product in Drum with Safety gears to
safeguard against liquid splashing 15 14
19. When liquid is fully displaced & only N2 starts coming, Stop Pump & Shift Drum
Entry Prohibited
20. Cordon off the area 13
20
21. Open the Drain valve the Utility connection drain valve & Start venting N2
22. Purge for around 1 hour & analyze vent sample periodically for HC / Inflammables
16
23. When the sampled is free of HC / Inflammables, give clearance of Hot / Maintanence 1
Reinstate the System to Original positions after N2 Purge Leg I & / II are complete
4
12 8 18
3
9
11
19
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N2 Purge Leg II - Typical Step wise Procedure for N2 Purge after Drum Filling from .e.g. Naphtha Tank T-NPT-001
Legend
Valve Open
Valve Closed
Pump Running
2 3 Pump Stopped
1 5
1. Confirm that the Tank Outlet Activated valve is Closed (and also all Other Activated valves)
2. Keep the manual isolation valve on the Tank Outlet Closed
3. Connect Utility N2 hose on the Utility connection 7
4. Coordinate with Control Room, Drum Filling Supervisor & Operator before starting N2
6. N2 Purging Started towards Drum Filling Unit
4
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5.4 Products Blending
Blending Tank T-BLD-001 is provided to blend different products to produce marketable

product of desired compositions.
The products to be blended in the Blending Tank should be transferred to the Blending Tank
one after the other in desired quantities, as judged by the increase in the level of the
Blending Tank after transfer of each Product transfer. The transfer of individual Product is
done from their respective Tanks through the Transfer Pump up to the Piping Manifold and
from the Manifold the Product will be diverted to the Blending Tank through appropriate hose
connections.
Since the Product hold up in the line from the Transfer Pump/s up to the Blending Tank has to
be N2 flushed to clear the holdup liquid in the line, for the Safety of Manifold Operator as
mentioned below, the holdup volume of Product in the line should be accounted for in arriving
at the desired quantities for final composition of Blended Product.
There will be a dead volume of the earlier Products blended and transferred up to the Tank
Outlet Actuated valve XV 8301 even if the Blended product of the Batch is fully transferred up
to the Outlet valve. Hence the composition of the dead volume should be taken into
consideration in blending a fresh batch of Products for Blending, to arrive at the final desired
composition.
The Products pumped to Blending Tank, will be made homogenous in composition by running
the dedicated Blended Product Transfer Pump P-BLD-001 in recirculation.
After homogenizing the composition of Blended composition, the Blended product can be
transferred for Tanker Loading.
Operations:
 Field Operator
 Manifold Operator
 Blending Operator
 Tanker Loading Supervisor / Operator during Tanker Loading of Blended Product
facilities
responsibilities for Transfer of Product from the Storage Tank in Dike I or Dike II to the Blending
Tank and the Blended Product for Tanker Loading
 The marked up drawings are furnished for illustration only consisting of One Product
from Dike I and One from Dike II. However, the same procedure may be followed for
Blending more number of Products, as desired
 The marked up drawing should be read in conjunction with the details herein, to note

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 N2 push of the Products to be blended (I leg), after their individual transfers to the Blending
Tank is required from their Transfer Pumps, to ensure the Safety of Operators for
disconnecting hoses at the Manifold, after their transfer
 N2 Purging is mandatory free of HC / Inflammables for Hot jobs on the line
 N2 Purge of individual Product lines (II leg) from their respective Tanks up to the Transfer Pump is
not required since these are dedicated lines
 N2 Purging is mandatory free of HC / Inflammables for Hot jobs on the line
 N2 push of the Blended Product to the TLF may be carried out, only if the new Blend of Products
is different and the composition of the new Blended Product is of significance.
 However, N2 Purge of Product lines and Blended Product transfer line to TLF is mandatory
for Hot maintenance jobs on the line.
 Coordinate & Reconfirm with the Blending Operator, Manifold Operator and the Field
Operator as to the Products to be transferred and the Location of the Tanks from which
the Products are to be transferred is in Dike I or Dike II for Products to be Blended 1, 2
or more as required
 Select the Correct Product Tank into which the Product is to be transferred on the
 Keep the Actuated Inlet valve Closed in Remote Manual Mode
 Keep the Actuated Outlet valve Open in Remote Manual Mode
Actuated Inlet valves from C-001 and C-002 of Process Block remain Closed
C-002 of Process Block remain Closed
 If the above conditions are fulfilled, the Tank is ready to Dispatch Product from the
Tank for Blending
 Coordinate with the Blending Operator, the Manifold Operator and the Field Operator to
Start Pumping the Product, when all of them are ready
 Receive information from the Blending Operator, Manifold Operator and Field Operator
b) Field Operator

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 Coordinate & Reconfirm with the Control Room, Manifold & Blending Operators as to
the Products to be Blended and the Location of the Tanks from which the Products are
to be transferred is in Dike I or Dike II and the sequential order in which the Products
are to be transferred
Actuated valves to TLF is Closed in the field
 Get the correct Pump ready for Pumping as follows:

 Go to the Right Pump location based on the Location of the Tank from which the Product is to
be Pumped from Dike I or Dike II and the Product to be Pumped based on the allocation of
Pumps for various Products / Solvents mentioned above
Products of Dike I
Methanol:
 Chose P-MTL-003A Or P-MTL-003B depending on availability
 Only in case of an Emergency or Non availability of both the Pumps P-MTL-003A & B,
P-SOL-009 can be taken in line for Methanol Export
 Open the isolation valve on the selected Tank (T-MTL-001 OR T-MTL-002) Outlet line
feeding the Suction header of the Pump selected Pump
 Close the isolation valve on the Outlet line of the other Tank (Not selected) leading to the
Suction header of the Pump
 Open the Suction isolation valve of the selected Pump P-MTL-003A Or P-MTL-003B
 Keep the Suction & Discharge isolation valves of the other Pump (Not selected) Closed
C09, White Spirit, Toluene, Styrene, Gasoline, Ethanol:

 Ensure that the isolation valves from the Methanol Tanks (T-MTL-001 & T-MTL-002)
Outlet lines joining the Suction header of P-SOL-009 are kept fully Closed
 Close the Isolation valves on the Outlet lines of all the Other Tanks and keep only the Outlet
line of the Tank whose Product is to be exported Open
Phenol, DEG, C10, C09, MPG, Ethyl Acetate

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T-PHL-001, T-DEG-001, T-C10-001, C-09-001,T-MPG-001, T-ETA-001 should be kept
Closed
 Open the Suction valve of the Pump and confirm that there is no leakage
Polyol, Base Oil

 The Pump for any of these Products is Gear Pump P-SOL-002
T-POL-001, T-BOL-001,002,003,004 should be kept Closed
 Open the Suction & Discharge valves of the Pump and confirm that there is no leakage
Products of Dike II
VAM, Xylene, Butyl Acetate, MEG, Naphtha (All except Bitumen)
 The Pumps for any of these Products is P-SOL-003A OR P-SOL-003B, depending on

availability
 Close the Isolation valves on the Outlet lines of all the Other Tanks to the Suction headers of
both the Pumps and Open Only the Outlet line of the Tank whose Product is to be
exported Only to the Suction header of the selected Pump P-SOL-003A OR
P-SOL-003B
 Keep the isolation valve on the selected Tank Outlet line to the Suction header of the
Pump Not selected Closed

 Applicable for all the above cases of Pumping - If leakages are observed near the Pump,
coordinate with the Other Operators and Stop the pump immediately
 Carry out the corrective actions for leakage and restart the Pump after coordination with the
Other Operators
 At the end of the Pumping operation, carry out N2 Purging of the Suction and discharge
lines in coordination with the Other Operators, if required and for Hot jobs on the line.
 N2 Purging, if required to be carried out, should be done segments wise, viz. Pump to
Blending Tank (after each Transfer) & Tank to Pump (only if required)

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 N2 Purge from the Storage Tank to the Transfer Pump for Dike I & Dike II Products
might not be required after every Dispatch for Blending , since the lines up to the
Transfer Pump are dedicated lines - Except Heat sensitive materials VAM & Phenol
(Dike I) and Bitumen & Styrene (Dike II)
 Coordinate & Reconfirm with the Control Room Operator, Blending Operator and the
Field Operator as to the Products to be transferred, the Location of the Tank from
which the Product is to be transferred for Blending is in Dike I or Dike II and the
sequential order in which the Products are to be transferred for appropriate Hose
Connections between the Feed line to the Blending Tank and the Manifold
 Connect one end of a hose with QRC to the Open end of Blending Tank feeding line
 Connect the QRC at the other end of the hose to the QRC connected to the Isolation valves of
the Correct Product line Connected to the Correct Manifold
 Open the two isolation valves connected to the hose feeding the Blending Tank
 Open the two isolation valves connecting the hose to the discharge line of Correct Transfer
Pump for Blending
 Coordinate and ensure through the Control Room and Field Operator that the Transfer line
of each Product is N2 purged and the line is free of holdup Product before uncoupling and
changeover of hose connections
 Give Clearance to the Jetty end Operator & Control Room to Start the Pump for each product as
per sequential order
 Coordinate with the Control Room Operator, Blending Operator and the Field Operator (near
 If leakages are observed near the Manifold end, coordinate with the Field Operator and
Control Room Operator to Stop pumping immediately
 Carry out the corrective actions for leakage and give clearance to the Field Operator and
 After completion of Pumping, coordinate with the Field Operator, Blending Operator and
Control Room Operator to N2 Purge from the Transfer Pump to the Blending Tank via the
Manifold
 Disconnect the hose connections after the Operations are completed
to self
d) Blending Operator
 Responsibilities include the following

 Confirm that the Inlet Actuated valve of the Tank is Open & the Outlet Actuated valve of the
Tank is Closed
 Confirm that all other valves are Closed

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 Coordinate with Control Room & Field Operator (Pumps) & give clearance for Pumping the
Products in the sequential order
 Observe & Confirm Level increase in the Tank during transfers
 Coordinate with Field and other Operators to N2 purge of the line holdup from the Transfer
Pump/s up to the Blending Tank and to get the N2 pressure regulated to avoid vigorous
agitation in the Tank
 After N2 Purge Completion coordinate with Control Room & Field Operator to Stop N2 Purge
 Coordinate with Control Room to Close the Inlet Actuated valve & Open the Outlet Actuated
valve of the Blending Tank
 Run the Pump in Recirculation to make the Blended Product homogeneous
 Coordinate with Control Room & TLF Supervisor for transfer of Blended Product to Tanker
loading
Preventive maintenance during Dispatch of Products for Blending
The procedure for Preventive maintenance is similar as for other Operations. However
detailed below is the procedure with changes as applicable for Blending
responsibilities for N2 Purge after Dispatch for Blending
 marked up drawing should be read in conjunction with the details given below, to note
5.4.1 Preventive maintenance during Dispatch for Blending

 All leakages should be coordinated through the Field Operator who in turn temporarily Stop
Pumping and restart the Pump after the Leakages are attended
(for Centrifugal Pumps) / PS (for Gear Pumps) on the Pump discharge line
known

A. Identification of Problem / Choked portion of the line
 If there is no problem with the Pump, then the line from the Storage Tank to the Transfer Pump or
from the Transfer Pump to the Manifold or from the Manifold to the Blending Tank may be choked

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responsibilities for Pigging & N2 Purge after Dispatches
The Blending Operator
 Check from the drain points of the Blending Tank Inlet line from the Manifold, if the Product
comes out normally from the drains
Manifold Operator
 Investigate to ascertain the status from the Transfer Pump to the Manifold is Choked
 Coordinate with the Field Operator to start N2 purge of the line from the Transfer Pump, as
depicted in the enclosed Marked up drawing with Stepwise procedure
 On starting of N2 Purge from the Transfer Pump as confirmed by the Field Operator, check
from the drain points, near the Manifold , if the liquid comes out with N2 Pressure
 If the Product comes out with N2 pressure from the drains, then the line from the
Transfer Pump up to the Manifold is clear, Otherwise the line is choked / blocked
somewhere in between
Field Operator
 Check from the drain points of the Tank Outlet line up to the Transfer Pump, if the Product
comes out normally from the drains(with the Tank Outlet valve Open) , confirming that the line
from the Tank up to the Transfer Pump is clear
 Whether or not the line from the Tank up to the Storage Tank is clear or not, proceed
with further investigations to ascertain the status from the Transfer Pump to the
Manifold
 Make arrangements for N2 Purge of the line from the Transfer Pump discharge as depicted in
the enclosed Marked up drawing with Step wise Procedure
 Get feedback from the Manifold Operator and Blending Operator regarding the Status of the
line from the Transfer Pump up to the Manifold and up to the Blending Tank for necessary
corrective actions
B. Corrective Actions - Line from the Transfer Pump up to the Manifold is

Choked
Blending, Manifold & Field Operators

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 If alternate Transfer Pump is available, as per allocation based on the Product

characteristics, under coordination with the other Operators, line up the alternative
Pump to commence Dispatch for Blending with appropriate connection of the hose to
the alternative pump
cleared
5.4.2 Breakdown maintenance during Dispatch for Blending

A. Transfer Line Leaks heavily involving Hot jobs
Manifold Operator
 If the leaky segment is from the Transfer Pump up to the Manifold, isolate the line from
the Manifold to the Blending Tank, by disconnecting the hose / positive isolation with
Blind / Slip plate
 After N2 purging for about 1 hour up to the Manifold, Check & Confirm if the line is Dry, N2
comes out with Pressure from the drain point & no liquid is present
Field Operator
 If the leaky segment is from the Storage Tank up to the Transfer Pump, Close all the
isolation valves from the leaky area and the discharge line of the Transfer Pump, with positive
isolation with Blind / Slip plate, on the discharge line flange of the Transfer Pump
 Insert Blinds / Slip plates as required for positive isolation of the Storage Tank for
carrying out the Hot job
 Start N2 purging of the line from the Storage Tank up to Transfer Pump as depicted in the
Marked up drawing
 If the leaky segment is between the Transfer Pump and the Blending Tank, under
coordination with Manifold and Blending Operators, make preparations and start N2 purging
from the Transfer Pump up to the Blending Tank, as depicted in the enclosed Marked up
drawing
 Continue N2 Purging until the line is free of HC / Inflammable material, as confirmed by tests
in the appropriate segment
 When the line is free of HC / Inflammable material, handover the appropriate segment of the
 Alternative Options available to save time to avoid delay due to the maintenance on the line, are
the same as above for Preventive maintenance

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 After the Pumping through the alternative line / alternative Tank is completed, continue with
N2 Purging in the first line until free of HC / Inflammable material, handover the line for
B. Blended Product Transfer Pump P-BLD-001 Breakdwon
 Since there is no Standby for the Transfer Pump, the only option is to get the maintenance of the
Pump expedited to start dispatching the Product to TLF
 If the maintenance of the installed Pump is time consuming, it may be replaced with ware
house spare Pump
C. Transfer Line to TLF Leaks heavily involving Hot jobs
 Make arrangements for N2 Purge of the line from the Transfer Pump T-BLD-001 discharge as
depicted in the enclosed Marked up drawing with Step wise Procedure
 Continue with N2 Purging in the first line until free of HC / Inflammable material, handover the
 Expedite the maintenance works to commence Pumping of Blended Product for Tanker
Loading

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Legend
Typical Step wise Procedure for Product Transfer for Blending of Dike I Tank .e.g. T-PHL-001 Valve Open
I Product to be Transferred to Blending Tank - For Illustration only Valve Closed

Pump Running
Pump Stopped
4
1
3

3. Open the Tank Outlet Manual isolation valve (Optional) 5
5. Coordinate & confirm to Control room & Field Operators that the Product is lined up for Transfer
376
Typical Step wise Procedure for Product Transfer for Blending .e.g. Naphtha Tank T-NPT-001
II Product to be Transferred to Blending Tank - For Illustration only
Legend
Valve Open
Valve Closed
4
Pump Running
1 Pump Stopped
5
2

6. Coordinate & confirm to Control room & Field Operators that the Product is lined up for Transfer
377
Procedure depicted for illustration only and does not represent th Products to be blended
Typical Step wise Procedure for Product Transfer for Blending of Dike I Tank e.g. Phenol T-PHL-001
Legend
I Product to be Transferred to Blending Tank - For Illustration only
Valve Open
Valve Closed
7 9 Pump Running
3
1 1. Keep all Tank Outlet valves Closed
2. Connect a hose from the Correct Tank Outlet to the Pump Suction line
2 3. Open the Correct Tank Outlet valve & Confirm No leak
5. Coordinate with Control Room, Manifold & Blending Operators before Starting the Pump 5
6. Start the Pump
4 6 7. Open the discharge valve
9. Product to Dike I Manifold
9
7 Typical Step wise Procedure for Product Transfer for Blending of Dike II Tank e.g. Naphtha Tank T-NPT-001
II Product to be Transferred to Blending Tank - For Illustration only
1. Keep all Tank Outlet valves to the Suction headers of Pumps Closed
1
2. Ensure the Tank Outlet isolation valve of the Selected Tank to the Suction header of Pump Not selected
(P-SOL-003B) Closed
3. Open the Tank Outlet valve of the Selected Tank only to the Suction header of selected Pump (P-SOL-003A)
5. Coordinate with Control Room, Manifold & Blending Operators before Starting the II Product Pump 5
3 6. Start the Pump
2
378
21 18
12
5
15
8 2
Procedure depicted for illustration only and does not represent th Products to be blended
Typical Step wise Procedure for Product Transfer for Blending of Dike I Tank e.g. Phenol T-PHL-001
First Product to be Transferred for Blending
1. Connect hose from Transfer Pump discharge line (I Product) to line feeding the Blending Tank
2. Open the isolation valves feeding the Blending Tank
3. Open isolation valves on the Transfer pump discharge line (I Product) near the manifold
4. Communicate Clearance for Pumping to C.R. & Field Operators for Pumping I Product
4&7
5. Product 1 to the Blending Tank
6. N2 Push the line hold up Product to the Blending Tank (Pl Refer marked up drawing for N2 Purge)
7. Coordinate with Control Room & Field Operators to Stop N2 Purge when complete
8. Close the isolation valves feeding the Blending Tank
9. Close the isolation valves on the Transfer pump discharge line (I Product for) near the manifold
10. Disconnect the hose from the Transfer pump discharge line with Safety gears
10
3
9
6
Typical Step wise Procedure for Product Transfer for Blending of Dike II Tank e.g. Naphtha Tank T-NPT-001
Second Product to be Transferred for Blending
20
13
11. Connect the hose (free end) to the Transfer Pump discharge line (II Product)
12. Open the isolation valves feeding the Blending Tank
13. Open isolation valves on the Transfer pump discharge line (II Product for) near the manifold 14 & 17
14. Communicate Clearance for Pumping to C.R. & Field Operators for Pumping II Product 11
15. Product 2 to the Blending Tank 19 16
16. N2 Push the line hold up Product to the Blending Tank (Pl Refer marked up drawing for N2 Purge)
17. Coordinate with Control Room & Field Operators to Stop N2 Purge when complete
18. Close the isolation valves feeding the Blending Tank
19. Close the isolation valves on the Transfer pump discharge line (II Product for) near the manifold
20. Disconnect the hose from the Transfer pump discharge line with Safety gears
21. Disconnect the hose from the Blending Tank feeding line with Safety gears
379
N2 Purge I leg - Step wise Procedure for N2 Purge after Dispatch to Blending Tank of Dike I Tank .e.g. T-PHL-001
I Product Legend
1 1. Coordinate with Control Room, Manifold & Blending Operators regarding completion of Quantity to be Dispatched Valve Open
2. Close Pump discharge valve Valve Closed
3. Stop the Pump
4. Close the Pump Suction & Tank Outlet valves Pump Running
5. Insert a Slip plate (blind) on the discharge of Pump 7 Pump Stopped
7. Clearance from Manifold & Blending Operators to commence N2 purge
10. N2 purge to the Blending Tank in progress
11. Message from Blending & Manifold Operators 'N2 Purge Complete - Stop N2' 11
N2 Purge II leg - Optional but Mandatory for Hot jobs & Heat Sensitive materials
14. Insert a Slip plate (blind) on the Suction of Pump
21 9 10 20
19 16. Place a Drum of the Product, insert the hose & secure the hose
19. Open Tank Outlet valves
14 12 6 22
4
5 23. Shift the filled Drums to Storage Area
18 17
15 3 N2 Purge I leg - Step wise Procedure for N2 Purge after Dispatch to Blending Tank of Dike II Tank e.g. Naphtha Tank T-NPT-001
II Product
16 1 1. Coordinate with Control Room, Manifold & Blending Operators regarding completion of Quantity to be Dispatched
23 2. Close Pump discharge valve
3. Stop the Pump
10 5. Insert a Slip plate (blind) on the discharge of Pump 7
9
7. Clearance from Manifold & Blending Operators to commence N2 purge
13
2 8. Open N2 & the Utility valve
12 9. Open the Pump discharge valve
8 6 10. N2 purge to the Ship in progress
11. Message from Blending & Manifold Operators 'N2 Purge Complete - Stop N2' 11
5
3
4 N2 Purge II leg - Optional but Mandatory for Hot jobs & Heat Sensitive materials
17 14. Connect a hose to the Utility connection

19 18
16 15. Place a Drum of the Product, insert the hose i& secure the hose
14 17. Open the Tank Outlet valve
21
20
After the above activities are completed, restore normal positions
380
Products In & N2 Purge (I leg) - Step wise Procedure for N2 Purge after Dispatch to Blending Tank of I & II Products
Legend
Valve Open
Valve Closed
5 Pump Running
7 1
Pump Stopped
3
2
10
12
1. Confirm that the Inlet Actuated valve of the Tank is Open

2. Confirm that the Outlet Actuated valve of the Tank is Closed
3. Confirm that all other valves are Closed as shown
4. Coordinate with Control Room & Field Operator (Pumps) & give clearance for Pumping the I Product
5. I Product in to Blending Tank 4,6,8,9,11,13,14
6. After Pumping completion I Product Coordinate with Control Room Field Operators to commence N2 Purge
7. N2 Purge of I Product from the Transfer Pump
8. Coordinate with Field Operator to regulate N2 Pressure to avoid vigorous agitation in the Tank
9. Coordinate with Control Room & Field Operators & give clearance for Pumping the II Product
10. II Product in to Blending Tank
11. After Pumping completion II Product Coordinate with Control Room Field Operators to commence N2 Purge
12. N2 Purge of II Product from the Transfer Pump
13. Coordinate with Field Operator to regulate N2 Pressure to avoid vigorous agitation in the Tank
14. After N2 Purge Completion coordinate with Control Room & Field Operator to Stop N2 Purge 381
Blending, Homogenization & Transfer of Blended Product to TLF
Legend
Valve Open
Valve Closed
Pump Running
Pump Stopped
1 6
8
2
9
10
1. After completion of Products IN & N2 Purge, coordinate with Control Room to Close the Inlet Actuated valve
2. Coordinate with Control Room to Open the Outlet Actuated valve of the Tank 1,2,7
3. Open the Suction valve of the Transfer Pump
4. Start the Pump
6. Open the Recirculation valve & Recirculate for around 1 hour until the composition is homogeneous
7. Coordinate with Control Room & TLF Supervisor before transfer of Product to Tanker loading
9. Open the isolation valve to TLF for Tanker loading of Blended Product
10. Blended Product to TLF
382
Typical Step wise Procedure for Tanker Loading of Blended Product from T-BLD-001
1. Tanker at Allocate Bay (e.g. Bay 3) after Tare weighing with valid FAN Legend
2. Check & Confirm FAN details in TMUI 2 Valve Open
3. Coordinate with Control Room to Open the DCV of allotted Bay (3)
4. Connect the Loading Arm Outlet to Tanker
5. Connect Earthing to Tanker Valve Closed
6. Open Only the manual isolation valve for the Blended Product on the distribution header 3,8 & 12
7. Ensure that Isolation valves for all Other Products on the allotted Bay are Closed
8. Coordinate with Control Room & Blending Operator to Start Pump
9. Product flows to the allotted Bay (3)
10. Open the Filling valve, Press "Start Filling" Button and Start Filling the Tanker
11. When Preset Quantity is filled, Confirm that the Flow Stops
12. Coordinate with Control Room & Confirm that DCV is Closed
13. Close the Filling valve 9
14. Disconnect Loading Arm connection to the Tanker
15. Disconnect Earthing to the Tanker
16. Guide Tanker Driver for Final Weighing
6
12
1
4
10 5 Earthing
13 15
14
383
N2 Purge IIIleg - Step wise Procedure for N2 Purge after Dispatch from T-BLD-001 to TLF
5
4
3
8
8
9
1. Ensure the Pump is Stopped & Electrically isolated 1

2. Keep the Pump Suction & Discharge valves fully Closed
3. Confirm that the Tank Inlet & Outlet Activated valve are Closed
4. Connect Utility N2 hose on the Utility connection
5. Close the Pump Recirculation valve
7. Coordinate with Control Room, Tanker Loading Supervisor & Operator before starting N2 7
9. N2 Purging Started towards TLF
384
Typical Step wise Procedure for N2 Purging of TLF line from T-BLD-001
9 Required Only for Hot jobs on the line / Maintenance
22
N2 Purge - Check for
1. Open Only the manual isolation valve for the Product on the distribution header HC /,Inflammables
20
2. Ensure that Isolation valves for all Other Products of the Bay (3) are Closed
3. Ensure that No Tanker is allocated for the Bay
4. Connect hose to the drain of the header
5. Place a Drum of the Product, insert the hose & secure the hose
6. Cordon off the Area with Sign board "Entry Prohibited"
7. Only the Operator filling the Drum should be inside the cordon with mandatory Safety gears
8. Coordinate with Control Room & Confirm that DCV to the Bay (3) is Closed
9. Coordinate with Control Room & Blending Operator to Start N2 purge Legend
7
10. Crack Open the Drain valve (10-15%) & regulate Opening to avoid Spray from the Drum due to excess Pressure
11. After the liquid is fully displaced and only N2 starts coming, continue for some time to purge the line free of HC Valve Open
12. Coordinate with Control Room & Field Operator to Stop N2 purging 8,9 &12,21
Valve Closed
13. Close the manual valve of the Product on the distribution header
14. Cloe the drain valve & shift the Utility hose to the next Bay
16,17,18,19. Repeat the above Steps for all the other 4 Bays for the Product line from that Tank, One at a time,
cordoning off each Bay to purge out the Product completely from the line
20. After the above steps, loosen the end flange of the main distribution header for the Product from the Blending Tank
21. Coordinate with Control Room & Blending Operator to Restart N2 Purge
22. Continue Purging with periodic checks until the gas outlet of the line is free of HC / Inflammable material
23. Hand over the line for Hot job
13
10
2
Entry Prohibited 14
6 Entry Prohibited
4
5
15
8
385
5.5 Recirculation of Bitumen / Other Products in their Tanks
Provision exists in all the Tanks to recirculate its contents. The recirculation of the contents of
the Tank is totally a manual operation, the only instrumentation involved being the Tank Outlet
Activated valve to be opened through SCADA.
Only Bitumen Tanks T-BTM-001 and T-BTM-002 are provided with Activated valves on the
Recirculation lines with some Automation, mentioned below
5.5.1 Recirculation of Bitumen in Tanks T-BTM-001 / T-BTM-002
To keep the contents of Bitumen Tank, the following are operations to be carried out
 Confirm that there is no Fire or Gas Detection Alarm

 Select the Tank T-BTM-001 / T-BTM-002 and select “REICRCULATION” on the HMI
 Once the above selection is made in Remote Auto mode, confirm the following:
 The Tank Inlet Activated valve is Closed
 The Activated valve for TLF viz. XV 5304 / XV 5404 is Closed
 The Tank Outlet Activated valve is Open
 Recirculation Activated valve is Open
Field Operator
 Confirm the position of Activated valves are as above in the field

 The Tank Inlet Activated valve is Closed
 The Activated valve for TLF viz. XV 5304 / XV 5404 is Closed
 The Tank Outlet Activated valve is Open
 Recirculation Activated valve is Open
 Open the Suction & Discharge valves of the Bitumen Transfer Pump viz. P-BTM-001 / Tank P-
BTM-002 attached to the Tank whose contents are to be recirculated
 Open the manual isolation valve on the recirculation line
 Start the Pump
 Observe and confirm that the PG on the Pump discharge indicates pressure, the PS is healthy and
recirculation of Bitumen takes place

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Pre-Comm., Comm. Start Up & Opertion Manual R2 Terminal

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What are the steps involved in pre-commissioning?

What are the steps involved in pre-commissioning?

What are the steps involved in commissioning?

What are the steps involved in commissioning?

HAZEL INTERNATIONAL FZE

PRE-COMMISSIONING, COMMISSIONING & OPERATING MANUAL

PCS Projects Consultancy Services

Startup & Operations

PCS Projects Consultancy Services

1.3 Packages Pre-Commissioning 32

PCS Projects Consultancy Services

3.2.2 Breakdown & Shutdown of Process Cooling water system 235

PCS Projects Consultancy Services

4.2.1 Tanker Unloading to Storage Tanks 288

4.3 Inter-Terminal Transfer of Products 316

5.4 Products Blending 368

PCS Projects Consultancy Services

5.5 Recirculation of Bitumen / Other Products in their Tanks 386

PCS Projects Consultancy Services

1.1 Electrical Installations Pre-commissioning

 HV Switch gear Commissioning & Certification

PCS Projects Consultancy Services

 Commissioning of HV Switch gear broadly cover the following major activities:

 HV to LV Transformers Pre-commissioning & Certification

 HV to LV Transformers Commissioning & Certification

 LV Switch gear Pre-commissioning & to be certified ready for Commissioning

 LV Switch gear Commissioning & Certification

PCS Projects Consultancy Services

Tag No. Location From No. Subsystem No.

*Contact Resistance Test eport to be

5 Indications have been chekced and are OK

7 Alarm checks have been carried out, found satisfactory

8 Punch List items cleared

9 The system is ready to be charged to be Commissioned in service

Remarks : Additional details / Comments, if any

Signatories Date Signature

PCS Projects Consultancy Services

Tag No/s. Location From No. Subsystem No.

INSULATION RESISTANCE: (TEST VOLTAGE: ……...KV)

HV SG tested satisfactorily with Hi Pot.

PCS Projects Consultancy Services

Location From No. Subsystem No.

Panel Designation Resistance in Micro ohms Remarks

Signatories Date Signature

PCS Projects Consultancy Services

Location From No. Subsystem No.

WINDING RESISTANCE OR CONTINUITY

Sl. RESISTANCE RESISTANCE IN

INSULATION RESISTANCE TEST

Signatories Date Signature

PCS Projects Consultancy Services

Tag No. Location From No. Subsystem No.

1 Protective relay characteristics have been tested and found in order

Operation checks on meters and remote metering on DMS have been

4 Alarm checks have been done

5 Earth switch interlock operation has been checked

6 Remote operation from DMS has been checked

8 Busbars have been energized.