005 Lpg Om & Sop.pdf

Operating Manual and Standard Operating Procedures for LPG

1|Page

1.0 1.1

TABLE OF CONTENTS PART-I

1.2 1.3

Introduction Overview of paradip BOOT facility for LPG A) Activities of the LPG facility B) Facilities for handling LPG Purpose Scope and Applicability

2.0 2.1 2.2 2.3

Design Basis Overview Receipt details Dispatch details

3.0 3.1

Process Description Overview 3.1.1 Process Flow Diagram (PFD) for LPG storage facility 3.1.2 Instrumentation

3.2

Integration between Refinery and LPG facility

4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13

Facilities for LPG Handling Mounded bullets Pumps Pipeline Details LPG Blending system Ethyl Mercaptan Dosing Instrumentation and Automation Tank Truck Loading Tank Truck Unloading/ Vapour Compression LT Flare Water Drain Pot Electrical system Fire fighting system Utility system

5.0 Operating Philosophy 5.1 5.2 5.3 5.4 5.5 5.6 5.7

LPG Receipt LPG Dispatch LPG Inter Bullet Transfer Water Draining Ethyl Mercaptan Dosing Off Spec LPG handling Tank Truck Unloading

6.0 Control Philosophy 6.1 LPG receipt and dispatch system 6.2 Safety Interlocks (ESD) 6.3 Alarms And Trips 6.4 Relief Valve Setting

2|Page

7.0 Roles and Responsibilities Part-II Standard operating procedures 9.0 Modes of Operation and Operating Procedure 9.1 Operation Mode for Receipt and Dispatch: 9.2 Operating Procedure 9.2.1 Bullet Operations in Normal Condition 9.2.2 Bullet Operations in Emergency Conditions 9.3 Documented ProcedureOperational Activities 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

LPG (ON-SPEC/ BLENDING SPILLAGE) RECEIPT Mercaptan Dosing to LPG Off-Spec LPG Receipt Batch Formation / Bullet Preparation Inter Bullet Transfer LPG Dispatch To Marketing Pipe Line LPG Tank Truck Loading LPG Dispatch To Pipe Line Off-Take Sick Truck Handling/ Tank Truck Unloading Off-Spec LPG Pumping To Alkylation/ DCU Units Off-Spec LPG Pumping To Fuel Gas Pool

APPENDIX-1 APPENDIX-2 APPENDIX-3 APPENDIX-4

: : : :

APPENDIX-5 APPENDIX-6 APPENDIX-7 APPENDIX-8 APPENDIX-9 APPENDIX-10

: : : : : :

APPENDIX-11 APPENDIX-12 APPENDIX-13 APPENDIX-14 APPENDIX-15

: : : : :

PART III APPENDIX

BULLET DETAILS BULLET WISE NOZZLES AND ASSOCIATED FITTINGS RECEIPT/ DESPATCH DETAILS PUMP 4.1 WATER DRAIN POT 4.2 MERCAPTAN DOSING SYSTEM 4.3VAPOUR COMPRESSION PACKAGE 4.4 RVP ANALYSER 4.5 LT FLARE 5.0 UTILITY DETAILS 6.0 XZV DETAILS 7.0 MOV/ HOV DETAILS 8.0 LIST OF PSVS INTEGRATION BETWEEN REFINERY AND STORAGE FACILITY 10.0 INSTRUMENTATION DETAILS (LEVEL TRANSMITTER, PRESSURE TRANSMITTERS ETC) TRIPS AND ALARMS SAFETY INTER LOCKS FIRE PROTECTION DETAILS FIRST AID FIRE FIGHTING DETAILS AGDC (ALARM AND GAS DETECTORS COMBUSTIBLE) 15.1 FDAS (FLAME DETECTOR AND ALARM SYSTEM) 15.2 GAS ALARM BEACON WITH HOOTER-AGB 15.3 MANUAL CALL POINT-MCP 15.4 GAS ALARM SIREN-AGS 15.5 FIRE ALARM BEACON-AFB 15.6 FIRE ALARM SIREN-AFS

3|Page

APPENDIX-16 :

TANK TRUCK CHECK LIST

4|Page

PART-I OPERATING MANUAL

5|Page

CHAPTER-1 INTRODUCTION 1.0 INTRODUCTION IOT Utkal Energy Services Limited is a consortium of IOT, OT and IVRCL. IOT is a 50:50 joint venture company of Indian Oil Corporation Limited (IOC) and Oiltanking Gmbh (based in Hamburg, Germany). The contract for Installation, Operation and Maintenance of crude and finished product tankage facility at Paradip Refinery Project, Paradip is awarded to IOT Utkal Energy Services Limited (IOTUESL) on Build-Own- Operate-Transfer (BOOT) Basis for 15 years from the date of commissioning. IOT, one of the parent companies of IOTUESL is handling Petroleum storage and distribution, related Operations and Engineering activities for Oil Industries in India and Abroad. The LPG handling facility at Paradip is built in the year _________ and commissioned in the year __________ for receipt, storage and dispatch of LPG. This facility is constructed as state-of-art technology which is fully automated. It meets the requirements of all applicable standards, established by Oil Industry Safety Directorate standards. This manual gives operating guidelines for the various operations at the Offsite facilities for IOT Paradip tankage facility to handle LPG. It consists of Design basis, Facility Details, Process Description, Operating Philosophy, Operational Modes and Activities, and SOP for all Operational Activities and PFD. This Operating Manual is meant for the purpose of references of contents in connection with LPG handling facility alone. LPG stands for Liquefied Petroleum Gas. It is a mixture of mainly propane and butane and contains some percentage of unsaturated hydrocarbons like Propylene and Butane. As per Indian Standard Specifications, it is characterized any of the three categories: a) Commercial Butane b) Commercial Propane and c) Commercial Butane and Propane Mixture LPG produced at Paradip Refinery falls in the category of Commercial Butane and Propane mixture(c). LPG at ambient temperature is in gaseous state, but it is liquefied under pressure. LPG is highly flammable. It is used as a domestic fuel for cooking. It is also used for industrial purpose. Handling of LPG requires basic knowledge of its behaviour and properties at different

6|Page

conditions. With the knowledge and experience on LPG, it can be safely handled both in liquid state when it is produced or dispatched and in gaseous state when it is used as a fuel. 1.1 OVERVIEW OF PARADIP BOOT LPG FACILITY A) Activities of the LPG facility: The principal activities of the LPG handling facility are Receipt of LPG through rundown lines from the refinery through blending unit Storage in horizontal mounded bullets. Ethyl Mercaptan dosing during receipt/ during batch formation as an odouriser. Preparation prior to dispatch – batch formation, water draining and sampling. Off-spec LPG / blending spillage receipt to bullets. Inter Bullet Transfer LPG dispatch to Marketing Terminal through pipe line transfer. LPG transfer to PBKD pipe line off-take. LPG dispatch to Tank Trucks. Pressure relief/ blow system to LT Flare There is no manufacturing process involved in this facility and it is only an intermediate storage facility for IOCL Paradip Refinery. B) FACILITIES FOR HANDLING LPG: The facility is comprised of the following or hooked up with other off site facilities to handle LPG. 8 nos of Rundown lines (3”, 3”, 3”, 4”, 4”, 6”, 8” & 10”) from different refinery units for the receipt of LPG from Refinery to the mounded bullets via blend header. Inline static mixer with RVP (via blend header) analyser for the receipt of LPG from the refinery. Dedicated pipelines with online CTMS for the product delivery to marketing and pipe line off-take. 9 nos of Mounded bullets for LPG storage in two different mounds. 7 bays at loading gantry for Tank Truck loading out of which 4 bays are common for propylene/ LPG and 3 bays are dedicated for LPG. Dedicated Metering Skid and 2 no weigh bridges for tank truck loading. Utility system viz. Instrument Air, Plant Air, Nitrogen, Service Water and Drinking Water. Variety of pumps of assorted capacities to carry out dispatch operations. Fully computerized central control room – OMS and SRRs. Fully Integrated Control System (ICS) 66 kVA Electrical supply for Product tankage facility through transformers. 1 no 350 kVA DG set to meet the emergency backup requirement for maintaining continuous supply to UPS system. Fire fighting system hooked up to main system of IOC for hydrant/ water monitor. LT Flare for pressure relieving/ blow down system. Water Drain Pot to collect water drained from the bullets. LPG Blending System. Ethyl Mercaptan dosing system. 1.2 PURPOSE

7|Page

The purpose of this manual is to ensure that all operations are carried out as per standard operating procedure so that LPG is received, stored and delivered through the facility in accordance with the respective specifications. To achieve highest level of safety and security in operations as per HSSE guidelines. Meeting best possible working conditions and achieving preset operational goal successfully. To achieve greater satisfaction for IOCL Paradip Refinery by ensuring that facilities are handled as per the best operating practices. 1.3 SCOPE AND APPLICABILITY This Standard Operating Procedure is applicable to IOT Utkal‟s Paradip BOOT facility, to be operated by IOT for all associated facilities and shall apply to all its employees, contractors, visitors and other agencies operating within this facility.

8|Page

CHAPTER-2 DESIGN BASIS 2.0 DESIGN BASIS: Storage and pump capacities for LPG are based on the Paradip refinery block flow diagram and production capacities. The LPG facility is based on the criterion for receipt of LPG (on-spec/ off-spec/ blending spillage) from refinery. 2.1 This document (Design Basis) indicates the requirements for design of the facilities required for receiving, storage and pumping of LPG. The design of this facility is based on refinery maximum production of 1059 KTPA (design case). 09 numbers of mounded storage bullets as below of each 2700 m³ (1500 MT) working capacity are provided for the storage of refinery‟s pressurized LPG product. Mound I: Six bullets (205-V-003/004/005/007/008/009) located together. Mound II: Three bullets (205-V-012/013/014) located together These LPG bullets are also designed to store pure propane, which may be required for the initial and subsequent black start-ups. A provision exists to receive propylene in LPG bullets from Inter bullet transfer header of propylene system; however this needs to be done in a controlled manner such that the resultant vapor pressure of the LPG mix in bullets doesn‟t exceed the design pressure corresponding to pure propane. LPG bullets will also store off-spec LPG and blending spillages so that maximum usage provided by these bullets is utilized under normal operation. From the bullets, pressurized LPG is pumped to the Marketing Terminal (or truck loading) and pipeline off take using 6 No (205-P-001A/B/C/D/E/F) of Can Type Centrifugal vertical pumps located in two pump houses (PH-05 & PH-06) in each consisting of 3 pumps. Product transfer can be achieved by using 2 pumps running and one stand by with a discharge rate of 190 m 3/ hr of each pump. When one set of bullets in any Mound is empty and product has to be transferred using two pumps, one for marketing terminal and other for pipeline off take simultaneously, we shall use one of the three pumps 205-P-001 A/B/C for marketing terminal and one of the other three pumps 205-P-001 D/E/F for pipeline off take and vice-versa. A hook up between the suction headers of pumps 205-P-001 A/B/C & 205-P-001 D/E/F serves the purpose. These Pumps also serve for Inter bullet transfer of LPG .(Between 205-V-003/4/5/7/8/9 via 205-P-001 A/B/C & between 205-V-012/13/14 via 205-P-001 D/E/F). However, only one pump shall be used for Inter bullet transfer service at a time. A hook up between the two inter bullet transfer return headers is also provided to facilitate transfer from one set of bullets to other.

9|Page

Accounting of product transferred to Marketing Terminal, Tank Truck loading and Pipe line off-take will be done by the flow meter provided in Metering Package. Ethyl Mercaptan dosing facility was provided to odourise the product either during receipt or during batch formation. The off-spec LPG from bullets (205-V003/4/5/7/8/9/12/13/14) is pumped through 3 no of off-spec LPG transfer pumps 205-P-027A/B/C to the Fuel Gas Pool at a rate of 20 m3/ hr where two pumps running and one stand by. All PSV outlets are connected to LT Flare. Each bullet is provided with a separate water draining and sampling provisions. Water drained from the bullet will be routed to Water Drain Pot. 2.2 RECEIPT DETAILS DESIGN PRESSURE (kg/cm 2)

DESIGN TEMPERATURE (Deg C)

LINE SIZE (Inch)

FCC

39.2

98

10

CCR

39.2

98

3

AVU – C3

39.2

98

3

PROPANEALKYLATION

39.2

98

3

AVU-BUTANE

39.2

98

4

C4

39.2

98

6

LPG- ALKYLATION

39.2

98

8

PROPANE – PRU

39.2

98

4

BLENDING HEADER

39.2

98

12

INLET HEADER

39.2

98

12

REFINERY UNIT

COMMON

FLOWRATE

2.3 DISPATCH DETAILS MARKETING TERMINAL

PIPE LINE OFFTAKE

TANK TRUCK LOADING

FUEL GAS POOL

DESIGN PRESSURE (kg/cm2)

39

39

32.3

22.3

DESIGN TEMP. (Deg Cent.)

-45 to 65

-45 to 65

-45 to 65

-45 to 65

PARAMETER

PUMP TAG NO.

LINE SIZE (Inch)

205-P-001 A,B,C, 12

205-P001 D,E,F

205-P001 A,B,C

205-P001 D,E,F 12

205-P001 A,B,C

205-P001 D,E,F 12

205-P-027 A,B,C 4

10 | P a g e

PUMP FLOW RATE BULLETS

190 m 3/hr

190 m 3/hr

190 m 3/hr

20 m 3/hr

VVVV-012, VV-012, V003,004,0 012,013, 003,004, 013, 003,004, 013, 003,004,005 05,007,00 014 005,007, 014 005,007, 014 ,007,008,00 8,009 008,009 008,009 9,012,013,0 14

11 | P a g e

CHAPTER-3 PROCESS DESCRIPTION LPG rundown from the different refinery units is blended on-line to achieve the required product specifications, controlled by a Blending Control System which regulates the vapor pressure of final blended stream by monitoring three highest vapor pressure feed streams (AT-006) . LPG blending streams are: 1. FCC LPG 2. CCR LPG 3. AVU Depropaniser C3 4. Propane from Alkylation Unit 5. AVU Depropaniser Butane 6. Unsaturated C4 from Intermediate storage area 7. LPG from Alkylation Unit 8. Propane purge from PRU. The component streams‟ rundowns are routed to the LPG Blending Header. An in-line static mixer (204-JS-001) is provided to achieve blend homogenization. The LPG product after blending is routed to designated Bullets. Blending spillage will be lined up to another designated bullet. If off-spec LPG receipt is there, it will be directly routed/ lined up to the designated bullet. Ethyl Mercaptan dosing is provided for product odorizing downstream of LPG blending and at LPG Pump Suction. After receipt, product recirculation will be done for minimum 4 hours and then one hour settlement time will be given. After settlement time, water draining/ checking will be done. If no water is there then product sampling will be done as per the SOP PBT/ Ops/ M/ V-03 Chapter 8.0 to ensure that the receipt LPG meets the required quality standard of domestic LPG as per IS4576 – 2004. Once the product passes the quality test, it can be delivered to marketing / pipe line offtake/ tank truck loading as per the IOC requirement. From the bullets, pressurized LPG is pumped to the Marketing Terminal (or truck loading) and pipeline off take using 6 nos (205-P-001A/B/C/D/E/F) of Can Type Centrifugal vertical pumps located in two pump houses (PH-05 & PH-06) in each consisting of 3 pumps. Product transfer can be achieved by using 2 pumps running and one stand by with a discharge rate of 190 m 3/ hr of each pump. Accounting of product transferred to Marketing Terminal/ pipeline off take and Tank Truck will be done by the flow meter provided in Metering Packages 205-A-035/ 205-A051and 205-A-002 to 005 respectively. All 7 loading bays are provided with Tank Truck unloading facility. A vapour compressor has been provided for this operation which is a common facility for both LPG and Propylene. For Tank Truck unloading without disturbing the operations in other bays, dedicated line up was given in Bay no. 1.

12 | P a g e

Pump Minimum Flow protection is ensured by the control loop recycling back to the inlet of Bullets. The off-spec LPG from bullets (205-V003/4/5/7/8/9/12/13/14) is pumped by 3x50% Offspec LPG transfer pumps 205-P-027A/B/C to the Fuel Gas Pool. 3.1 INSTRUMENTATION: Each bullet is provided with two nos. of Level transmitters (One Servo and one Guided Wave Rader gauge).The servo gauge is associated with multipoint temperature transmitters which feeds the TGS. It also consists of a pressure transmitter which generates High, High High, Low and Low Low alarms. High and Low level alarm is provided in the TFMS for all the bullets. For High High and Low Low level in the bullet safety interlocks has been provided. Details of all the safety interlocks are given in Appendix-11 Instrument details for each bullet is furnished in Appendix-10 Each bullet consists of two PSVs to protect bullet from over pressurization. All lines are provided with PSVs wherever necessary for protection against over pressurization during thermal expansion. All PSV outlets are connected to LT flare. Detailed PSV location and set pressures are given in Appendix-8 Flow control valves are provided at all pump discharge headers for pump minimum flow by-pass. Facility is also provided with Flame detectors and Gas detectors to detect flame and LEL of air gas mixture at LPG pump house area, Tank truck loading area and Mound area. The bullet inlet XZV in the receipt line closes at the High -High Level and the outlet XZV in the dispatch line closes and pump trips at the Low-Low Level. All LPG pumps are provided with pressure transmitters in the discharge line which trips the pump at High High and Low Low pressure with alarm. 3.2 INTEGRATION BETWEEN REFINERY AND LPG STORAGE FACILITY: The LPG storage facility has the following process streams and utility streams in connectivity with the refinery. The process streams are: 1. Receipt from refinery is from the following rundowns FCC LPG CCR LPG AVU Depropaniser C3 Propane from Alkylation Unit AVU Depropaniser Butane Unsaturated C4 from Intermediate storage area LPG from Alkylation Unit Propane purge from PRU. 2. Off-Spec LPG transfer to Refinery Fuel Gas Pool, Alkylation and DCU.

13 | P a g e

The utility streams are: 1. 2. 3. 4. 5.

Service water Potable water Plant air Instrument air Nitrogen.

For detailed parameters of the above streams refer APPENDIX-5

14 | P a g e

CHAPTER- 4 LPG STORAGE FACILITIES 4.0 LPG Storage facility has been equipped with the latest and state-of-art systems in order to facilitate the receipt of LPG into mounded storage bullets, odourising, water draining, dispatch to Marketing terminal, pipe line off-take and to tank trucks. The facilities/systems are as under: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Mounded Bullets Pumps Pipelines LPG Blending System Ethyl Mercaptan Dosing Instrumentation and Automation Tank Truck Loading Tank Truck Unloading/ Vapour Compression LT Flare Water Drain Pot Electrical System Fire Fighting System Utility System Fire & Gas detection system

4.1 MOUNDED STORAGE BULLET LPG storage facility is provided with 09 mounded bullets, each having 2700 m³ (1500 MT) working capacity. The entire bullet assembly is placed inside a concrete mound filled with highly compacted sand, which will act as protecting medium in case of any mishaps. Mounded bullets are erected / placed on the compacted sand without any concrete support. Mound is filled with compacted sand up to the top of the mounded bullets. PVC and Terram sheets are provided over the compacted sand to prevent water ingress. To drain out rain water, perforated PVC drain pipes are provided all around the top of the mounded bullet. Since mounded tanks are completely buried, there is no risk of any external source of fire impingement or thermal radiation affecting the safety of the large capacity storage. So this type of storage will eliminate the possibility of Boiling Liquid Expanding Vapour Explosion (BLEVE). This will reduce risk substantially compared to the over ground pressurized Horton sphere or Bullets. Bullets details are given in APPENDIX-1 4.2 PUMPS The facility has different capacities of pumps used for product delivery to marketing terminal, pipe line off-take, tank trucks and off-spec pumping to fuel gas pool/ alkylation unit/ DCU. Pump details are provided in APPENDIX: 4.3 PIPELINE DETAILS

15 | P a g e

Various sizes of pipe lines as detailed in APPENDIX- 3.0 & 3.1 are provided for receipt and dispatch of LPG. 4.4 BLENDING SYSTEM: The Blending System comprises of: The LPG rundown streams are routed to the LPG auto Blender. LPG Blender consists of BRCs, RVP analyzer & Blend Control System to maintain the desired RVP. 'LPG Blending Control System' controls the recipe blending operation based on product RVP. (Refer Equipment Operating Manual for details). 4.5 ETHYL MERCAPTAN DOSING: Ethyl Mercaptan is commonly used as the odorant for LPG because of its distinctive smell. The assessment of odour level and the amount of ethyl Mercaptan to be dosed are determined as per the guidelines given in IS :1448 - 1968 (P : 75) or instructed by IOCL. Dosing unit consists of a vertical cylindrical tank with nitrogen blanketing facility and PSV connected with its out let to LT Flare. Two nos of double diaphragm dosing pumps are provided (one running and one stand by) and the delivery of the pumps is connected with a rotameter to know rate of dosing inline with the requirement. Details of the facility given below. Ethyl Mercaptan charging to the storage tank is done through an air operated pump. Detailed procedure for dosing/ charging was given in SOP- .

205-P-105 ETHYL MERCAPTAN TRANSFER PUMP CAPACITY @ suction cond. 0.40 m 3/hr DIFFERENTIAL PRESS 2.0 Kg/cm 2 DIFFERENTIAL HEAD 23.8 mlc

ID HEIGHT DESIGN PRESSURE DESIGN TEMPERATURE

205-VT-105 ETHYL MERCAPTAN STORAGE VESSEL 750 mm 1500 mm 3.5 Kg/ cm 2g 650C

205-P-043 A/B ETHYL MERCAPTAN DOSING PUMP CAPACITY @ suction cond. 15 LPH DIFFERENTIAL PRESS 15.0 Kg/cm 2 DIFFERENTIAL HEAD 179.0 mlc 4.6 INSTRUMENTATION AND AUTOMATION 4.6.1 AUTOMATION

16 | P a g e

LPG Storage Facility is equipped with State of Art Automation. It comprises of: Fully Automated Tank Gauging System (TGS). Distributed Control System, Emergency Shutdown System (ESD) and Gas Detection System (GDS). Fire Detection and Alarm Systems. In-Line LPG Blending System during receipt. Field Instrumentation and communication system CCTV system Paging communication system VHF and Base station Gas Detectors & Flame Detectors Heat Detectors & Quartz bulb Detectors CTMS Pressure Relief and Blow Down System Refer Manual on Automation for details. 4.6.2 Detailed list of XZVs Furnished in APPENDIX-6 4.6.3 PRESSURE RELIEF / BLOW DOWN SYSTEM Each bullet has two safety relief valves at top vapour zone of the bullet to release LPG to flare system in case of over pressurization of Mounded bullet. PSVs are designed for Fire condition with each PSV having 100% relieving capacity. Set pressure of safety valve is 18.5 kg/cm 2(g). Discharge of PSVs is connected to flare system with lock open type isolation valves on both side of PSV. PSV by pass line with double isolation valve is provided for manual depressurization especially for M&I preparation etc. Pipe Lines are also provided with PSVs where ever necessary. Details, location and set pressures are given in APPENDIX-8 Tank truck loading facility, loading arms are also connected with LT Flare to blow down the small portion between loading arms and tank truck inlet flange connection during disconnection. 4.6.4 GAS DETECTION GAS DETECTORS & FLAME DETECTORS Gas detector & UVIR (ultra violet & Infrared) Flame detectors are provided which are connected to Emergency Shut Down System. In case of any leak, gas detector system sense the leak & give alarm in control room DCS. 4.6.5 HEAT DETECTORS & QUARTZ BULB DETECTORS: Heat detectors & QBDs are also installed at various locations of LPG area. These are set to blow off at 79 Deg. C or rate of rise in temperature is more than 15 Deg. F/Min. Actions arising out of blowing off the detectors are connected to deluge valves and

17 | P a g e

indication of deluge sprinkler operation will be sounded in the Control Room. 1. All ROVs will be closed 2. Running pumps will trip 3. Deluge valves will open to start sprinklers 4.6.6 SAFETY INTERLOCKS, TRIPS AND ALARMS. LPG facility is provided with various safety interlocks, trips and alarms system during various operations carried out within the plant during receipt, storage and dispatch. Detailed list of the above is given in APPENDIX-11 4.6.7 METERING SKIDS During LPG dispatch to marketing terminal, pipe line off-take and tank truck loading accounting of product will be done by the flow meter provided in Metering Package. (Refer Equipment Operating Manual for details). 4.7 Tank Truck Loading/ Unloading Facility. Fully Automated Truck Loading Bays comprising 22 Loading Arms (7 + 4 liquid loading arms for LPG and Propylene respectively, 7 + 4 vapour balance arms for LPG and Propylene respectively) 7 loading Bays: 7 LPG Bays (out of 7 bays, 4 are common for LPG and Propylene) along with Metering Skid Facility. Additional two weigh bridges installed at entry gate of each 50 MT for Tank truck weight measurement. There are 2 Liquid headers from LPG and Propylene Pump House to respective Metering Skids of 12” size, from Metering Skids to TLF 3” size. Each header along with bay/s is dedicated for a particular product (LPG and Propylene). There are 2 vapour headers from LPG and Propylene Bullet to vapour compressor is of 8” size, vapour compressor to TLF 3” size. Each header along with bay/s is dedicated for a particular product (LPG and Propylene). For details of pumps, header and loading bay, please refer P & ID of PH and TLF bays in the appendix. Liquid and Vapour loading arms are connected to Flare, for venting of LPG within spool between loading arms and Tank Truck after loading/ unloading completion. All the bays are provided with SDV‟s to shutdown the loading in case of emergency. There is a provision for unloading tank trucks in all bays, where as bay no. 1 can be especially used for unloading operation without disturbing the operations in other bays. 4.8 LT FLARE All the PSV outlets are connected with LT Flare. Following Major Facilities are installed for the LT Flare System: 1. Flare Header 2. LT Flare Stack (220-FL-007 A/B) 3. LT Flare Tip (220-A-007 A/B) 4. Flare ignition control package (220-A-008)

18 | P a g e

5. Flare Meter (Ultrasonic flow meter with Pressure & temp. compensation)- with alarms at Low & High figures (FIA-0036, PIA-0051, TIA-0027) 6. Provision of Steam/Instrument air lines 7. Provision of Fuel gas/N2 supply line 8. Piping system including valves, fittings etc. connecting LPG Pressurized Storage & Propylene mounded storage area 4.10 WATER DRAIN POT If any water is found in LPG bullet will drained as per the SOPXXXXX. The drained water will be routed to Water Drain Pot through a closed loop system. (Refer bullet water draining procedure for details). Details of the Water drain pot is as under: 205-VT-110 WATER DRAIN POT ID 1900 mm HEIGHT 4300 mm DESIGN PRESSURE 3.5 Kg/cm 2g DESIGN TEMPERATURE -450C/ 650C 4.11 ELECTRICAL SYSTEM The electrical set-up in the Product side is as follows: Power Transformers (312N-205-TR-301/302) There are two 66 KV / 6.6 KV Power Transformers for the incoming power source. The secondary of the Power transformer is fed to 6.6 KV HT Panel 312N -205-SG-301. Distribution Transformers (312N-205-TR-401/402/403/404) There are four numbers of 6.6 KV / 0.415 KV Distribution Transformers. The incomer of the Distribution Transformers is from the 6.6. KV HT Panel and the outgoing are fed to the PMCC Panels. 6.6 KV HT Panel (312N-205-SG-301) The HT Panels includes power feeder to the HT Motors and also to the Distribution Transformers. There are 30 no HT Motors in all. Power & Motor Control Centre (312N-205-SG 401/402) There are two PMCCs which are utilised for feeding the power to Motor Control Centres, LT motors, Power Distribution Boards and Main Lighting Distribution Boards. Motor Control Centres (312N-205-MCC-401/402) There are two Motor Control Centres for LT motors power feeding. Main Lighting Distribution Boards (312N-205-DB-401/403/405)

19 | P a g e

There are three numbers of MLDBs to feed power for Building lighting, Tank Lighting, Pump House Lighting, High mast lighting. Power Distribution Boards (312N-205-DB-402/404/406/407) The Power Distribution Boards are utilised to feed the power to Welding Sockets, Metering House, Pressurisation Units, and Power Panels in buildings, EOT cranes, Air Monitoring Station, Flare package, MOV Distribution boards and others. Essential Services Board (312N-205-DB-501) The Essential Services Board is utilised to distribute power from the DG set during power failure. 350 KVA DG set (312N-205-DG-501) One 350 KVA DG set is located near the Substation for power supply in case of failure of the main incomer supply. The DG set is synchronised with the main power via AMF Panel and supplies the power at critical locations through Essential Services Board. The DG power is for the below mentioned purposes i)

Emergency Lighting for Substation SS312N, SRR 819, OMS 801, SMB 492, Operator‟s Shelter room 485-7. ii) Supply for UPS in SRR & OMS Rooms: 801 –205-UPS-501 , 801 –205-UPS-601, 819 –205-UPS-501, 819 –205-UPS-601 iii) Substation DCDB (110V): 312-205-DCB-701 Uninterrupted Supply System The terminal consists of four nos of UPS systems for Critical services. They are as under: 801 –205-UPS-601: Supply for DCS , ESD, GDS, F&G, Metering House I,II,III & IV, Analyser Shelter for LPG & Diesel. 801 –205-UPS-501: Supply for Telecommunication, PA/GA system and PMS 819 –205-UPS-601: Supply for DCS, ESD, GDS, F&G and Tank Gauging System 819 –205-UPS-501: Supply for Telecommunication, PA/GA system and PMS Substation Automation System:

The SAS panel (312N-205-SAS-901) shall regulate and monitor the complete integration of the substation 312N. Consisting of Numerical relays and SCADA, SAS will mainly perform the following functions: Protection of the equipments Fault monitoring and fault distance calculation. Creating and Monitoring the Switching sequences for optimal efficiency. SRR & OMS buildings The SRR & OM&S control room shall be the centralized operating point for oil movements/ storage and transfer which will be interfaced to MCR, utility services control room and the jetty side control room at the port. The other specialized control system

20 | P a g e

shall be for machine monitoring, custody transfer flow metering system, GDS (Gas Detection System) and TGS (Tank Gauging System). The control systems requirements for the project are outlined herein. The following facilities shall be provided:1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Distributed Control System Emergency Shutdown System Fire Detection and Alarm System Gas Detection System Machinery Monitoring System Analyzer Systems Metering Systems Auxiliary Systems (e.g. Tank Gauging etc) Other Control and Instrumentation Systems as required Field Instrumentation

CATHODIC PROTECTION SYSTEM Prevention of corrosion of Bullets in sand mounded structures very important both from the safety and life time operational point of view. The Cathodic Protection System implemented here is the Impressed Current Cathodic Protection System. Purpose Mounded Bullets

Description CP Transformer Rectifier Unit Anode Junction box Cathode Junction box

Qty. 02 04 02

4.12 FIRE FIGHTING SYSTEM The Fire Fighting System comprises of Fire water ring main, deluge and sprinkler system, double hydrant with hose box, water monitors, DCP, CO2 and manual call points etc. For the detailed operation of the system refer Fire Fighting Manual. Location and nos are provided in APPENDIX-13,14,15 4.14 UTILITY SYSTEM: Utilities required for this facility is received from IOCL Refinery. The following Utility facilities have been provided in the battery limit: Service water: Service water is supplied through a 2" piping network and to the bullets and tank truck loading area through a 3/4" piping network. Cooling water: There is a provision of 3" piping network to supply and return cooling water to the facility. Plant Air: There is a 2" plant air header connected with Ethyl Mercaptan dosing facility. Instrument Air: There is a 2" instrument air header in the battery area.

21 | P a g e

Nitrogen: There is a provision to supply Nitrogen to tanks through a 2" piping network, also there is a 1" piping network to supply nitrogen to pump house. Potable water: There is a provision of 2" piping network to supply potable water to the facility. For details on parameters of utility system refer Appendix-5

22 | P a g e

CHAPTER-5 OPERATING PHILOSOPHY The operating philosophy for LPG receipt, dispatch, Inter Bullet Transfer(within same Mound Bullets or between the Bullets in Mound-1 & Mound-2), Water Draining and sampling are described as under: 5.1 LPG RECEIPT: LPG on-spec, off-spec and blending spillage is received through rundown lines from refinery. Receipt finalization will be done after water draining if any, using bullet level, temperature, pressure and density. LPG receipt from the refinery will be on round the clock basis from different units through different dedicated rundown lines depending upon their plant running and production basis. The LPG receipt through pipeline from the refinery is hooked up with the Mound -1 (6 bullets) and Mound-II (3 bullets) inlet common header to enable the receipt to all bullets as per the receipt plan. 5.2 LPG DISPATCH: LPG dispatch will be done to Marketing Terminal, Pipe line off-take (PBKD) and tank truck loading. From the bullets pressurized LPG is pumped to the Marketing Terminal, pipeline off take and truck loading using 6 nos (205-P-001A/B/C/D/E/F) of Can Type Centrifugal vertical pumps located in two pump houses (PH-05 & PH-06) in each consisting of 3 pumps. Product reconciliation during this dispatch operation will be done by the flow meters provided in Metering Package (205-A-035, 205-A-051 & 205-A-053) The off-spec LPG from bullets is pumped back to refinery using Off-spec LPG transfer pumps (205-P-027A/B/C) and the product reconciliation will be done using bullet level, temp and pressure (opening and closing). 5.3 LPG Inter Bullet Transfer: For LPG product transfer between the bullets within the same mound (Mound-I or Mound –II) and within the bullets of different mounds (Mound-I & Mound –II) can be done using the same product transfer pumps (205-P-001 A/B/C/D/E/F). However, only one pump shall be used for Inter bullet transfer service at a time. A hook up between the two inter bullet transfer return headers is also provided to facilitate transfer from one set of bullets to other. Product reconciliation (receipt bullet/ dispatch bullet) will be done based on bullets level, temperature, pressure and density. 5.4 WATER DRAINING: After LPG receipt bullet re-circulation will be done for minimum 4 hours (batch formation) and then one hour settlement time will be given.

23 | P a g e

After settlement check for the water presence, if found then water draining will be done as per the procedure. 5.5 ETHYL MERCAPTAN DOSING: To odourise LPG prior to dispatch, Ethyl Mercaptan was used as odourising agent during receipt/ batch formation of the product. For this purpose, dosing system was provided with two sets of pumps. Quantity of Ethyl Mercaptan added to LPG will be assessed through the dosing tank calibration. 5.8

LT Flare

The LT flare system disposes off low temperature (below 0°C) & low pressure (atmospheric) discharges which originate mainly from LPG and Propylene storage & transfer system. The pilot burners (at flare tip) are fed by fuel gas & instrument air (from battery limit with flow monitoring); the ignition panel ignites the pilot burners by flame-front ignition. Each pilot is fitted with its dedicated flame detector to monitor the constant flame presence since that sustains stable combustion under all flaring and design conditions.

24 | P a g e

CHAPTER- 6 CONTROL PHILOSOPHY 6.1 LPG Storage and Transfer System Product area has got two control rooms OM&S 801 and SRR 819. OM&S 801 comprises of DCS (redundant), a common PLC for ESD and GDS with a redundant one, PLC for FDAS (redundant), TGS, PA system and CCTV. In the building 801 there are about fifteen operator consoles are present for all above mentioned systems. The control system is powered by two UPS system having rating of 125kva and 25kva respectively. DCS is the primary operating window for tankage facilities and other field equipments. ESD+GDS system is also connected to DCS network through serial communication. The FDAS PLC is also connected to the DCS network through serial communication. All substation (SS 312N) signals like PMCC, MCC HT switch gear are also connected through serial communication. The DCS and PLC networks are of Ethernet . Fire alarm panels are provided for buildings (OM&S technology, SS building and drivers building) are all connected to FDAS system through Ethernet network. ESD and GDS systems are having Common PLC (redundant) which takes the input from different Field Transmitters. FDAS is controlled by separate PLC (redundant) with inputs from across the field. OM&S 801, SS 312N and Operator drivers building and OM&S technology building are having Fire Alarm Panels (FAP#1, FAP#3, FAP#2 and FAP#4 respectively) which are interfaced to FDAS system at OM&S, which also receives signals from Field Mounted Fire Detectors through Marshalling cabinets. Substation Automation System located in SS 312N (substation) is connected to DCS Ethernet through Serial Gateways which in turn act as an Interfacing Unit between DCS and MCC/PMCC/PMC(IOCL). Operator Shelter is equipped with one number of DCS Operator Console from where Engineer can monitor the Tankage Operations. SRR 819 also consists of DCS,PLC for GDS+ESD(redundant), PLC for FDAS,TGS , PA system and CCTV facilities. The control system is powered by two UPS supply having rating of 35kva and 15 kva. The FDAS and ESD+GDS plcs of both OM&S 801 and SRR 819 are interconnected via safety network (Ethernet).All the buildings are interconnected through fibre optic cable. The operator shelter is also connected to SRR 819 through fiber optic cable. The FAP of operator shelter and SMB building are connected to FDAS system of SRR 819. Bullet gauging system mainly comprises of two types of guided wave gauges one is radar gauge and other one is servo gauge. Power Supply to these Gauges is from UPS. The signals from Bullet Gauges come to Communication Interface Unit in SRR-819 and which in turn is connected to DCS Ethernet Network and Tank Farm Management System(TFMS) provided at control room. Hardware Consoles have been provided in each control room to indicate the signals of field instruments in the control room. 6.2 SAFETY INTERLOCKS (ESD): Furnished in Appendix-8 6.3 ALARMS AND TRIPS: Furnished in Appendix -9 6.4 RELIEF VALVE SETTING: Furnished in Appendix –10

25 | P a g e

CHAPTER-7 ROLES and RESPONSIBILITY This chapter describes the responsibilities to be assumed by IOCL Refinery, IOCL Marketing Terminal, IOCL pipe line division and IOT during operations. 8.1 ROLE OF IOT and IOCL Refinery ROLE OF IOT:  Receipt, storage and dispatch of LPG, Off-spec LPG as per BOOT agreement  Preparation of documentation related to stock accounting, logbook and Loss or gain.  Joint inspection of bullet level, temperature and pressure of Bullet, sampling with IOCL refinery/ his representative before and after each receipt and transfer operations.  Coordination with IOCL Refinery for receipt and dispatch operations.  Maintain reliable communication with IOCL refinery, Marketing and Pipeline division. ROLE OF IOCL REFINERY  Planning and Coordination with IOT, Marketing division, Pipeline division, Excise, Surveyor for various activities related to receipt and dispatch of LPG.  FAN and Invoice generation in SAP for LPG Tank Truck loading/ unloading against IOT‟s TAS invoice in MT/ Kg.  Nominating representative for initial/ final bullet out turn finalisation for the receipt/ dispatch operations, Bullet Sampling, monitoring of operations etc.  Testing of samples in the Refinery Laboratory.  Provide reliable communication between IOCL refinery main control room, marketing and pipeline division and IOT.  Excise related formalities.  Round the clock security of pipeline beyond BOOT-3 battery limit. 8.2 RESPONSIBILITY OF IOT OFFICERS 1)

OPERATIONS-IN-CHARGE: PRODUCT AREA

He is the FPR (First Person Responsible) who has the overall responsibilities of all Operations and maintains the Work instructions. His scope of work: Execution of from refinery, storage and dispatch to marketing terminal, pipe line division and tank trucks etc. as per SOP. Regular Co-ordination with client (IOCL). Stock loss control within target as per agreement with IOCL All licenses maintenance and re-validation including payment of statutory fees as applicable. To maintain all As-Built drawings, certificates, license copies, etc Daily inspection of the facilities through nominated officers Housekeeping of facilities of both office and field Facility modification work as required from time to time by IOC To monitor all maintenance and AMC works Automation and maintaining their efficiency Quality and Quantity Planning & Co-ordination

26 | P a g e

Reports/ Documentation. 2) SHIFT IN-CHARGE: PRODUCTS He is the FPR (First Person Responsible) for overall implementation of all shift operations, Disciplined by Operations-in-charge. His scope of work: Overall in-charge in the shift for all activities. To monitor shift activities. To ensure safe operations for all hot, cold, electrical and height work. Stock Accounting and daily activity reporting. Supervise all operations on regular and surprise basis and record to be maintained. To assign duty to other engineers on daily basis. Issuance of all work permits to be authorized by Ops – In charge. Deployment of contract workers for assistance in various activities at various locations. Overall coordination and communication for various operations. Coordinating and Communicating with IOCL Refinery, IOC marketing and pipe line division, shift officers for smooth operation Keep a close watch at the bullet levels and monitoring switching over activities. Overall control of operations 3)

SHIFT ENGINEER: He is the FPR (First Person Responsible) for conducting the work specified within the Work Instructions. His scope of work: Overall up keeping / housekeeping of the facility(Cleanliness/valve greasing/ painting/ Sign Boards/Fire extinguishers/Line indicators etc) Supervise all operations Ensure safe operations To take care of / supervise all maintenance, modification jobs (Repair, Blinding/Deblinding, Hot work, Cold work, Excavation, Confined space). To ensure work-in-progress as per planning, as per SOP, as per Permits issued. Get/verify issued proper permits for all maintenance jobs. Leakages, defects and any abnormalities to be reported immediately to concerned heads. Ensure disposal of waste products, hoses, trays and drums to nominated area. Illumination Status. Report if found insufficient. Initiate to solve the problem. Ensure masking tapes and bonding (with copper strips/wires) for all flange joints. Ensure Fire Extinguishers status (whether available at specified locations, working conditions, and serviced status). Section I/C to maintain Log Book on shift basis. Enter each and every defects, events, leakages and action taken as rectification. Compliance reporting with the help of Daily, Monthly, Quarterly, Half yearly and Yearly Checklists. Suggestions to improve operations and any other areas. Ensure to start work only after acquiring relevant work permits. Maintain records of all permits. Preventive maintenance checks. 8.3 CONTACT DETAILS IOT: 1)

Occupier:

27 | P a g e

Name: Debashis De Contact no.: +919937577158 Email id: [email protected] 2)

Products Operations-in-charge Name: NV Subrahmanyam Contact no.: +919178466140 Email id:[email protected]

3)

Maintenance-in-charge Name: Madhukar Chatlawar Contact no.:+919178466077 Email id: [email protected]

4)

Shift in-charge Contact no.: Email id: [email protected]

5)

HSSE in-charge Name: Contact no.: Email id:

IOCL REFINERY: 1)

Officer in charge Name: Contact no. Email id:

2)

Control Room Officer Name: Contact no. Email id:

3)

Fire Fighting Chief: Name: Contact no. Email id: IOCL Marketing Terminal:

1)

Planning and Coordination Officer: Name: Contact no. Email id:

2)

Control Room Officer Name: Contact no. Email id:

28 | P a g e

3)

Fire Fighting Chief: Name: Contact no. Email id:

IOCL Pipe line division: 1) Planning and Coordination Officer: Name: Contact no. Email id: 2) Control Room Officer Name: Contact no. Email id: 3) Fire Fighting Chief: Name: Contact no. Email id:

29 | P a g e

PART-II STANDARD OPERATING PROCEDURE

30 | P a g e

CHAPTER-8 MODES OF OPERATION and OPERATING PROCEDURE OPERATION MODE FOR RECEIPT and DISPATCH: 8.1 RECEIPT MODE: LPG is received from refinery via rundown lines through blending unit and inline static mixer to the designated bullet. Off-spec/ blending spillage will be received in another designated bullet. Receipt Pipeline Set Up: For receipt from refinery, nine rundown lines are laid of various sizes (3”, 4”, 6”, 8” and 10”) up to blending unit. From blending unit, 12” line is running up to Mound-I. In this main header 12” tapping are provided for individual bullet inlet. Sampling: Joint sampling Bullets is done after every receipt from Refinery and Inter Bullet Transfer operation. Samples taken are sent to IOCL for lab analysis; receipt out turn is prepared based on the density given in lab report. Communication For effective communication between Terminal, Refinery and Field VHF based station along with handheld Radios are provided. Phone lines provide additional means of communication between Refinery and Terminal. Before the commencement of operation, ensure effectiveness of communication system. Safety: The entire safety requirement of the pipelines for the receipt operation of LPG beyond the battery limit of BOOT-3 finished product site is fulfilled by IOCL and the entire safety requirement of the Bullets, associated pipelines and equipments for receipt within BOOT3 limit is furnished by IOT. PSV to be kept lined up to release pressure developed in the line due to thermal changes. Leakage of any kind should be arrested prior to PLT operation by IOCL outside battery limit. Documents: Documentation related to receipt operations such as log sheets, Out Turn Reports etc to be prepared by IOT and retained under custody of IOT. 8.2 DISPATCH MODE: LPG is dispatched via Pipeline to Marketing terminal, Pipe line off-take and loading of tank trucks at loading gantry.

31 | P a g e

Dispatch Pipeline Set Up: For dispatch from individual bullets 18” discharge headers are connected with 18” common discharge line up to pump house. 12'' dedicated pipeline setup is provided to transfer LPG from pump house to Marketing Terminal and Pipe line division through Metering Skids 205-A-035 & 205-A-51 respectively. 10” tap off pipe line from 12” pump delivery header to TT loading gantry up to metering skid 205-A-053 after that 3” pipe line to individual loading bays. Sampling: Prior to Tank truck loading/ dispatch to Marketing Terminal or Pipe line transfer nominated Bullet sampling is done, if required; sent for lab analysis and out turn report is prepared based on the density given in the lab report else the receipt finalized samples with lab analysis report can be referred for Out Turn Finalisation and quality assessment.. Communication For effective communication between Terminal, Refinery, Marketing, Pipe line division and Field VHF based station along with handheld Radios are provided. Phone lines are provide as additional means of communication between Refinery, Marketing, Pipe line division and Terminal. Before the commencement of operation, ensure effectiveness of communication system. Safety: The entire safety requirement of the pipelines for the dispatch operations of LPG beyond the battery limit of BOOT-3 finished product site is fulfilled by IOCL and the entire safety requirement of the Tanks, associated pipelines and equipments for dispatch operations within BOOT-3 limit is furnished by IOT. PSV to be kept lined up to release pressure developed in the line due to thermal changes. Leakage of any kind should be arrested prior to PLT operation by IOCL outside battery limit. Documents: Documentation related to dispatch operations such as log sheets, Out Turn Reports etc to be prepared by IOT and retained under custody of IOT. 8.3 Tank Truck entry set up & document. Types of Tank Truck: Generally Tank trucks are of standard type (OISD 159) only. Usually the Tanks have single compartment. 1. 2. 3. 4.

Construction & fittings: Tank : Cylindrical Steel tank. Master Cut off Switch should be provided. Wiring : Wiring should be double pole conduit and not exposed. Double pole wiring should be provided.

32 | P a g e

5. Earthing Cleat should be provided. 6. Junction box provided & in working condition. 7. Fire Screen should be provided. It should fully cover the tank as per approved drawing. 8. Spark Arrestor of ISI mark should be welded to exhaust pipe. 9. Pressure-safety valve provided. 10. Other fittings: Baffle plates inside tank, safety valve (PV valve), manhole cover, pressure gauge, rota gauge, . 11. Drivers cabin made of steel and if made of wood then should be covered with Steel (Fire Screen). 12. Hazchem sign, name of contractor with address and telephone No. displayed prominently. 13. Locking arrangement as required by IOCL. Requirements to be complied by TT are 1. Valid Explosive License and drawing. 2. Driving license authenticated for hazardous goods. 3. VALID CERTIFICATE FROM „RTO‟ (R.C. AND F.C) 4. Valid Calibration Chart. 5. Liquid and Vapour nozzles with isolation valve in good condition. 6. Carries 2 nos. 10 Kg. DCP extinguishers in easily accessible and removable position with Truck No. date of checking and charging painted on it and 1 no. of 2 Kg CO 2 extinguisher in the driver cabin. 7. First Aid Box and emergency kit (radium cone, safety ribbons etc.) 8. Shear section on discharge pipe should be provided. 9. Emergency information panel correctly displayed as MV Act 1988. 10. Transport Emergency Card (TREM CARD) 11. SPARE WHEEL 12. NO VISIBLE DENT OR CORROSION ON THE BULLET 13. Tool box containing Leather hand gloves and heat resistant hand gloves, Safety Goggles , 2 nos. red flags non-metallic tools, wooden plugs of appropriate size and sealing compound. Capacity: TTs come in capacities ranging from 6 MT to 18 MT. Safety TT should have all the fittings as mentioned in construction & fittings. TT should comply all the requirements mentioned above. Overfilling is to be avoided for serious fire hazards. Sick TTs are to be strictly rejected. Document: Indent is to be registered with IOCL S & D for requirement of product by the IOCL. IOCL will appoint suitable transporter who will provide TT that fits into abovementioned criteria. 8.4 OPERATING PROCEDURE BULLETS 8.4.1 BULLET OPERATIONS IN NORMAL CONDITION Refer file-PBT/Ops/ M/ V-03, Chapter- 10 8.4.2 BULLET OPERATIONS IN EMERGENCY CONDITIONS

33 | P a g e

Refer file-PBT/Ops/M/ V-03, chapter- 11 8.7 DOCUMENTED OPERATING PROCEDURE: OPERATIONAL ACTIVITY

REF. DOCUMENT OF OPERATING PROCEDURE

BULLET COMMISSIONING

IOT/ PBT/OM/03/ BULLET, Chapter- 4

BULLET PRE-COMMISSIONING

IOT/ PBT/OM/03/ BULLET, Chapter- 3

BULLET DE-COMMISSIONING

IOT/ PBT/OM/03/ BULLET, Chapter- 5

BULLET SAMPLING

IOT/ PBT/OM/03/ BULLET, Chapter- 8

BULLET CLEANING

IOT/ PBT/OM/03/ BULLET, Chapter- 6

BULLET WATER DRAINING

IOT/ PBT/OM/03/ BULLET, Chapter- 7

BULLET STOCK ACCOUNTING

IOT/ PBT/OM/03/ BULLET, Chapter- 9

PIPELINE COMMISSIONING PIPELINE DE-COMMISSIONING PIPELINE BLOWING PIPELINE CLEANING PIPELINE PRESSURE TESTING PIPELINE STRIPPING PUMP START UP PUMP SHUT DOWN LPG BLENDING SYSTEM VAPOUR COMPRESSION CTMS LT FLARE DCS/ ESD/ FDAS WATER DRAIN POT

34 | P a g e

CHAPTER-09 OPERATIONAL ACTIVITIES 1)

LPG Receiving from RUNDOWN LINES:

LPG is received from refinery through the run down lines. All operations for receiving of LPG from refinery are done by IOT in co-ordination with IOCL. (For detailed procedure refer LPG receipt SOP in Chapter-10) 2)

Off-LPG Receipt from Refinery:

Off-LPG is received from refinery through a dedicated pipe line. All operations for receiving of LPG from refinery are done by IOT in co-ordination with IOCL. (For detailed procedure refer LPG receipt SOP in Chapter-11) 3) LPG bullet batch formation: LPG recirculation: LPG recirculation for minimum 4 hours is done in order to circulate product in the bullet using pump for homogenizing the product. Every Bullet is recirculated before sampling and subsequent deliveries. (For detailed procedure refer file-PBT/Ops/M/ V-03, Chapter-13) Water Draining: After receiving LPG into the bullet, it is to be re-circulated and allowed for minimum one hour settling. After settling, water is drained off from the bullet if present. Bullet water draining implies to draining of accumulated alkaline water settled in the bullet. The water is drained to water draining pot through a closed loop insulated piping system. (For detailed procedure refer file-PBT/Ops/M/ V-, Chapter- 7) Sampling: A liquid sample is transferred from the source into a sample container by purging the container and filling it with liquid LPG to 80% of the capacity. Different sampling bombs are to be used for drawing samples for different tests like vapour pressure, density, volatility and copper corrosion. 4) LPG pumping to Marketing Terminal: The LPG from the bullets is pumped to IOCL marketing terminal after getting clearance from IOCL. Accounting of product transferred will be done based on Metering Skid. (For detailed procedure refer SOP of Chapter-15) 5) LPG pumping to Pipe Line Division: The LPG from the bullets is pumped to IOCL pipe line off-take (PBKD) after getting clearance from IOCL. Accounting of product transferred will be done based on Metering Skid. (For detailed procedure refer SOP of Chapter-17)

6) LPG product dispatch through tank trucks:

LPG transfer to tank trucks will be done through Metering Skid in 7 bays at tank truck

35 | P a g e

loading gantry. 7) LPG tank truck unloading: LPG tank truck/ sick truck unloading is done in bay no.1 at tank truck loading gantry. Bay no. 1 was having dedicated unloading facility to carry out unloading operation, without disturbing the other bays loading operations. For detailed procedure refer LPG tank truck unloading SOP chapter-18) 8) Off-spec LPG Transfer Refinery: The Off-spec LPG from the bullets is pumped back to IOCL refinery after getting clearance from IOCL. Accounting of product transferred will be done based bullet level, temperature, pressure and density. (For detailed procedure refer SOP of Chapter-19&20) 9) Inter Bullet Transfer of LPG: To resolve the ullage and quality problem if any, it is required to carry out inter Bullet transfer of LPG (bullets within the same mound or between two mounds) on advice from Refinery. IOT undertakes inter Bullet transfer of LPG. (For detailed procedure refer Crude SOP- Chapter-14). 10) Ethyl Mercaptan Dosing: To odourise LPG prior to dispatch, Ethyl Mercaptan was used as odourising agent. Ethyl Mercaptan dosing will be done to LPG during receipt through the Mercaptan dosing pumps. If the Mercaptan dosing is not sufficient, provision is having for dosing operation during batch formation. THE FOLLOWING SAFETY, HEALTH AND ENVIRONMENTAL REQUIREMENTS TO BE FOLLOWED IN ALL THE BOVE OPERATIONAL ACTIVITIES

 Only Authorised / Competent Personnel shall conduct the work outlined in this Work Instruction.  Use of Personnel Protective Equipment (PPE) as specified in the Terminal Health Safety Security Environment (HSSE) Policy is mandatory.  Material Safety Data Sheet (MSDS) of LPG is available and field officers should be aware of the hazards and precautions to handle the cargo.  Any leak found in the system is arrested immediately and the record of the same is maintained.  In case of Pipe line transfer operations, emergency stop procedure shall be clearly communicated to Marketing/ Pipe line division and should stop the discharge operation immediately any time at the request of the IOC officer.

36 | P a g e

CHAPTER-10 LPG (ON-SPEC/ BLENDING SPILLAGE) RECEIPT 10.1 OBJECTIVE: The objective of the SOP is to define the general procedure for LPG receipt from IOCL refinery division to LPG storage bullets via rundown lines. 10.2 SCOPE: The SOP is applicable for all LPG receipt operation from IOCL refinery division to LPG storage bullets through Blending Unit within LPG terminal. 10.3 DESCRIPTION: The LPG rundowns streams from the process units shall be received in the offsite LPG storage Bullets via Blender header. The LPG component rundown streams for blending of LPG are as follows 1. 2. 3. 4. 5. 6. 7. 8.

FCC LPG CCR LPG AVU Depropaniser C3 Propane from Alkylation Unit AVU Depropaniser Butane Unsaturated C4 from Intermediate storage area LPG from Alkylation Unit Propane purge from PRU.

The LPG rundown streams are routed to the LPG auto Blender. LPG Blender consists of BRCs, RVP analyzer & Blend Control System to maintain the desired RVP. 'LPG Blending Control System' controls the recipe blending operation based on product RVP. Blended LPG Product is routed to normally one of pressurized storage bullets (205-V3/4/5/7/8/9/12/13/14) lined up for receiving. The LPG product rundown line to bullet is back pressure controlled at the downstream of static mixer near blender to maintain C3 streams in liquid phase. 10.4 SPECIFIC OPERATIONAL REQUIREMENTS: 1. No LPG receiving operation shall be conducted without instruction from Officer incharge of IOCL. 2. Receipt plan shall be developed (as per instructions of the IOCL Refinery) by IOT. 3. Receipt plan is verified by the Products Operations-in-charge and executed by Shiftin-charge. 4. Control Room to ensure that the Field Officers are fully aware of all operation within the LPG bullet area. Continuous, short, precise and clear communication is maintained between Control Room Officer and Field Officers during Receipt Operation. 5. All the activities in the storage facility are carried out as per the Work Instructions and instructions from Control Room. Field Officer should notify the Control Room upon completion of all tasks. 6. In case bullet is to be commissioned, to be reinstated to services after cleaning/ maintenance work, obtain “Bullet and connected pipeline fitness certificate” from

37 | P a g e

IOCL nominated surveyor/representative. 7. Pre-commissioning checklist to be checked when receipt to be done during commissioning or in empty Bullet or after maintenance of the bullet. 8. Ensure that the receipt line and bullet is free from air (either purging with LPG vapour is completed-refer bullet commissioning procedure for details). 9. Receiving operation shall commence at minimum rate to avoid generating static electricity accumulation in empty bullets. 10. Receiving rate is maximized if the receiving bullet level reaching the inlet pipe inside the bullet (1.2m). 11. Storage bullet should not be filled up above safe level. A high-level alarm is set below safe level to warn the Control room officers. The High-high alarm is set at maximum safe fill level which will automatically close the receiving SDV of bullet once it is actuated. In the event that the level to be raised above safe level, a Management of Change (MOC) must be raised prior to conducting the task with authorization from IOC. 12. Positive flow rates to be ensured during receipt operation in one or two bullets as there can be a reverse flow if any rundown line stops or reduces the discharge rate or during receiving bullet switch over. 13. Communication- For effective communication between Refinery storage, IOCL refinery Control room and IOT, VHF base station along with handheld radios and telephones are provided. Before commencement of operation, ensure effectiveness of communication system. 14. Continuous, short, precise and clear communication is maintained between Control Room Officer and Field Officers during Receipt Operation. 15. Ensure next receipt bullet is ready prior to first bullet top up. 10.5 RESPONSIBILITY: IOCL Refinery’s role:          

Production planning of LPG and dispatch to BOOT storage facility. Maintaining flow rates during initial start up if the lines are empty. Providing required data for blending ratios. Overall co-ordination for the smooth operation. Initial and final quantity assessment, out turns preparation in coordination with IOT for the receipt operations. Excise related formalities, documentation etc for the receipt and storage operations. Appointing surveyor for sampling. Product quality assessment and samples retention. Providing sampling bombs. Supply of required quantity of Ethyl Mercaptan as required for odourising.

IOT’S ROLE: Coordinate with IOCL officers for receipt operations. Preparation of LPG bullet for receipt. Line ups from BOOT 3 battery limit to bullets for the receipt of on-spec/ off-spec LPG.\ Joint reconciliation of the receipt operations with IOCL/ IOCL representative. Documentation and preparation of outturn reports (before and after receipt). The Operations-in-charge is overall responsible for maintaining the quality of this Work Instruction.  The Shift Manager is responsible for overall implementation of this Work Instruction.      

38 | P a g e

 The CCR Officer and Field officers are responsible for conducting the work specified within this Work Instruction. 10.6 PREPARATION S.No. 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25

Description A Receipt plan developed in the control room and verified. The required order prepared for the Receipt operation and work instructions are printed accordingly. IOCL/ IOCL representative available at terminal prior to receipt operation for initial out turn preparation. Discharging nominations, initial rates and max rates agreed with IOCL and documented in the receipt Logbook. Close all the inlet and outlet valves of the receipt bullets (on-spec and blending spillage). Note down the opening level, temperatures, pressures and densities and prepare joint initial out turn report. Ensure next bullets (for the receipt of on-spec and blending spillage) are ready and the out turn report was prepared. Confirm from IOCL, the qty of LPG receipt per hour and calculate the qty of Mercaptan to be dosed during receipt. Ensure sufficient quantity of Mercaptan is available in the dosing tank, and the system is in working condition. If quantity of Mercaptan is not sufficient then charging to be done as per SOP…… Establish proper communication between refinery, field and control room. Ensure LPG blending system was taken in line and is in working condition. Ensure vapour balancing was done to other bullet from the receipt bullet. Ensure all Hand Operated Valves in receipt line are in working condition and no leaks. Ensure all instrumentation and automation system provided in LPG receipt lines in working condition. Open LPG receipt run down line valves at battery limit and ensure no leaks. Check all Flow Control Valve upstream and downstream valves are open and bypass valves closed. Open LPG blending unit upstream valves. (Confirm from IOCL about the running units and open that particular run down line valves) Open 12” upstream and downstream valves of PDV 1001 and ensure no leaks. Close 12” bypass valve for PDV 1001. Open 8” valve in vapour inlet/ outlet line of vapour balancing bullet. Open 8” valve in vapour inlet/ outlet line for LPG receipt bullet. Check other bullets 10” blending spillage valve is fully closed. Open 10” blending spillage inlet line for the blending spillage receipt bullet and ensure no leaks. Check other connected lines to inlet header of receipt bullet are in fully closed position. Check 12” main inlet line of other bullets is in close position.

FPR SI/OI SI/OI SI/OI SI/OI FO/OI FO/SI/OI SI/OI SI/OI SI/OI FO/SI/OI FO/OI FO/OI FO/SI/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

39 | P a g e

26 27

Check receipt bullet inlet XZV open position. Line up Mercaptan dosing system as per SOP.

FO/SI/OI FO/OI

10.7 PROCEDURE: S. No. 1 2 3 4

5 6

7

8 9

1

2

Description Inform Refinery about the terminal readiness for the receipt of LPG. Once refinery confirms the delivery, Open 12” main inlet valve of LPG receipt bullet and ensure no leaks and start Mercaptan dosing pumps and adjust the stoke as per SOP. Once the receipt starts, note the time of starting of discharge as conveyed by the IOCL refinery. Field officer/ control room officer confirms the receipt of product, field officer observes and clears the area for any leak, intimate the same, if found, to Control Room and do the necessary course of action. Once LPG (on-spec and blending spillage) starts filling the bullet, check the bullet level is increasing and pumping rate and pressure of receipt. TFMS report screen in the Officer Engineering station is checked for any movement in the non-operational bullets. During the receipt operation, regular monitoring of the following items are required:Flow rate, pressure, temperature (lines and bullets) Check for any leakages in the system Blending system, RVP analyser LT Flare system Observance of safety rules and regulations Verification of product receipt with IOCL refinery dispatch on random basis to be done. For any abnormal variation between the discharge qty and receipt qty, investigate the reason. If the difference is more than 5%, intimate the same, to concerned IOCL official for further course of action. Switching over of receipt bullet It is required to change the receipt of the LPG from one Bullet to another Bullet; this procedure can be carried out without stopping the receipt operation. As soon as the receiving bullet attains High Level, the next bullet for receiving of LPG from should be lined up as under: First open the valves (Body and header) of the Bullet which will be lined up for receipt and then close the valve of the Bullet currently under receipt.

FPR SI/OI FO/OI SI/OI FO/OI

SI/OI SI/OI

SI/OI

SI/OI SI/OI

FO/SI/OI

FO/OI

Before closing, ensure that the valves of receipt bullet are open. Generally after 10-15% of opening of the valve in new bullet, closing of the previous bullet is done after ensuring smooth opening of valves and rise of level for second receipt bullet and steady pressure

40 | P a g e

3 4 5

1 2 3 4 5 6

of the pipe lines. The above same procedure to be followed for the next bullets to receive the product. On filling of the first bullet, close the line-up of first bullet. Now make the third bullet ready for receipt and so on for the next bullets to be filled. Record the level, temperature and pressures of the First bullet to be done along with the IOCL representative, assess the provisional receipt quantity. Completion Procedure Record the completion time of the receipt to the first bullet. Ensure fully close of the inlet valve which is opened for above operation. Record the level, temperature and pressures of the First bullet to be done along with the IOCL representative, assess the provisional receipt quantity. Close the vapour balancing line of the first Bullet. All timing and provisional bullet receipt figures noted in receipt log book. Batch formation, water draining and sampling will be done as per SOPs given in Bullet Operations Manual and then final out turn is prepared.

FO/SI/OI FO/OI SI/OI

SI/OI FO/OI SI/OI

FO/OI FO/SI/OI

10.8 SAFETY PRECAUTIONS: S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13

14

Description Ensure positive receipt lineup. Pressures in the pipe lines and bullets should not be more than design pressure. If bullet is empty (first time commissioning or after maintenance activity) LPG to be received at minimum flow rate (velocity 1 m/s). Ensure all ESD, GDS, FDAS are in place and in working condition. Ensure all PSVs are in line and their outlets are open to LT Flare. Ensure LT Flare is in order. Ensure proper illumination while carrying out operations. Ensure all first aid fire fighting equipments are in place and in working condition. Ensure agreed flow rates and pressures (between IOC and IOT) are maintained during receipt operation. Positive line up and positive flow rates to be ensured during receipt operation. Ensure that the receipt bullet was lined up to vapour balancing bullet during operation. Monitor rise in levels of the bullets other than receipt bullet. At a time only one operation (receipt or dispatch or batch formation or water draining or sampling) to be carried out on bullets. Storage bullet should not be filled up above safe level. A high-level alarm is set below safe level to warn the Control room officers. The High-high alarm is set at maximum safe fill level which will automatically close the receiving SDV of bullet once it is actuated. In the event that the level to be raised above safe level, a

FPR FO/OI FO/SI/OI FO/SI/OI SI/OI FO/OI SI/OI FO/SI/OI SI/OI FO/SI/OI FO/SI/OI FO/OI SI/OI SI/OI

FO/SI/OI

41 | P a g e

15 16

Management of Change (MOC) must be raised prior to conducting the task with authorization from IOC. Monitor required Mercaptan dosing quantity on hourly basis. Ensure that rundown lines of refinery shut down units are isolated from the blending unit.

FO/SI/OI FO/OI

10.9 PFD FOR LPG RECEIPT FROM REFINERY

42 | P a g e

CHAPTER-11 MERCAPTAN DOSING DURING RECEIPT OF LPG 11.1 OBJECTIVE: The objective of the SOP is to define the general procedure for Ethyl Mercaptan dosing to LPG as an odouriser. 11.2 SCOPE: The SOP is applicable for dosing of Ethyl Mercaptan to LPG during receipt operation from IOCL refinery division run down lines to LPG storage bullets through Blending Unit within LPG terminal and during batch formation. 11.3 DESCRIPTION: 1. LPG is an odorless gas, heavier than air. Any leakage developed from a source of LPG can go undetected, thereby creating a grave safety hazard. Therefore, if LPG is to be distributed as a utility gas to the consumers, it shall be odorised by addition of a warning agent of such characteristics that it is detectable by a distinct odour down to a concentration in air of not over one fifth of the lower limit of flammability. 2. Ethyl Mercaptan is commonly used as the odorant for LPG because of its distinctive smell. The assessment of odour level and the amount of ethyl Mercaptan to be dosed are determined as per the guidelines given in IS :1448 - 1968 (P : 75) or instructed by IOCL. 3. Ethyl Mercaptan dosing will be done at the downstream inline static mixer during LPG receipt to Bullets. If not, having provision at pumps suction during batch formation. 4. System has been designed with 1 running and 1 stand by pump.

11.4 SPECIFIC OPERATIONAL REQUIREMENTS: 1. Ethyl Mercaptan dosing to LPG, plan shall be developed by IOT in accordance with the IOCL refinery requirements. 2. This plan is verified by the Operations–in-charge and executed by Shift Manager. Control Room to ensure the Field Officer is fully aware of all operations associated with Mercaptan charging to storage vessel and dosing, P&IDs, field piping network, product characteristic, operation facility and troubleshooting. 3. Ensure that the Ethyl Mercaptan storage vessel is having sufficient quantity, if not Mercaptan charging to be done as per the procedure. 4. Communication- For effective communication between Refinery storage, IOCL refinery Control room and IOT, VHF base station along with handheld radios and telephones are provided. Before commencement of operation, ensure effectiveness of communication system. 5. Continuous, short, precise and clear communication is maintained between Control Room Officer and Field Officers during Receipt Operation. 11.5 RESPONSIBILITY: IOCL Refinery’s role:  Planning of LPG dispatch and ppm of Mercaptan dosing.

43 | P a g e

 Supply required quantity of Ethyl Mercaptan.  Ensure communication is proper between Refinery and IOT and overall co-ordination for the smooth operations. IOT’S ROLE:  Coordinate with IOCL officers for receipt operations and ensure ppm level of ethyl Mercaptan to be dosed.  Calculation of ethyl Mercaptan quantity to be dosed as per the receipt plan and ppm given by IOCL.  Ethyl Mercaptan charging and dosing.  Reconciliation of the quantity and raising indent for ethyl Mercaptan in advance.  Documentation.  The Operations-in-charge is overall responsible for maintaining the quality of this Work Instruction.  The Shift Manager is responsible for overall implementation of this Work Instruction.  The CCR Officer and Field officers are responsible for conducting the work specified within this Work Instruction. ETHYL MERCAPTAN DOSING CALCULATION Formula for determining the quantity of Mercaptan to be dozed: Nomenclature: Quantity of LPG pre-determined to be received in the Bullet per hour: X MT Required Mercaptan level in the product: Y ppm Specific gravity of Mercaptan: Z Calculations: 1 ppm means 1 part per every million parts 1 MT of LPG = 1 MT*1000 Kgs.*1000 grams = 1,000,000 grams or 1,000,000 parts. Thus if required Mercaptan dosage is Y ppm it means Y grams for 1,000,000 grams of LPG (i.e. 1 MT) Therefore for X MT of LPG the quantity of Mercaptan required for dozing = Y*X grams. Since specific gravity of Mercaptan is Z, quantity of Mercaptan required = (Y*X)/Z cc = ((Y*X)/Z)/1000 litres = A litres Each centimeter level of the Mercaptan storage tank is equal to 5litres of Mercaptan. Therefore the level drop required for X MT of LPG to be dozed with Y ppm of Mercaptan = A/5 centimeters Sample calculation Say X = 1000 MT, Y = 25 ppm and Z = 0.847 Qty. of Mercaptan required = (25*1000)/0.847 Required level drop in the storage tank

= 29515.938 cc = 17709.56/1000 = 29.52litres = 17.70/5cms. = 5.9cms.

11.6 PREPARATION S. No. 1

Description LPG receipt plan developed in the control room and verified.

FPR SI/OI

44 | P a g e

2 3 4

5 6 7 8

The required order prepared for the receipt operation and work instructions printed accordingly. Ethyl Mercaptan dosing calculation as above in line with the receipt plan. Ensure sufficient quantity of Mercaptan is available in the Ethyl Mercaptan storage vessel, and the system is in working condition. If quantity of Mercaptan is not sufficient then charging to be done as per the procedure. Establish proper communication between field and control room. Open 2” out let of the Ethyl Mercaptan storage vessel and line up to any one of the pump (205-P-043 A or 205-P-043 B). Open 2” valve on pump delivery line and ensure no leaks. Open 2” valve at Mound II connected with inlet header after ensuring receipt of LPG.

SI/OI SI/OI FO/OI FO/SI/OI FO/OI FO/OI FO/OI

11.7 PROCEDURE: S. No. 1 2 4 5 6 7 8 9 10

Description Record initial level of the Mercaptan storage vessel. Start ethyl Mercaptan dosing pump. Physically check for leakages if any through the system. Stop the operation in case leakages observed and rectify. Monitor the level of the Ethyl Mercaptan storage vessel. Reconciliation to be done on hourly basis between LPG receipt and Mercaptan dosing. Accordingly adjust the pump delivery. All operational timings/ operational activities should be logged in Mercaptan dosing log book as per the format. After completion of the operation, stop the pump, close the Mercaptan dosing point valve provided on LPG inlet stream, and pump delivery, suction valves which are opened for operation. Record final level of the Mercaptan storage vessel. Prepare the reconciliation report and log.

FPR SI/OI FO/OI FO/OI FO/SI/OI SI/OI FO/SI/OI FO/OI FO/OI SI/OI

11.8 SAFETY PRECAUTIONS: S. No. 1 2 3 4 5 6 7 8 9

Description Pressures in the pipe lines and storage vessel should not be more than design pressure. Ensure all ESD, GDS, FDAS are in place and in working condition. Ensure all PSVs are in line and their outlets are open to LT Flare. Ensure LT Flare is in order. Ensure proper illumination while carrying out operations. Ensure all first aid fire fighting equipments are in place and in working condition. Positive line up and positive flow rates to be ensured during the operation. Monitor level of the storage vessel and hourly dosing rate. Ensure no leaks.

FPR FO/SI/OI SI/OI FO/OI SI/OI FO/SI/OI SI/OI FOOI FO/SI/OI FO/OI

11.9 ANNEXUR-4.2

45 | P a g e

46 | P a g e

CHAPTER-12 OFF-SPEC RECEIPT 12.1 OBJECTIVE: The objective of the SOP is to define the general procedure for LPG Off-Spec receipt from IOCL refinery division to LPG storage bullets via rundown lines. 12.2 SCOPE: The SOP is applicable for all LPG Off-Spec receipt operation from IOCL refinery division to LPG storage bullets within LPG terminal. 12.3 DESCRIPTION: The LPG Off-Spec rundowns streams from the process units shall be received directly in the offsite LPG storage Bullets. LPG Off-Spec Product is routed to normally one of pressurised storage bullets (205-V3/4/5/7/8/9/12/13/14) lined up for receiving. 12.4 SPECIFIC OPERATIONAL REQUIREMENTS: 1. If receipt is being done to a newly constructed bullet ensures that vapour purging was completed prior to liquid receipt. 2. Operations in-charge should ensure that the field officers are fully aware of their roles and responsibilities as required and are fully understood the SOP. 3. Field officer should have full awareness of LPG product characteristic, operation facility and troubleshooting. 4. Operating personnel should be thorough with LPG Mounded P&IDs, field piping network and operating procedure prior to be involved in mounded bullet operation. 5. Control room to ensure that the field officer are fully aware of all operation within the LPG bullet area. 6. Officer has to ensure the status of HOV‟s. 7. Ensure bullet Off-Spec receipt line up as per the diagram and position of valves. 8. Vapour balancing line up to other bullet if required. 9. Ensure no deliveries from the receipt bullet. 10. Ensure next bullet is ready prior to first bullet top up. 12.5 RESPONSIBILITY: IOCL Refinery’s role:  Production planning and dispatch to BOOT storage facility.  Maintaining flow rates during initial start up.  Overall co-ordination for the receipt operation. IOT’S ROLE:  Coordinate with IOCL officers for off-spec receipt operations.  Preparation of LPG bullet for off-spec receipt.  Line ups from the BOOT-3 battery limit to bullet for the receipt of off-spec receipt.

47 | P a g e

 Joint reconciliation of the off-spec receipt operations with IOCL/ IOCL representative.  Documentation and preparation of outturn reports.  The Operations-in-charge is overall responsible for maintaining the quality of this Work Instruction.  The Shift Manager is responsible for overall implementation of this Work Instruction.  The CCR Officer and Field officers are responsible for conducting the work specified within this Work Instruction. 12.6 PREPARATION S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Description A Receipt plan developed in the control room and verified. The required order prepared for the Receipt operation and work instructions are printed accordingly. IOCL/ IOCL representative available at terminal prior to receipt operation for initial out turn preparation. Discharging nominations, initial rates and max rates agreed with IOCL and documented in the receipt Logbook. Close all the inlet and outlet valves of the receipt bullets (off-spec). Note down the opening level, temperatures, pressures and densities and prepare joint initial out turn report. Ensure next bullets (for the receipt of off-spec) are ready and the out turn report was prepared. Ensure the proper communication between refinery, field and control room. Ensure that the instruments and equipment‟s are inline and having proper communication. Ensure bullet vapour balancing was done to other bullet. Ensure all HOV in off-spec receipt line are in working condition. Open the off-spec LPG receipt line 4” valve in battery limit. Open the 4” valve in between unit-204&&205. Close all other valves in that bullet. Close 4”off-spec valves in remaining bullets. Check that bullet inlet and vapour line XZV is open.

FPR SI/OI SI/OI SI/OI SI/OI FO/OI FO/SI/OI FO/SI/OI FO/SI/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

12.7 PROCEDURE: S. No. 1 2 3 4 5 6

Description Inform Refinery about the terminal readiness for the off-spec receipt of LPG. Once refinery confirms the delivery, Open 4” off-spec inlet valve of LPG receipt bullet and ensure no leaks. Once the receipt starts, note the time of starting of discharge as conveyed by the IOCL refinery. Field officer/ control room officer confirms the receipt of product, field officer observes and clears the area for any leak, intimate the same, if found, to Control Room and do the necessary course of action. Once LPG (off-spec) starts filling the bullet, check the bullet level is increasing and pumping rate and pressure of receipt. TFMS report screen in the Officer Engineering station is checked for

FPR SI/OI FO/OI SI/OI FO/SI SI/OI SI/OI

48 | P a g e

7

8 9

1

2

any movement in the non-operational bullets. During the receipt operation, regular monitoring of the following items are required:Flow rate, pressure, temperature (lines and bullets) Leaking of the System LT Flare system Observance of safety rules and regulations Verification of product receipt with IOCL refinery dispatch on random basis to be done. For any abnormal variation between the discharge qty and receipt qty, investigate the reason. If the difference is more than 5%, intimate the same, to concerned IOCL official for further course of action. Switching over of receipt bullet It is required to change the receipt of the LPG from one bullet to another, this procedure can be carried out without stopping the receipt operation. As soon as the receiving bullet attains High Level, the next bullet for receiving of LPG from should be lined up as under: First open the valves (Body and header) of the Bullet which will be lined up for receipt and then close the valve of the Bullet currently under receipt.

SI/OI

SI/OI SI/OI

FO/SI/OI

FO/OI

Before closing, ensure that the valves of receipt bullet are open.

3 4 5

1 2 3 4 5

Generally after 10-15% of opening of the valve in new bullet, closing of the previous bullet is done after ensuring rise of level and steady pressure of the pipe lines. The same is done for the bullets to be lined up next, after receipt operation of the bullet under receipt. On filling of the first bullet, close the line-up of first bullet. Now make the third bullet ready for receipt and so on for the next bullets to be filled. Record the level, temperature and pressures of the First bullet to be done along with the IOCL representative, assess the provisional receipt quantity. Completion Procedure Record the completion time of the receipt to the first bullet. Ensure fully close of the inlet valve which is opened for above operation. Record the level, temperature and pressures of the First bullet to be done along with the IOCL representative, assess the provisional receipt quantity. All timing and provisional bullet receipt figures noted in receipt log book. Close the vapour balancing line of the first bullet after ensuring that there is no pressure rise in the bullet from normal.

FO/SI/OI FO/SI/OI SI/OI

SI/OI FO/OI SI/OI SI/OI FO/OI

12.8 SAFETY PRECAUTIONS:

49 | P a g e

S. No. 1

2 3 4 5 6 7

Description Before lining up bullet, check and calculate the ullage availability. Lining up of receiving bullet should be done carefully to avoid pressure surges, overfilling etc. Check from processing units the flow rate of Off-Spec LPG and cross check this quantity with the rate of Off-Spec receipt. Also calculate the time when change over is likely to come. This must be checked in each shift should the figures differ, investigate at both the ends. Before changing over Off-Spec receipt from one storage bullet to another; inform concerned processing units. While changing over Off-Spec receipt from one bullet to another first open the vessel which is to receive and establish the flow of LPG fluid before closing the other vessel, which was receiving earlier. Ensure no leaks. Ensure proper illumination while carrying out operations after day light hours. Ensure first aid firefighting systems and safety systems are in place and in working condition.

FPR FO/OI

SI/OI SI/OI FO/OI FO/OI FO/SI/OI SI/OI

12.9 PFD FOR OFF-SPEC RECEIPT

50 | P a g e

CHAPTER-13 RE - CIRCULATION OF LPG BULLET 13.1 OBJECTIVE: The objective of the SOP is to define step by step approach to perform recirculation of LPG in a mounded bullet for batch formation. 13.2 SCOPE: The SOP is applicable for all operational requirements and procedures in relation to recirculation of individual bullets for LPG batch formation prior to sampling for lab analysis. 13.3 DESCRIPTION: 1. Re-Circulation of LPG in any mounded bullet is a must to ensure homogeneity before offering the bullet for sampling and lab certification/dispatch. 2. The circulation of any mounded bullet is done using LPG transfer pumps 205-P001A/B/C (PH-05) for Mound I bullets and 205-P-001D/E/F (PH-06) for Mound II bullets. 13.4 SPECIFIC OPERATIONAL REQUIREMENTS: 1. Recirculation to be carried out for minimum 4 hours to ensure homogeneity of the product for sampling. 2. If Mercaptan dosing was not done during receipt, then it will be done from provision made at pump suctions as per the procedure. 3. Dispatch plan shall be developed by IOT in accordance with the IOCL refinery requirements. 4. This plan is verified by the Operations–in-charge and executed by Shift Manager. 5. Control Room to ensure the Field Officer is fully aware of all operations within the facility, LPG product characteristic, troubleshooting and lineup. 6. Continuous, short, precise and clear communication should be maintained between Control Room Officer and Field Officers during Pumping Operation. 7. Ensure effectiveness of communication between control room and field before commencement of operation. 8. All the recirculation activities in the facility shall be carried out as per the Work Instructions and instructions from Control Room. Field Officer should notify the Control Room upon completion of all tasks. 13.5 RESPONSIBILITY: IOCL Refinery’s role:  Overall co-ordination for the smooth operation. IOT’S ROLE:  Coordinate with IOCL officers for re-circulation operations.  Preparation of LPG bullet for re-circulation.  Line up bullets for re-circulation.

51 | P a g e

 The Operations-in-charge is overall responsible for maintaining the quality of this Work Instruction.  The Shift Manager is responsible for overall implementation of this Work Instruction.  The CCR Officer and Field officers are responsible for conducting the work specified within this Work Instruction. 13.6

PREPARATION

S. No. 1 2

Description A batch formation plan developed in the control room and verified. The required order prepared for the batch formation operation and work instructions are printed accordingly. Take the provisional out turn report after receipt operation from refinery as given in SOP as opening for recirculation. Establish proper communication between field and control room. Ensure all Hand Operated Valves in batch formation line are in working condition and no leaks. Open the 6” Inter Bullet Transfer valve in the batch formation bullet. Close all the 6” Inter Bullet Transfer valves in the other bullets. Open the 10” Inter Bullet Transfer suction valve in the batch formation bullet outlet. Ensure all the XZV's in the batch formation bullet are open. Open 10” valve in the pump Inter Bullet Transfer suction and close the 10” main dispatch suction in the pump used for batch formation. Open 6” valve in the pump Inter Bullet Transfer delivery and close the 8” main dispatch delivery. Close the 6” double ball valve placed in Inter Bullet Transfer hook up line with other mound. Open the 6” valves in upstream and downstream of HV-0012 and close its bypass valve. Check the pump for lubrication oil, coolant, cooling water, direction of rotation etc.

3 4 5 6 7 8 9 10 11 12 13 14

FPR SI/OI SI/OI SI/OI FO/SI/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

13.7 PROCEDURE: S.No. 1 2 3 4 5 6 7 8

Description Inform the IOCL about the Batch formation operation. Start the pump and ensure that there is a positive differential pressure at the pump discharge. Slowly open the pump delivery valve. Observe the pump condition for any abnormal vibration, sound etc. Keep watch on running pump. Physically ensure for no leakages in the system. Continue recirculation for minimum 4 hours, after getting clearance from the control room, stop the operation. Close the entire valves lined up for recirculation. All operational timings/ operational activities should be logged in dispatch log book as per the format. Give one hour settlement time for the recirculation bullet, check for water presence and if found water draining to be done as per the procedure.

FPR SI/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/SI/OI FO/OI

52 | P a g e

9

After water draining, LPG sampling is done for lab analysis in presence of IOCL/ IOCL representative.

FO/SI/OI

13.8 SAFETY PRECAUTIONS: S.No 1 2 3 4 5 6 7 8 9 10 11

Description Do not perform the operation while leakages are observed. Pressures in the pipe lines should not be more than design pressure. Ensure all ESD, GDS, FDAS are in place and in working condition. Ensure all PSVs are in line and their outlets are open to LT Flare. Ensure LT Flare is in order. Ensure proper illumination while carrying out operations. Ensure all first aid fire fighting equipments are in place and in working condition. Ensure no other operations on the bullet except recirculation. Clear communication should be there between field and control room. Ensure that the bullet was lined up to vapour balancing bullet during operation. Ensure all the instrument and equipment used for the batch formation operation are in working condition and has proper communication with automation system.

FPR FO/OI FO/OI SI/OI FO/OI SI/OI FO/SI/OI SI/OI FO/SI/OI FO/SI/OI FO/OI FO/SI/OI

13.9PFD FOR RE - CIRCULATION OF LPG BULLET

53 | P a g e

CHAPTER-14 INTER BULLET TRANSFER 14.1 OBJECTIVE: The purpose of the SOP is to define a general procedure for LPG transfer from one storage bullet to other within the same mound or between two mounds. 14.2 SCOPE: The SOP is applicable for all Inter Bullet Transfer operations of LPG bullets within the storage facility. 14.3 DESCRIPTION: Inter Bullet Transfer of LPG is required for the following reasons: a. If required to create ullage in a bullet. b. To offer bullet for maintenance. Inter Bullet Transfer is done using LPG transfer pumps, 205-P-001A/B/C (PH-05) for Mound I bullets and 205-P-001D/E/F (PH-06) for Mound II bullets. 14.4 SPECIFIC OPERATIONAL REQUIREMENTS: 1. If bullet has to be emptied out, then take necessary clearances and follow the bullet decommissioning procedure SOP. If not, then minimum dead stock to be maintained in the bullet so that pump will not get affected by cavitation etc. 2. Ensure that there is sufficient ullage available in the receiving bullet to accommodate the quantity from source bullet. 3. Control Room to ensure the Field Officer is fully aware of all operations within the LPG storage facility. 4. Continuous, short, precise and clear communication should be maintained between Control Room Officer and Field Officers during Inter Bullet Transfer Operation. 5. All the activities in the facility shall be carried out as per the Work Instructions and instructions from Control Room. Field Officer should notify the Control Room upon completion of all tasks. 6. Field officer should have full awareness of LPG product characteristic, operation facility, troubleshooting and line ups. 7. Bullet Level Alarm Set point screen in Control Room shall be used to give alarm prior to low level in the discharge bullet and high level in the receipt bullet. 14.5 RESPONSIBILITY: IOCL Refinery’s role:  Communicate IOT upon requirement and quantity to be transferred between the bullets. Overall co-ordination for the smooth operation.  Product quality assessment and samples retention after Inter Bullet Transfer.  Joint reconciliation of the Inter Bullet Transfer operations with IOT. IOT’S ROLE:

54 | P a g e

Coordinate with IOCL officers for Inter Bullet Transfer operations. Preparation of LPG bullets for Inter Bullet Transfer. Line up and all operational activities for Inter Bullet Transfer. Joint reconciliation of the INTER BULLET TRANSFER operations with IOCL/ IOCL representative.  The Operations-in-charge is overall responsible for maintaining the quality of this Work Instruction.  The Shift Manager is responsible for overall implementation of this Work Instruction.  The CCR Officer and Field officers are responsible for conducting the work specified within this Work Instruction.    

14.6 PREPARATION S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Description An Inter Bullet Transfer plan developed in the control room and verified. The required order prepared for the Inter Bullet Transfer operation and work instructions are printed accordingly. Close all the inlet and outlet valves of the Inter Bullet Transfer bullets. Note down the opening level, temperatures, pressures and densities and prepare joint initial out turn report. Establish proper communication between field and control room. Ensure vapour balancing to be done between these bullets. Ensure all Hand Operated Valves in Inter Bullet Transfer line are in working condition and no leaks. Close all the 6” Inter Bullet Transfer receipt line valves in the other bullets. Open the 6” Inter Bullet Transfer receipt line valve in the receipt bullet. Open the 10” Inter Bullet Transfer suction valve in the dispatch bullet. Ensure all the XZV's in the Inter Bullet Transfer bullet are open. Ensure all other valves are closed except 10” Inter Bullet Pump suction valve of the respective pump. Ensure 6” ball valve (two no‟s) fully closed, placed in Inter Bullet Transfer pump delivery line. (a hook up between Mound I and Mound II required if Inter Bullet Transfer to be done between two mounds) Check the pump for lubrication oil, coolant, cooling water, direction of rotation etc.

FPR SI/OI SI/OI SI/OI FO/SI/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

14.7 PROCEDURE: S. No. 1 2 4 5

Description Inform the IOCL officer about the Inter Bullet Transfer operation. Check the line up of the entire system to transfer LPG from delivery Bullet to receipt bullet. Start the pump and ensure that there is a positive differential pressure at the pump discharge. Slowly open the pump delivery valve. Observe the pump condition for any abnormal vibration, sound etc. Keep watch on running pump.

FPR SI/OI FO/OI FO/OI FO/OI

55 | P a g e

6 7 8 9 10 11 12 13

Monitor the levels/ pressures of the both bullets and line pressures throughout the operation./OI Ensure that there is no abnormal variation in transfer operation between the bullets (dispatch and receipt). Record hourly dispatch figures (receipt and dispatch). Physically ensure for no leakages in the system. Stop the operation as soon as the nominated quantity was transferred. Close the entire delivery line up. Record final readings of the both bullets level, temperature and pressures and prepare joint final out turn report. All operational timings/ operational activities should be logged in dispatch log book as per the format.

FO/OI/OI FO SI/OI FO FO/OI FO OI/SI SI/OI

14.8 SAFETY PRECAUTIONS: S. No 1 2 3 4 5 6 7 8 9 10 11 12

Description Do not perform the operation while leakages are observed. Hourly recheck quantity delivered and received between the bullets. Do not perform the operation while discrepancy in discharge and receipt figures is observed. Pressures in the pipe lines should not be more than design pressure. Ensure pump minimum flow recycle lined up to dispatch bullet and flow control valve is in operation if required. Ensure all ESD, GDS, FDAS are in place and in working condition. Ensure all PSVs are in line and their outlets are open to LT Flare. Ensure LT Flare is in order. Ensure proper illumination while carrying out operations. Ensure all first aid fire fighting equipments are in place and in working condition. Positive line up and positive flow rates to be ensured during dispatch operation. Ensure no other operations carried out on these two bullets. Clear communication should be there between field and control room.

FPR OI/FO OI/SI FO/OI FO OI/SI FO SI/OI FO SI/OI OI FO/OI FO/SI/OI

14.9. INTER BULLET TRANSFER

56 | P a g e

CHAPTER-15 LPG DESPATCH TO MARKETING TERMINAL 15.1 OBJECTIVE: The objective of the SOP is to define a step-by-step approach for performing the Pumping of LPG to the Marketing Terminal. 15.2 SCOPE: The SOP is applicable for all Pumping Operations from LPG storage bullets to Marketing Terminal. 15.3 DESCRIPTION: 1. LPG from storage bullets is dispatched to Marketing Terminal using LPG transfer pumps, 205-P-001A/B/C (PH-05) for Mound I bullets and 205-P-001D/E/F (PH-06) for Mound II bullets. 2. Accounting of product transferred to Marketing Terminal is done by CTMS 205-A-035. 15.4 SPECIFIC OPERATIONAL REQUIREMENTS: 1. A written confirmation should be received from IOCL regarding product transfer to Marketing Terminal. 2. Dispatch plan shall be developed by IOT in accordance with the IOCL refinery requirements for LPG transfer to marketing terminal. 3. This plan is verified by the Operations–in-charge and executed by Shift Manager. 4. Control Room to ensure the Field Officer is fully aware of all operations within the facility, LPG product characteristic, troubleshooting and line up. 5. Continuous, short, precise and clear communication should be maintained between Control Room Officer and Field Officers during Pumping Operation. 6. Ensure effectiveness of communication between IOT, IOCL refinery, IOCL Marketing Terminal and IOT field before commencement of operation 7. All the transfer activities in the facility shall be carried out as per the Work Instructions and instructions from Control Room. Field Officer should notify the Control Room upon completion of all tasks. 8. Bullet Level Alarm Set point screen in Control Room shall be used to give alarm prior to low level in the tank. 9. Bullet level, temperature and pressure are used for reconciliation between bullet and Metering Skid (205-A-035). Actual quantity delivered to marketing terminal is based on flow meter only. 15.5 RESPONSIBILITY: IOCL Refinery’s role: Communicate to IOT the quantity to be transferred to Marketing Terminal pipe line. Nominating IOCL representative for the out turn finalisation prepared by IOT. Excise and Custom related formalities Ensure effectiveness of communication between IOT and IOC Marketing Terminal and overall co-ordination for the smooth delivery operation.  Provide LPG lab analysis report (bullet nominated for product transfer) to IOT and IOCL Marketing Terminal.    

57 | P a g e

 Ensure effectiveness of communication between IOCL Refinery, Marketing Terminal and IOT and overall co-ordination for the smooth product transfer operations IOT’S ROLE:  Preparation of LPG bullet for transfer.  Coordinating with the IOC refinery and Marketing Terminal during LPG transfer operation.  Joint witness of readings of Metering Skid, LPG Bullet (level, temperature and pressure) with IOCL nominated representative before and after dispatch.  Product reconciliation, preparation of outturn and documentation.  The Operations-in-charge is overall responsible for maintaining the quality of this SOP.  The Shift Manager is responsible for overall implementation of this SOP  The Planning and Co-ordination department is overall responsible for preparation of pumping plan.  The Control room Officer and Field officers are responsible for conducting the work specified within this SOP. 15.5 S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PREPARATION Description Ensure bullet free of water, lab analysis of the product completed and product passed the test. Collect quality test report from IOC. Confirm from IOC refinery quantity to be dispatched to Marketing Terminal. IOCL/ IOCL representative/ Marketing Terminal representative/ surveyor available at terminal prior to delivery operation for initial out turn preparation. Discharging nominations, initial rates and max rates agreed with IOCL Marketing Terminal and documented in the dispatch log book. Close all the inlet and outlet valves of the dispatch bullet. Note down the opening level, temperature and pressure. Use lab density and prepare joint initial out turn report. Note the initial reading of the flow meter in the Metering Skid (205A-035. If more than one bullet required for the dispatch then ensure that the out turn report was prepared for the other bullet also. Establish proper communication between refinery, Marketing Terminal, field and control room. Ensure all Hand Operated Valves in delivery line are in working condition and no leaks. Ensure calibration validity and working condition of Mass Flow Meter (205-A-035) installed in line to product transfer between Boot-3 Terminal to Marketing Terminal as per CTMS operating manual. Ensure LPG transfer pumps are in good working condition. Check the pump for lubrication oil, cooling water, direction of rotation etc. Ensure 18” main out let valves of other bullets are in closed position. Ensure 18” common header isolation between Mound I and Mound II is fully closed.

FPR SI/OI SI/OI SI/OI SI/OI SI/OI SI/OI SI/OI FO/SI/OI FO/OI SI/OI FO/OI FO/OI FO/OI FO/OI

58 | P a g e

15 16 17 18 19 20 21 22 23 24 25 26

Open 18” out let valve for the dispatch bullet and ensure no leaks. Ensure 4” LPG product transfer pump minimum flow recycle receipt valve of other bullets in closed position. Open 4” LPG product transfer pump minimum flow recycle for the dispatch bullet. Ensure 10” and 6” Inter Bullet Transfer suction and delivery respectively of the product transfer pump are closed. Open 10” Product Transfer pump main suction valve. Open upstream and downstream valves of 4” pump minimum flow recycle flow control valve. Close 6”, 3”&12” valve of alkylation unit, DCU & marketing terminal lines respectively. Ensure 10” tank truck loading gantry Metering Skid upstream valve is closed. Open 12” marketing terminal header valve. Open Metering Skid (205-A-035) upstream and downstream valves. Ensure XZV 0179 is open. After confirmation from IOCL marketing terminal for their readiness to receive the product open 12” valve at downstream of XZV 0179.

FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

15.7 PROCEDURE: S.No. 1 2 3 4 5 6 7

1

2

Description Start the pump and ensure that there is a positive differential pressure at the pump discharge. Slowly open the pump delivery valve. Observe the pump condition for any abnormal vibration, sound etc. Keep watch on running pump. Monitor the flow rate, if stabilized then start second pump. Monitor the levels/ pressures of the both bullets and line pressures throughout the operation. Ensure that there is no abnormal variation in transfer operation between the bullet and Metering Skid quantities. Record hourly dispatch figures (both bullet and Metering Skid). Physically ensure for no leakages in the system. Switch over of dispatch bullet It is required to change the dispatch of LPG from one bullet to another, this procedure can be carried out without stopping the operation and informing to IOCL refinery/ IOCL Marketing Terminal about the switch over. As soon as dispatch bullet about attain Low level, the next bullet for dispatch of LPG should be lined up as under: First open the valves (Body and header) of the bullet which will be lined up for dispatch and then close the valve of the bullet currently under dispatch.

FPR FO/OI FO/OI FO/OI SI/OI FO/OI SI/OI FO/OI

FO/SI/OI

FO/OI

Before closing, ensure that the valves of the dispatch bullet are open.

59 | P a g e

3 4 5

8 9 10 11 12

Generally after 10-15% of opening of the valve in new bullet, closing of the previous bullet is done after ensuring decrease of level of second bullet and steady pressure of the pipe lines. The same is done for the bullets to be lined up next, after dispatch operation of the bullet. On completing the first bullet, close the line up of the first bullet. Now make the third bullet ready for dispatch and so on for the next bullet to be dispatched. Record level, temperature and pressures of the first bullet to be done along with IOCL refinery/ IOCL marketing terminal representative, and finalise the out turn report. Completion Procedure Record the completion time of the dispatch from the first bullet. Ensure fully close of the valves which are opened for the above operation. Record final readings of bullet level, temperature and pressures and prepare joint final out turn report. Confirm quantity received by IOCL marketing terminal. All operational timings/ operational activities should be logged in dispatch log book as per the format.

FO/SI/OI FO/OI SI/OI

SI/OI FO/OI SI/OI SI/OI SI/OI

Special Note: 1. Actual quantity transferred to Marketing Terminal is based on accounting from CTMS (205-A-035). 2. Individual bullets outturn is prepared and reconciliation is done between bullets and Metering Skid. Product Transfer Operation through Duty Meter S.No. 1 2 3

Description Ensure upstream and downstream MOVs of Stand by meter and master meter are closed. Ensure calibration MOVs of duty meter and stand by meter are closed. Open upstream and downstream MOVs of Duty meter.

FPR FO/OI FO/OI FO/OI

Product Transfer Operation through Standby Meter S.No. 1 2 3

Description Ensure upstream and downstream MOVs of Duty meter and master meter are closed. Ensure calibration MOVs of Duty meter and stand by meter are closed. Open upstream and downstream MOVs of Standby meter.

FPR FO/OI FO/OI FO/OI

Calibration of Duty meter during Product Transfer Operation S.No. 1

Description Ensure upstream and downstream MOVs of Standby meter closed.

FPR FO/OI

60 | P a g e

2 3 4 5

Ensure calibration MOV of standby meter is closed. Close downstream MOV of Duty meter and open downstream MOV of Master meter. Open calibration MOV and upstream MOV of Duty meter Above procedure is repeated with respect to line up as required to calibrate Standby meter.

15.8 SAFETY PRECAUTIONS: S.No. Description 1 Do not perform the operation while leakages are observed. Hourly recheck quantity delivered from storage and receipt by 2 marketing terminal. Do not perform the operation while discrepancy in discharge and receipt figures is observed. 3 Pressures in the pipe lines should not be more than design pressure. Ensure pump minimum flow recycle lined up to dispatch bullet and 4 flow control valve is in operation. Ensure all instrumentation and automation system provided in LPG 5 dispatch lines in working condition. 6 Ensure all ESD, GDS, FDAS are in place and in working condition. 7 Ensure all PSVs are in line and their outlets are open to LT Flare. 8 Ensure LT Flare is in order. 9 Ensure proper illumination while carrying out operations. Ensure all first aid fire fighting equipments are in place and in 10 working condition. Ensure agreed flow rates and pressures (between IOC marketing 11 terminal and IOT) are maintained during dispatch operation. Positive line up and positive flow rates to be ensured during 12 dispatch operation. 13 Ensure no other operations on the bullet except dispatch. Clear communication should be there between the IOT field and 14 control room, IOT and marketing terminal about the operation.

FO/OI FO/OI FO/OI FO/OI

FPR FO/OI SI/OI FO/OI FO/OI SI/OI SI/OI FO/OI SI/OI FO/SI/OI SI/OI FO/SI/OI FO/OI FO/SI/OI FO/SI/OI

15.9 LPG DESPATCH TO MARKETING TERMINAL FROM MOUND-01 15.11 LINE-UP AS PER APPENDIX-18

61 | P a g e

CHAPTER-16 LPG TANK TRUCK LOADING 16.1 OBJECTIVE: The objective of this SOP is to define the general procedure for product dispatch to Tank Truck taking all safety precautions. 16.2 SCOPE: This SOP is applicable for all operational requirements and procedures in relation to product transfer from bullets to tank trucks. 16.3 DESCRIPTION: LPG from the Bullets is transferred to tank trucks at LPG Tank Truck Loading Gantry using pumps. 7 bay loading gantry is provided for loading of Tank Trucks. LPG from the bullets V-003/ 004/005/007/ 008/ 009 of Mound-I or from V-012/ 013/ 014 of Mound-II is transferred to TTLG using PH – 05 (205-P-001A/B/C) or PH-06 (205-P-001D/E/F). Accounting of LPG transferred to LPG tanker is done by Flow Meter provided at the metering package (205-A-053). 16.4 SPECIFIC OPERATIONAL REQUIREMENTS: 1. Quality certificate of the product in the mounded bullet used for TT loading. 2. LPG Tank Truck loading should be done only after written confirmation from IOCL. Confirm the quantity to be dispatched and planning for the TT loading on daily basis. 3. Ensure that there is sufficient quantity of LPG available in the nominated bullet for Truck loading leaving the dead stock. 4. If sufficient quantity is not available in the bullet, then change over to another bullet may be required during; hence, next bullet to be made ready prior to first bullet completion. 5. Ensure calibration validity and working condition of Metering Skid installed in line to product transfer Tank Truck Loading. 6. Operations in charge should ensure that the field officers are fully aware of their roles and responsibilities as required and are fully understood the SOP. 7. Field officer should have full awareness of LPG product characteristic, operation facility, troubleshooting and line ups. 8. Ensure no other operations except TT loading from the bullet. 9. Establish proper communication between field and control room. 10. Tank Trucks being placed for the loading should confirm to safety check list as mentioned in Annexure prior to entry into the Terminal premises.

62 | P a g e

16.5 RESPONSIBILITY: IOCL ROLE: Planning of LPG dispatch through TT loading. Intimating IOT about the TT schedule, quantity to be loaded. Generating FAN, Invoice against IOT‟s TAS invoice in MT/ Kg. Ensure safety confirmation of tank truck being placed for loading. Joint reconciliation and finalisation of out turn prepared by IOT before and after Tank Truck loading.

    

IOT’S ROLE:  Preparation of LPG bullet for dispatch.  Joint reconciliation and out turn preparation, documentation before and after Tank Truck loading.  Security has to check the safety check list for all the TT's as per the Tank Truck Safety Check List attached in APPENDIX: 16.  Line up and loading of LPG Tank trucks as per IOCL requirement.  Ensure all safety rules and regulations follow up by the personnel entering the LPG premises and working in the area.  The Operations-in-charge is overall responsible for maintaining the quality of this Work Instruction.  The Shift Manager is responsible for overall implementation of this Work Instruction.  The CCR Officer and Field officers are responsible for conducting the work specified within this Work Instruction. 16.6 PREPARATION S.No. 1 2 3 4 5 6 7 8 9 10 11 12

Description Ensure quantity to be loaded in Tank Truck from IOCL. Ensure product quality test report obtained from IOCL for the product being dispatched to tank trucks. Note the opening reading of Metering Skid installed for Tank Truck loading and check the communication of the Metering Skid. Ensure pump being used is in working condition (check as per the pumps operating manual). Record Initial Level, Temp, Density and Pressure of the bullet used for Tank Truck Loading. If change over required in between the TT loading, then make the next bullet ready. Calculate the total quantity, and the quantity to be transferred. Ensure out let XZV of dispatch bullet is in open position. Ensure all hand operated valves of inlet and out let on the dispatch bullet are closed. Ensure other bullets 2 numbers 18” HOVs connecting bullet out let to pump suction header are closed. Open 2 numbers 18” hand operated valves connecting dispatch bullet and pump suction header. Open 4” hand operated pump minimum flow inlet valve to the dispatch bullet.

FPR SI/OI SI/OI SI/OI FO/OI SI/OI SI/OI SI/OI FO/OI FO/OI FO/OI FO/OI FO/OI

63 | P a g e

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

37

Close 10” IBT pump suction and Open 10” pump main suction. Ensure other pumps 8” delivery valves are in closed position. Close 6” IBT delivery valve and open 8” pump main delivery of the operating pump. Close pump delivery line 3” & 6” valves connected to Alkylation and DCU at battery limit. Close Pump delivery header 3” & 6” valves near Pump House – 5 inter connected with Pump House – 6 delivery header (Alkylation and DCU). Isolate 12” hand operated valves on pump delivery line connected with Pipe Line off-take and Marketing Terminal. Ensure 205-A-035 upstream 12” hand operated valve is in closed position. Open the 12” valve in pump common delivery header and line up to Tank Truck loading gantry metering skid. Close all the MOV's inside the Metering Skid for calibration. Close the all Master Meter and stand-by meter hook ups connected to duty meter. Open the 10” valve in upstream of Metering Skid (205-A-053). Open inlet/outlet of the Duty Meter MOV's. Ensure XZVs of liquid lines in open condition for all loading bays. Ensure Tank Truck unloading and FLT lines are positively isolated with spectacle blind. Open 3” valve in downstream of sight glass in liquid loading line. Open 3” valve in upstream of liquid loading arm. Open 2 numbers 3” vapour balancing valves at the downstream of vapour loading arm. Open the 3”, 2 no. ball valve in bullet loading vapour balancing line and ensure that spectacle blind between them is through & open the 3” ball valve in TT vapour balancing line joining with bullet common vapour header. Close 4” and 3”, Total 6 no of ball valve which are joined with spectacle blinds provided for TT unloading. Open the vapour balancing of the dispatch bullet by opening the 8” valve in the bullet vapour line and ensure that the vapour XZV's is in open position. After carrying out the safety checks for the Tank Truck at the entry gate, allow the Tank Truck to weighbridge for tare weight measurement after weighment TT will proceed to Gantry. After TT reaching the gantry, fix the male coupling in the TT and ensure no leak checked by opening the liquid inlet/ outlet manifold valve. Ensure there is a positive LPG vapour pressure inside the Tank Truck prior to loading. Ensure that Filling Advice Note (FAN) from S & D (sales and dispatch) has been signed by concern officer and field officer has to cross check that all entries are corrected, if any variation observed, then clarify with S&D officer. Place the TT inside the allocated bay in proper position and place the wooden blocks under front and rear tyres and instruct driver to switch off the master switch and confirm.

FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

FO/OI

64 | P a g e

38 39

Place the DCP extinguisher in front of the TT. Connect earthing clamp to the tank truck at designated place. Connect the liquid loading and vapour balancing arms to the TT respective manifolds. Open the 3” liquid and vapour line valves of the Tank Truck manifold. Show the proximate card and generate the loading details in BCU to authourise the Tank Truck loading in the designated bay. After authorization (TT number, Loading quantity and Bay) start TT loading. Positive earthing/bonding circuit will allow start of loading by communicating through LRCS/PLC as safety interlock.

40 41 42 43

16.7

FO/OI FO/OI FO/OI FO/OI FO/OI

PROCEDURE:

Loading Operation by Duty Meter S.No. 1 2 3 4 5 6 7 8 9

Description Once again re-check the line up and safety precautions to be followed while Tank Truck loading. Slowly Open the liquid and vapour line ball valves at loading arm. Ensure flow of liquid to the Tank Truck and monitor the loading operation continuously. After completion of loading close the liquid and vapour line valves of tank truck and lines. Blow down the product entrapped in the loading arms to FLT. After completion of blow down close valves and disengage loading arms. Ensure that wheel chokes are removed & instruct driver to remove the TT from the bay and go to assigned place. Remove the male coupling and fix blind or flange with mechanical gasket. After completion of the TT loading again TT will be allowed to pass through the weigh bridge for gross weight measurement. TT can be passed out with proper clearance of S&D

FPR FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

SPECIAL NOTE: Loading Operation by Stand- by Meter: All the loading procedure will be same as mentioned above, only the Metering Skid arrangement and requirement will change as mentioned below S.No. 1 2 3

Description Close the inlet/outlet MOV of the duty to be isolated. Open the inlet/outlet MOV of the standby meter to be lined up. Open the HOV in hook up between standby and duty meter to be lined up.

FPR FO/OI FO/OI FO/OI

Loading Operation by Duty/Stand- by with Master Meter for Calibration: All the loading procedure will be same as mentioned above, only the Metering Skid arrangement and requirement will change as mentioned below

65 | P a g e

S.No. 1 2 3

S.No. 1 2

3

4

5

6 7 8 9 10

11 12

Description Close the outlet of the MOV of the duty/ standby meter to Calibrated. Close the inlet MOV of the Master meter and open the MOV of duty/standby calibrating line. Open the outlet MOV of Master Meter and HOV of the line hooked up with the duty/standby to be calibrated.

Description The driver observes the Green lamp flashing and presses the „START‟ pushbutton on the RIT. He observes that loading begins Upon detection of „Start‟ push button press, the system issues a remote command to the Batch Controller. The Green lamp is set to glow steadily. The Batch Controller activates the pump demand output to the DCS. Depending on the number of batch controllers demanding the pump, the DCS executes the auto pump sequencing logic (as defined in the DCS logic) and turns ON a pump if it is not already ON. Loading begins with the help of electronic flow control unit and multistage set stop valve. While loading, the Batch Controller handles all primary loading functions and the LRC monitors the loading operation. The Batch Controller continuously monitors the Earth safety interlock and stops the loading upon negative input In the normal loading sequence, the load status to “LOADING” indicating that the load is in progress. During Loading Operation Batch controller monitors the FlowMeter and flowrate of the Loading arm. LOADING COMPLETION PROCEDURE Loading stops after equivalent amount of product is delivered by flow meter, it sends signal to Batch controller to stop loading. After loading is complete, the Batch Controller displays a message to „Disconnect earth‟. The Green lamp turns OFF and Red lamp turns ON. The Red lamp is turned OFF when earth is disconnected The driver observes that the Red lamp is ON, realizes that the truck has been loaded and disconnects earth. He then drives out of the loading bay. The loading bay is now free to receive the next tank truck. The bay is free from loading operation. Next TT in queue can be placed in bay and start loading. Batch control sends signal to LRC. The driver is instructed to proceed to the exit gate. Shows the proximity card, the gate is fully open and drives out of the loading area. The driver after exiting approaches the operator at the S&D Room and hands over the respective card. The card must be shown to reader for load completion and automatic IOT Exit pass generation through software. The driver then receives the IOT TAS invoice and exits the terminal gate.

FPR FO/OI FO/OI FO/OI

FPR

66 | P a g e

Loading Interrupt Handling Interruptions at the loading bay may occur in one of the following forms: 1. Safety interlocks failure. 2. Alarm raised by Batch Controller. 3. Stop Command at the bay. 4. Stop command from the control room. 5. Emergency shutdown. Though loading stops on occurrence of any of the above interruptions, the method of recovery of the batch and the lamp indication on the LCP differ in each case and hence needs elaboration. a. Interruption due to Safety Interlock Failure Loading at the bay stops immediately. The Batch Controller Action on Interlock failure displays the earth loss alarm. Lamp status on Interlock Red lamp is set to flashing failure Action on recovery of The Batch Controller displays a message : Press START when ready interlock or STOP to cancel” Sequence continues. Lamp status on recovery The green lamp is set to flashing of Interlock Available with Batch Controller and hence will not be Batch status downloaded again from LRCS

b. Interruption due to Alarm by Batch controller Action on Alarm Loading at that Batch Controller stops immediately. The Batch detection by Batch Controller displays the alarm condition and then a request to Controller present supervisor card. Lamp status on detection Yellow lamp is set to flashing of alarm Action on supervisor card Load is PART LOADED. Batch Controller displays a message to present card and the sequence continues. c. Interruption due to Stop press on RIT Action on Stop Loading at that Batch Controller stops immediately. The Batch Controller press on RIT displays a message to “Press Start when ready or Stop to cancel”. Lamp status on Red lamp turns ON. Stop Press Action on Start is Green lamp turn ON and loading continues from where it was Left off . pressed Batch status if Start Available with Batch Controller and hence will not be downloaded is pressed again from LRCS. Action on Stop Load is PART LOADED and Batch Controller displays a message to press again disconnect earth. On detection of removal of earth, TT is released from bay. Batch status if Stop Batch is released and batch is PART LOADED. is pressed second time d. Interruption due to Stop command from control room

67 | P a g e

Action on Stop command from OIC in control room Lamp status on Stop command from control room Action on resume command from control room Lamp status on resume command from control room Batch status

Loading of that batch stops immediately. The Batch Controller display an error message. Yellow lamp is set to flashing Batch Controller(s) displays a message “Press START when ready or STOP to cancel”. Sequence continues Green lamp starts flashing Batch shall be downloaded again

e. Emergency Shut Down Action on Loading at all bays stops immediately. The Batch Controller(s) display Emergency Shut “PerTT Loading Automation Softwaresive loss” alarm down pushbutton press Lamp status on Red lamp is turned ON Stop command from control room Batch status Batch(es) shall be downloaded again. 16.8 S.No. 1 2 3 4 5 6 7

16.9

SAFETY PRECAUTIONS:

Description Ensure proper illumination while carrying out operations. Ensure first aid fire fighting systems and safety systems are in place and in working condition. Clear communication should be there between the field and control room. Line up should be done carefully and must be ensured to avoid wrong line up. Ensure no leaks. Ensure all instrumentation and automation is in place and working. Ensure that Tank Truck safety check list was ful-filled at the security.

FPR FO/OI SI/OI FO/SI/OI FO/OI FO/OI SI/OI FO/OI

PFD FOR LPG TANK TRUCK LOADING FROM MOUND-1 PFD FOR LPG TANK TRUCK LOADING FROM MOUND-2

16.10 PFD FOR LPG TANK TRUCK LOADING 16.12 LOADING LINE-UP AS PER APPENDIX-18

68 | P a g e

CHAPTER-17 LPG DESPATCH TO PIPE LINE OFFTAKE 17.1 OBJECTIVE: The objective of the SOP is to define a step-by-step approach for performing the Pumping of LPG to the Pipe Line off take. 17.2 SCOPE: The SOP is applicable for all Pumping Operations from LPG storage bullets to Pipe Line off take. 17.3 DESCRIPTION: 1. LPG from storage bullets is dispatched to Pipe Line off take using LPG transfer pumps, 205-P-001A/B/C (PH-05) for Mound I bullets and 205-P-001D/E/F (PH-06) for Mound II bullets. 2. Accounting of product transferred to Marketing Terminal is done by CTMS 205-A-035. 17.4 SPECIFIC OPERATIONAL REQUIREMENTS: 1. A written confirmation should be received from IOCL regarding product transfer to pipeline off take. 2. Dispatch plan shall be developed by IOT in accordance with the IOCL refinery requirements for LPG transfer to Pipe Line off take. 3. This plan is verified by the Operations–in-charge and executed by Shift Manager. 4. Control Room to ensure the Field Officer is fully aware of all operations within the facility, LPG product characteristic, troubleshooting and lineup. 5. Continuous, short, precise and clear communication should be maintained between Control Room Officer and Field Officers during Pumping Operation. 6. Ensure effectiveness of communication between IOT, IOCL refinery, IOCL Pipe Line off take and IOT field before commencement of operation 7. All the transfer activities in the facility shall be carried out as per the Work Instructions and instructions from Control Room. Field Officer should notify the Control Room upon completion of all tasks. 8. Bullet Level Alarm Set point screen in Control Room shall be used to give alarm prior to low level in the tank. 9. Bullet level, temperature and pressure are used for reconciliation between bullet and Metering Skid (205-A-051). Actual quantity delivered to marketing terminal is based on flow meter only. 17.5 RESPONSIBILITY: IOCL Refinery’s role: Communicate to IOT the quantity to be transferred to Pipe line division. Nominating IOCL representative for the out turn finalisation prepared by IOT. Excise and Custom related formalities Ensure effectiveness of communication between IOT and IOCL Pipe line division and overall co-ordination for the smooth delivery operation.  Provide LPG lab analysis report (bullet nominated for product transfer) to IOT and IOCL Pipe line division.    

69 | P a g e

 Ensure effectiveness of communication between IOCL Refinery, Pipe line division and IOT and overall co-ordination for the smooth product transfer operations IOT’S ROLE:  Preparation of LPG bullet for transfer.  Coordinating with the IOC refinery and Pipe Line off take during LPG transfer operation.  Joint witness of readings of Metering Skid, LPG Bullet (level, temperature and pressure) with IOCL nominated representative before and after dispatch.  Product reconciliation, preparation of outturn reports and documentation.  The Operations-in-charge is overall responsible for maintaining the quality of this SOP.  The Shift Manager is responsible for overall implementation of this SOP  The Planning and Co-ordination department is overall responsible for preparation of pumping plan.  The Control room Officer and Field officers are responsible for conducting the work specified within this SOP. 17.5 PREPARATION S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Description Ensure bullet free of water, lab analysis of the product completed and product passed the test. Collect quality test report from IOC. Confirm from IOC refinery quantity to be dispatched to pipeline off take division. IOCL/ IOCL representative/ Marketing Terminal representative/ surveyor available at terminal prior to delivery operation for initial out turn preparation. Discharging nominations, initial rates and max rates agreed with IOCL pipeline off take Terminal and documented in the dispatch log book. Close all the inlet and outlet valves of the dispatch bullet. Note down the opening level, temperature and pressure. Use lab density and prepare joint initial out turn report. Note the initial reading of the flow meter in the Metering Skid (205A-051. If more than one bullet required for the dispatch then ensure that the out turn report was prepared for the other bullet also. Establish proper communication between, pipeline off take Terminals, field and control room. Ensure all Hand Operated Valves in delivery line are in working condition and no leaks. Ensure calibration validity and working condition of Mass Flow Meter (205-A-051) installed in line to product transfer between Boot3 Terminal to pipeline off take Terminals as per CTMS operating manual. Ensure LPG transfer pumps are in good working condition. Check the pump for lubrication oil, cooling water, direction of rotation etc. Ensure 18” main out let valves of other bullets are in closed position. Ensure 18” common header isolation between Mound I and Mound

FPR FO/SI/OI SI/OI SI/OI SI/OI FO/SI/OI FO/SI/OI FO/SI/OI FO/SI/OI FO/OI FO/SI/OI FO/OI FO/OI FO/OI FO/OI

70 | P a g e

II is fully closed. Open 18” out let valve for the dispatch bullet and ensure no leaks. Ensure 4” LPG product transfer pump minimum flow recycle receipt valve of other bullets in closed position. Open 4” LPG product transfer pump minimum flow recycle for the dispatch bullet. Close 6”, 3”&12” valve of alkylation unit, DCU & marketing terminal lines respectively. Ensure 10” and 6” Inter Bullet Transfer suction and delivery respectively of the product transfer pump are closed. Open 10” Product Transfer pump main suction valve. Open upstream and downstream valves of 4” pump minimum flow recycle flow control valve. Open 12” valve in pump delivery common header valve. Open Metering Skid (205-A-051) upstream and downstream valves. Ensure XZV 3002 is open. After confirmation from IOCL pipeline off take terminals for their readiness to receive the product open 12” valve at downstream of XZV 3002.

15 16 17 18 19 20 22 23 24 25 26

FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI/SI

17.6PROCEDURE: S.No. 1 2 3 4 5 6 7

1

2

Description Start the pump and ensure that there is a positive differential pressure at the pump discharge. Slowly open the pump delivery valve. Observe the pump condition for any abnormal vibration, sound etc. Keep watch on running pump. Monitor the flow rate, if stabilized then start second pump. Monitor the levels/ pressures of the both bullets and line pressures throughout the operation. Ensure that there is no abnormal variation in transfer operation between the bullet and Metering Skid quantities. Record hourly dispatch figures (both bullet and Metering Skid). Physically ensure for no leakages in the system. Switch over of dispatch Bullet It is required to change the dispatch of LPG from one bullet to another, this procedure can be carried out without stopping the operation and informing to IOCL refinery/ IOCL Marketing Terminal about the switch over. As soon as dispatch bullet about attain Low level, the next bullet for dispatch of LPG should be lined up as under: First open the valves (Body and header) of the bullet which will be lined up for dispatch and then close the valve of the bullet currently under dispatch. Before closing, ensure that the valves of the dispatch bullet are open, generally after 10-15% of opening of the valve in new bullet, closing of the previous bullet is done after ensuring decrease of level in the second bullet and steady pressure of the pipe lines.

FPR FO/OI FO/OI FO FO/SI SI SI FO

SI/OI

FO/OI

71 | P a g e

3 4 5

8 9 10 11 12

The same is done for the bullets to be lined up next, after dispatch operation of the bullet. On completing the first bullet, close the line up of the first bullet. Now make the third bullet ready for dispatch and so on for the next bullet to be dispatched. Record level, temperature and pressures of the first bullet to be done along with IOCL refinery/ IOCL marketing terminal representative, and finalise the out turn report. Completion Procedure Record the completion time of the dispatch from the first bullet. Ensure fully close of the valves which are opened for the above operation. Record final readings of bullet level, temperature and pressures and prepare joint final out turn report. Confirm quantity received by IOCL marketing terminal. All operational timings/ operational activities should be logged in dispatch log book as per the format.

SI/OI FO/SI SI/OI

SI FO/OI SI/OI SI FO/SI

Special Note: 1. Actual quantity transferred to Marketing Terminal is based on accounting from CTMS (205-A-051). 2. Individual bullets out turn is prepared and reconciliation is done between bullets and Metering Skid. Product Transfer Operation through Duty Meter S.No. 1 2 3

Description Ensure upstream and downstream MOVs of Stand by meter and master meter are closed. Ensure calibration MOVs of duty meter and stand by meter are closed. Open upstream and downstream MOVs of Duty meter.

FPR FO/OI FO/OI FO/OI

Product Transfer Operation through Standby Meter S.No 1 2 3

Description Ensure upstream and downstream MOVs of Duty meter and master meter are closed. Ensure calibration MOVs of Duty meter and stand by meter are closed. Open upstream and downstream MOVs of Standby meter.

FPR FO/OI FO/OI FO/OI

Calibration of Duty meter during Product Transfer Operation S.No. 1 2 3

Description Ensure upstream and downstream MOVs of Standby meter closed. Ensure calibration MOV of standby meter is closed. Close downstream MOV of Duty meter and open downstream

FPR FO/OI FO/OI FO/OI

72 | P a g e

MOV of Master meter. 4 Open calibration MOV and upstream MOV of Duty meter Above procedure is repeated with respect to line up as required to 5 calibrate Standby meter. 17.8 SAFETY PRECAUTIONS: S.No. Description 1 Do not perform the operation while leakages are observed. Hourly recheck quantity delivered from storage and pipeline off 2 take CTMS. Do not perform the operation while discrepancy in discharges figures is observed. 3 Pressures in the pipe lines should not be more than design pressure. Ensure pump minimum flow recycle lined up to dispatch bullet and 4 flow control valve is in operation. Ensure all instrumentation and automation system provided in LPG 5 dispatch lines in working condition. 6 Ensure all ESD, GDS, FDAS are in place and in working condition. 7 Ensure all PSVs are in line and their outlets are open to LT Flare. 8 Ensure LT Flare is in order. 9 Ensure proper illumination while carrying out operations. Ensure all first aid fire fighting equipments are in place and in 10 working condition. Ensure agreed flow rates and pressures (between IOC pipeline off 11 take terminal and IOT) are maintained during dispatch operation. Positive line up and positive flow rates to be ensured during 12 dispatch operation. 13 Ensure no other operations on the bullet except dispatch. Clear communication should be there between the IOT field and 14 control room, IOT and marketing terminal about the operation.

FO/OI FO/OI FPR FO/SI/OI SI/OI FO/SI/OI FO/OI FO/SI/OI SI/OI FO/OI SI/OI FO/SI/OI SI/OI FO/SI/OI FO/SI/OI FO/SI/OI FO/SI/OI

17.9 PFD FOR LPG DESPATCH TO PIPE LINE OFFTAKE FROM MOUND-1 17.10 PFD FOR LPG DESPATCH TO PIPE LINE OFFTAKE FROM MOUND-2 17.11 LINE-UP AS PER APPENDIX-18

73 | P a g e

CHAPTER-18 LPG TANK TRUCK UNLOADING/SICK TT HANDLING 18.1 OBJECTIVE: The objective of this SOP is to define the general procedure for LPG TT unloading and SICK Truck unloading taking all safety precautions. 18.2 SCOPE: This SOP is applicable for all operational requirements and procedures in relation to product transfer from Tank Trucks to bullets. 18.3 DESCRIPTION: In the 7 bay loading gantry, all bays are provided with Tank Truck unloading facility where in loading needs to be suspended during unloading of Tank Trucks at bay no 2 to 7. Bay no 1 is having separate unloading line up for handling sick trucks/ tank trucks unloading while loading operation is in progress at other bays. Unloading of Tank trucks is done by differential pressure using Vapour Compressor 205-A006-V-01. Accounting of LPG transferred to bullet from sick TT is done by joint outturn report prepared in presence of IOCL representative. 18.4 SPECIFIC OPERATIONAL REQUIREMENTS: 1. Unloading of LPG tank trucks should be done after written confirmation from IOCL representative. 2. Ensure minimum 0.5 kg/cm 2 pressure of LPG vapour left in the tank truck after unloading. 3. Control Room to ensure the Field Officers is fully aware of all operations within the facility. 4. Continuous, short, precise and clear communication should be maintained between Control Room Officer & Field Officers during unloading operation. 5. All the activities in the facility shall be carried out as per the Work Instructions and instructions from Control Room. 6. Field Officer should notify the Control Room upon completion of all tasks. 7. Field officer should have full awareness of LPG product characteristic, operation facility, troubleshooting and line ups for loading and unloading of TT. 8. Ensure no other operations except TT unloading from bay no-1 or all bays to designated bullet. 9. Tank Trucks being placed for the unloading should confirm to safety check list as mentioned in Annexure prior to entry into the Terminal premises. 18.5 RESPONSIBILITY: IOCL ROLE:  Planning of LPG Receipt through TT unloading.  Intimating IOT about the TT schedule, quantity to be unloaded.

74 | P a g e

 Generating Tank Truck invoice as per the unloading details given by IOT.  Ensure safety confirmation of tank truck being placed for unloading.  Joint reconciliation and finalisation of out turn prepared by IOT before and after Tank Truck unloading. IOT’S ROLE:  Preparation of LPG bullet for Tank Truck unloading.  Joint reconciliation and out turn preparation with IOCL before and after Tank Truck unloading.  Documentation of Out- Turn report.  Security has to check the safety check list for all the TT's as per the list attached in the APPENDIX:  Line up and unloading of LPG Tank trucks as per IOCL requirement.  Ensure all safety rules and regulations follow up by the personnel entering the LPG premises and working in the area.  The Operations-in-charge is overall responsible for maintaining the quality of this Work Instruction.  The Shift Manager is responsible for overall implementation of this Work Instruction.  The CCR Officer and Field officers are responsible for conducting the work specified within this Work Instruction. 18.6 PREPARATION S.No. 1 2 3 4 6

7 8 9 10 11 12 13 14

Description Ensure quantity to be unloaded from Tank Truck as per IOCL instruction. Ensure product quality test report obtained from IOCL for the product being unloaded from tank trucks to bullets. Ensure inlet and out let HOVs of the nominated bullet are closed. Record Initial Level, Temp, Density and Pressure of the bullet used for Tank Truck unloading and prepare initial out turn report. Ensure LPG compressor being used is in working condition (check as per the compressor operating manual). If change over required in between the TT unloading then make the next bullet ready and its out turn prepared. Calculate the total quantity, and the quantity to be unloaded from Tank Trucks by measuring weighment as per weighbridge SOP XXXX. Ensure Inlet and Vapour line XZV of nominated bullet is in open position. Ensure 6” Tank Truck unloading line inlet HOV to non-operating bullets is closed. Open 6” Tank Truck unloading line inlet HOV to nominated bullet. Ensure that Propylene Tank Truck vapour balancing is stopped and 3” HOV in TT loading gantry and 10” double ball valves are isolated. Ensure that 8” vapour balancing HOV in nominated bullet is open. Open 8” LPG compressor suction HOV. Open 3 nos. of 10” common (for LPG & Propylene) compressor suction valves.

FPR SI/OI FO/OI FO/OI SI/OI FO/SI/OI SI/OI FO/SI/OI FO/SI/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

75 | P a g e

15

Ensure 3” vapour recovery valves in TT gantry for LPG and Propylene are closed. Open 4” compressor delivery valve. In TT gantry 2 set of double ball valves of 4” are provided for Sick TT unloading and whole TT unloading, open any one set of valves as per the operation. Ensure 3” blow down valves in all the bays are closed. In case of sick TT unloading at Bay-01 close the 3” upstream HOV in Vapour line and open 3” downstream HOV in vapour line. Close the 3” HOV adjacent to sight glass and open the 3” HOV adjacent to Check valve in liquid line. Open the 3” unloading double ball valve tapped between sight glass and check valve.

16 17 18 19 20 21 18.7 S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

S.No. 1 2 3

FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

PROCEDURE:

Description Recheck the unloading line up and open Tank Truck vapour loading line valve. Start the compressor and check for vibrations, discharge pressure. After getting positive pressure in compressor open the 3” valve of vapour arm. After TT reaching positive pressure than bullet, open the 3” liquid arm valve. Conform the flow of liquid and keep continuous monitoring on unloading operation. Once it conform that the TT is fully unloaded then stop the compressor. Change the lineup for vapour recovery by closing 4” TT unloading valve and open 3” sick TT evacuation valve. In compressor suction close the 10” (two nos.) sick TT evacuation valve and open the 4” bypass valve. And then start the compressor and make vapour recovery. After getting the required pressure in TT stop the compressor and close the valves in liquid and vapour arm and blow down the vapour in spool piece between TT and arms. Disengage the loading arm and remove the TT from the bay. Place the TT out of the bay and remove the male coupling and fix blind. After getting the proper clearance from the S&D send the TT out. Note all the operational activities and timings in log book and the log sheets as per the formats.

18.8

FO/OI

FPR FO/OI FO/OI FO/OI FO/OI FO/SI/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/SI/OI

SAFETY PRECAUTIONS: Description Ensure proper illumination while carrying out operations. Ensure first aid fire fighting systems and safety systems are in place and in working condition. Clear communication should be there between the field and control room.

FPR FO/SI/OI SI/OI FO/SI/OI

76 | P a g e

4 5 6 7 8

Line up should be done carefully and must be ensured to avoid wrong line up. Ensure no leaks. Pressures in the pipe lines should not be more than design pressure. Ensure all ESD, GDS, FDAS are in place and in working condition. Ensure all PSVs are in line and their outlets are open to LT Flare.

FO/OI FO/OI FO/SI/OI SI/OI SI/OI

18.9 PDF FOR LPG TANK TRUCK UNLOADING 18.10 LINE-UP AS PER APPENDIX-18

77 | P a g e

CHAPTER-19 OFF-SPEC LPG PUMPING TO ALKYLATION UNIT/ DCU UNIT 19.1 OBJECTIVE: The objective of the SOP is to define a step-by-step approach for performing the Pumping of Off-LPG to the Alkylation Unit/ DCU Unit. 19.2 SCOPE: The SOP is applicable for all Pumping Operations from off-spec LPG storage bullets to Alkylation Unit/ DCU Unit. 19.3 DESCRIPTION: 1. Off-spec LPG from storage bullets is dispatched to Alkylation Unit/ DCU Unit using LPG transfer pumps, 205-P-001A/B/C (PH-05) for Mound I bullets and 205-P-001D/E/F (PH06) for Mound II bullets. 2. Accounting of product transferred to fuel gas pool is to done by the bullet initial and final parameters. 19.4 SPECIFIC OPERATIONAL REQUIREMENTS: 1. A written confirmation should be received from IOCL regarding product transfer to pipeline off take. 2. Dispatch plan shall be developed by IOT in accordance with the IOCL refinery requirements for off-spec LPG transfer to alkylation and DCU. 3. This plan is verified by the Operations–in-charge and executed by Shift Manager. 4. Control Room to ensure the Field Officer is fully aware of all operations within the facility, LPG product characteristic, troubleshooting and lineup. 5. Continuous, short, precise and clear communication should be maintained between Control Room Officer and Field Officers during Pumping Operation. 6. Ensure effectiveness of communication between IOT, IOCL refinery and IOT field before commencement of operation. 7. All the transfer activities in the facility shall be carried out as per the Work Instructions and instructions from Control Room. Field Officer should notify the Control Room upon completion of all tasks. 8. Bullet Level Alarm Set point screen in Control Room shall be used to give alarm prior to low level in the tank. 9. Bullet level, temperature and pressure are used for reconciliation as there is no Metering Skid. 19.5 RESPONSIBILITY: IOCL Refinery’s role:  Communicate to IOT the quantity to be transferred to alkylation unit and DCU.  Excise and custom related formalities if any.  Ensure effectiveness of communication between IOT and overall co-ordination for the smooth delivery operation.  Joint witness with IOT official for LPG storage bullet (level, temperature and pressure) nominated for dispatch.  Finalise the outturn prepared by IOT (initial and after).

78 | P a g e

IOT’S ROLE:  Preparation of LPG bullet for transfer.  Coordinating with the IOC refinery during off-spec LPG transfer operation to alkylation and DCU.  Joint witness of readings of LPG Bullet (level, temperature and pressure) with IOC refinery before and after dispatch.  Reconciliation.  Documentation and preparation of outturn reports.  The Operations-in-charge is overall responsible for maintaining the quality of this SOP.  The Shift Manager is responsible for overall implementation of this SOP  The Planning and Co-ordination department is overall responsible for preparation of pumping plan.  The Control room Officer and Field officers are responsible for conducting the work specified within this SOP. 19.6 PREPARATION S.No. 1 2 3 4 5 7 8 9 11 12 13 14 15 16 17 18

Description Confirm from IOC refinery quantity to be dispatched to alkylation unit or DCU. IOCL/ IOCL representative/ surveyor available at terminal prior to delivery operation for initial out turn preparation. Discharging nominations, initial rates and max rates agreed with IOCL alkylation unit or DCU and documented in the dispatch log book. Close all the inlet and outlet valves of the dispatch bullet. Note down the opening level, temperature and pressure. Use lab density and prepare joint initial out turn report. If more than one bullet is there for the dispatch then ensure that the out turn report was prepared for the other bullet also. Establish proper communication between refinery, alkylation unit or DCU, field and control room. Ensure all Hand Operated Valves in delivery line are in working condition and no leaks. Ensure LPG transfer pumps are in good working condition. Check the pump for lubrication oil, cooling water, direction of rotation etc. Ensure 18” main out let valves of other bullets are in closed position. Ensure 18” common header isolation between Mound I and Mound II is fully closed. Open 18” out let valve for the dispatch bullet and ensure no leaks. Ensure 4” LPG product transfer pump minimum flow recycle receipt valve of other bullets in closed position. Open 4” LPG product transfer pump minimum flow recycle for the dispatch bullet. Ensure 10” and 6” Inter Bullet Transfer suction and delivery respectively of the product transfer pump are closed. Open 10” Product Transfer pump main suction valve.

FPR SI/OI SI/OI SI/OI FO/SI/OI FO/SI SI/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

79 | P a g e

19 20 21 22 23

Open upstream and downstream valves of 4” pump minimum flow recycle flow control valve. Close the 6” and 3” valve of alkylation unit and DCU respectively in hook up line with other mound pumphouse. Close 12” valve in pipeline off take tapping. Close 12” marketing terminal header valve. Open the 6” alkylation valve in BOOY-3 battery limit if the product is transferring to alkylation unit, if the product is transferred to DCU close the alkylation valve and open the 3” DCU BOOT-3 battery limit valve.

19.7 PROCEDURE: S.No. Description Start the pump and ensure that there is a positive differential 1 pressure at the pump discharge. Slowly open the pump delivery valve. 2 Observe the pump condition for any abnormal vibration, sound etc. Keep watch on running pump. Monitor the flow rate, if stabilized 3 then start second pump. Monitor the levels/ pressures of the both bullets and line pressures 4 throughout the operation. Ensure that there is no abnormal variation in transfer operation 5 between the bullet and Metering Skid quantities. 6 Record hourly dispatch figures. 7 Physically ensure for no leakages in the system. Switch over of dispatch bullet It is required to change the dispatch of LPG from one bullet to another, this procedure can be carried out without stopping the 1 operation and informing to IOCL refinery/ IOCL alkylation unit or DCU about the switch over. As soon as dispatch bullet about attain Low level, the next bullet for dispatch of LPG should be lined up as under: First open the valves (Body and header) of the bullet which will be lined up for dispatch and then close the valve of the bullet currently 2 under dispatch. Before closing, ensure that the valves of the dispatch bullet are open, generally after 10-15% of opening of the valve in new bullet, closing of the previous bullet is done after ensuring decrease of second bullet level and steady pressure of the pipe lines. The same is done for the bullets to be lined up next, after dispatch 3 operation of the bullet. On completing the first bullet, close the line up of the first bullet. 4 Now make the third bullet ready for dispatch and so on for the next bullet to be dispatched. Record level, temperature and pressures of the first bullet to be 5 done along with IOCL refinery/ IOCL alkylation unit or DCU representative, and finalise the out turn report. Completion Procedure 1 Record the completion time of the dispatch from the first bullet. Ensure fully close of the valves which are opened for the above 2 operation.

FO/OI FO/OI FO/OI FO/OI FO/OI

FPR FO/OI FO/OI FO FO/SI FO/SI SI FO/OI

SI/OI

FO/OI

FO/SI/OI FO/SI/OI

SI/OI

SI FO/OI

80 | P a g e

3 4 5

Record final readings of bullet level, temperature and pressures and prepare joint final out turn report. Confirm quantity received by IOCL alkylation unit or DCU. All operational timings/ operational activities should be logged in dispatch log book as per the format.

19.8 SAFETY PRECAUTIONS: S.No. Description 1 Do not perform the operation while leakages are observed. 2 Pressures in the pipe lines should not be more than design pressure. Ensure pump minimum flow recycle lined up to dispatch bullet and 3 flow control valve is in operation. 4 Ensure all ESD, GDS, FDAS are in place and in working condition. 5 Ensure all PSVs are in line and their outlets are open to LT Flare. 6 Ensure LT Flare is in order. 7 Ensure proper illumination while carrying out operations. Ensure all first aid fire fighting equipments are in place and in 8 working condition. Ensure agreed flow rates and pressures (between IOC refinery and 9 IOT) are maintained during dispatch operation. Positive line up and positive flow rates to be ensured during dispatch 10 operation. 11 Ensure no other operations on the bullet except dispatch. Clear communication should be there between the IOT field and 12 control room, IOT and IOCL refinery about the operation.

SI/OI SI FO/SI/OI

FPR FO/OI FO/SI/OI FO/OI SI/OI FO/OI SI/OI FO/OI/SI SI/OI FO/SI/OI FO/SI/OI FO/SI/OI FO/SI/OI

81 | P a g e

CHAPTER-20 OFF-SPEC LPG PUMPING TO REFINERY FUEL GAS POOL 20.1 OBJECTIVE: The objective of the SOP is to define a step-by-step approach for performing the Pumping of Off-LPG to the Fuel Gas Pool. 20.2 SCOPE: The SOP is applicable for all Pumping Operations from off-spec LPG storage bullets to Fuel Gas Pool. 20.3 DESCRIPTION: 1. Off-spec LPG from storage bullets is dispatched to Fuel Gas Pool using off-spec LPG transfer pumps, 205-P-027A/B/C for all 9 bullets located in Mound I & Mound II. 2. Accounting of product transferred to fuel gas pool is to done by the bullet initial and final parameters. 20.4

SPECIFIC OPERATIONAL REQUIREMENTS:

1. A written confirmation should be received from IOCL regarding product transfer to pipeline off take. 2. Dispatch plan shall be developed by IOT in accordance with the IOCL refinery requirements for off-spec LPG transfer to fuel gas pool. 3. This plan is verified by the Operations–in-charge and executed by Shift Manager. 4. Control Room to ensure the Field Officer is fully aware of all operations within the facility, LPG product characteristic, troubleshooting and lineup. 5. Continuous, short, precise and clear communication should be maintained between Control Room Officer and Field Officers during Pumping Operation. 6. Ensure effectiveness of communication between IOT, IOCL refinery and IOT field before commencement of operation. 7. All the transfer activities in the facility shall be carried out as per the Work Instructions and instructions from Control Room. Field Officer should notify the Control Room upon completion of all tasks. 8. Bullet Level Alarm Set point screen in Control Room shall be used to give alarm prior to low level in the tank. 9. Bullet level, temperature and pressure are used for reconciliation as there is no Metering Skid. 20.5 RESPONSIBILITY: IOCL Refinery’s role:  Communicate to IOT the quantity to be transferred to Fuel Gas Pool.  Excise and custom related formalities if any.  Ensure effectiveness of communication between IOT and overall co-ordination for the smooth delivery operation.  Joint witness with IOT official for LPG storage bullet (level, temperature and pressure) nominated for dispatch.  Finalise the outturn prepared by IOT (initial and after).

82 | P a g e

IOT’S ROLE:  Preparation of LPG bullet for transfer.  Coordinating with the IOC refinery during off-spec LPG transfer operation.  Joint witness of readings of LPG Bullet (level, temperature and pressure) with IOC refinery before and after dispatch.  Reconciliation.  Documentation and preparation of outturn reports.  The Operations-in-charge is overall responsible for maintaining the quality of this SOP.  The Shift Manager is responsible for overall implementation of this SOP  The Planning and Co-ordination department is overall responsible for preparation of pumping plan.  The Control room Officer and Field officers are responsible for conducting the work specified within this SOP. 20.6 PREPARATION S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description Confirm from IOC refinery quantity to be dispatched to Fuel Gas Pool. IOCL/ IOCL representative available at terminal prior to delivery operation for initial out turn preparation. Discharging nominations, initial rates and max rates agreed with IOCL refinery and documented in the dispatch log book. Close all the inlet and outlet valves of the dispatch bullet. Note down the opening level, temperature and pressure. Use lab density and prepare joint initial out turn report. Establish proper communication between refinery, field and control room. Ensure all Hand Operated Valves in delivery line are in working condition and no leaks. Ensure off-spec LPG transfer pumps are in good working condition. Check the pump for lubrication oil, cooling water, direction of rotation etc. Ensure 6” valve for off-spec pump suction outlet in bullet are close. Open 6” valve for off-spec pump suction outlet in the bullet to be dispatched and ensure no leak. Ensure 3” off-spec pump minimum flow recirculation valve in all bullet are closed Open 3‟ off-spec pump minimum flow recirculation valve in the bullet to be dispatched and ensure no leak. Make the vapour balancing for the bullet by opening 8” valve in bullet vapour line. Ensure all the XZV‟s are open. Open the 6” valve in pump suction. Open upstream and downstream valves of 3” pump minimum flow recycle flow control valve.

FPR SI/OI SI/OI SI/OI FO/SI/OI FO/SI/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI FO/OI

20.7 PROCEDURE:

83 | P a g e

S. No. 1 2 3 4 5 6 7

1

2

3 4 5

1 2 3 4 5

Description Start the pump and ensure that there is a positive differential pressure at the pump discharge. Slowly open the pump delivery 4” valve. Observe the pump condition for any abnormal vibration, sound etc. Keep watch on running pump. Monitor the flow rate, if stabilized then start second pump. Monitor the levels/ pressures of the both bullets and line pressures throughout the operation. Ensure that there is no abnormal variation in transfer operation between the bullet and Metering Skid quantities. Record hourly dispatch figures of Bullet. Physically ensure for no leakages in the system. Switch over of dispatch bullet It is required to change the dispatch of LPG from one Bullet to another Bullet; this procedure can be carried out without stopping the operation and informing to IOCL refinery about the switch over. As soon as dispatch bullet about attain Low level, the next bullet for dispatch of LPG should be lined up as under: First open the valves (Body and header) of the bullet which will be lined up for dispatch and then close the valve of the bullet currently under dispatch. Before closing, ensure that the valves of the dispatch bullet are open, generally after 10-15% of opening of the valve in new bullet, closing of the previous bullet is done after ensuring decrease of level in the second bullet and steady pressure of the pipe lines. The same is done for the bullets to be lined up next, after dispatch operation of the bullet. On completing the first bullet, close the line up of the first bullet. Now make the third bullet ready for dispatch and so on for the next bullet to be dispatched. Record level, temperature and pressures of the first bullet to be done along with IOCL refinery representative, and finalise the out turn report. Completion Procedure Record the completion time of the dispatch from the first bullet. Ensure fully close of the valves which are opened for the above operation. Record final readings of bullet level, temperature and pressures and prepare joint final out turn report. Confirm quantity received by IOCL fuel gas pool in refinery. All operational timings/ operational activities should be logged in dispatch log book as per the format.

FPR FO/OI FO/OI FO SI/OI FO/SI/OI SI/OI FO/OI

FO/SI/OI

FO/OI

FO/SI/OI FO/SI/OI SI/OI

SI/OI FO/OI SI/OI SI/OI FO/SI/OI

20.8 SAFETY PRECAUTIONS: S. No. 1 2

Description Do not perform the operation while leakages are observed. Verification of product dispatch from Bullet and receipt by refinery on random basis with IOCL to be done. Do not perform the

FPR FO/SI/OI SI/OI

84 | P a g e

3 4 5 6 7 8 9 10 11 12 13

operation while discrepancy in discharge and receipt figures is observed. Pressures in the pipe lines should not be more than design pressure. Ensure pump minimum flow recycle lined up to dispatch bullet and flow control valve is in operation. Ensure all ESD, GDS, FDAS are in place and in working condition. Ensure all PSVs are in line and their outlets are open to LT Flare. Ensure LT Flare is in order. Ensure proper illumination while carrying out operations. Ensure all first aid fire fighting equipments are in place and in working condition. Ensure agreed flow rates and pressures (between IOC refinery and IOT) are maintained during dispatch operation. Positive line up and positive flow rates to be ensured during dispatch operation. Ensure no other operations on the bullet except dispatch. Clear communication should be there between the IOT field and control room, IOT and IOCL refinery about the operation.

FO/SI/OI FO/OI SI/OI FO/OI SI/OI FO/SI/OI SI/OI FO/SI/OI FO/SI/OI FO/SI/OI FO/SI/OI

85 | P a g e

PART-III APPENDICES

86 | P a g e

APPENDIX-1.0: BULLET DETAILS:

S. No.

Bullet No.

ID(M)

1 2 3 4 5 6 7 8 9

V-003 V-004 V-005 V-007 V-008 V-009 V-012 V-013 V-014

6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4

NOMINAL Safe Liquid Inlet Inside LENGTH( CAPACITY HH H L LL Filling The Bullet Distance M) (M3 (mm) (mm) (mm) (mm) Capacity From Bottom (M) WATER) (M3) 93.45 93.45 93.45 93.45 93.45 93.45 93.45 93.45 93.45

3130 3130 3130 3130 3130 3130 3130 3130 3130

1.235 1.235 1.235 1.235 1.235 1.235 1.235 1.235 1.235

APPENDIX-2.0: NOZZLES AND ASSOCIATE FITTINGS FOR EACH BULLET

NAME N1 N2 N3 N4 N5 K1 K2 K3 K4 K5 M1 M2 D1 D1

DESCRIPTION QTY SERVICE 1 Liquid outlet 1 Vapour inlet/outlet 1 LIQUID INLET 1 SAFETY RELIEF VALVE 1 SPARE 1 PRESSURE TRANSMITTER 1 LEVEL TRANSMITTER(SERVO) 1 LEVEL TRANSMITTER(GWR) 1 TEMERATURE TRANSMITTER 1 LEVEL SWITCH 1 MANHOLE 1 MANHOLE 1 DOME 1 DOME

PIPE NB 500 250 350 200 100 80 200 100 80 100 600 600 1500I.D 1500I.D

SCH/THK SCH.80 SCH.80 SCH.80 SCH.80 SCH.80 SCH.160 SCH.160 SCH.160 SCH.160 SCH.160 28THK 28THK 28THK 28THK

FLANGE RATING 300# 300# 300# 300# 300# 300# 300# 300# 300# 300# 300# 300# ---

87 | P a g e

2.1 BULLET MANIFOLD CONNECTIONS: CONNECTIONS PROPYLENE IBT TT UNLOADING STARTUP BLENDING SPILLAGE LPG RECEIPT OFF SPEC RECEIPT PUMP MINIMUM FLOW IBT OFF SPEC PUMP MINIMUM FLOW INLET HEADER VAPOUR BALANCE DISPATCH SUCTION IBT SUCTION OFF SPEC PUMP SUCTION WATER DRAINING

SIZE 6” 6” 3” 10” 12” 4” 6” 6” 3” 12” 8” 18” 10” 6” 3”

APPENDIX-3.0: RECEIPT DETAILS REFINERY UNIT

DESIGN PRESSURE (Kg/ cm2) DESIGN TEMPERATURE (0C) LINE SIZE (in)

FCC

39.2

98

10

CCR

39.2

98

3

AVU – C3

39.2

98

3

PROPANEALKYLATION

39.2

98

3

AVU-BUTANE

39.2

98

4

C4

39.2

98

6

LPG- ALKYLATION

39.2

98

8

PROPANE – PRU

39.2

98

4

FLOWRATE

3.1DISPATCH DETAILS PARAMETER

MARKETING TERMINAL

PIPE LINE OFF-TAKE

TANK TRUCK LOADING

FUEL GAS POOL

Design Pressure

39 (Kg/ cm 2)

39 (Kg/ cm 2)

32.3 (Kg/ cm 2)

22.3 (Kg/ cm 2)

Design Temp

-45 to 65 (0C)

-45 to 65 (0C)

-45 to 65 (0C)

-45 to 65 (0C)

12”

12”

12”

4”

190 m3/hr

190 m3/hr

190 m3/hr

20 m3/hr

Line Size Pump Flow rate Pump Tag No. Connected Bullet

205-P-001 A,B,C,

205-P-001 D,E,F

205-P-001 A,B,C

VVV003,004,005 012,013,014 003,004,005

205-P-001 205-P-001 D,E,F A,B,C V-012, 013, 014

205-P-001 D,E,F

205-P-027 A,B,C

VV-012, 013, V003,004,0 014 003,004,005,00

88 | P a g e

,007,008,00 9

,007,008,00 9

05,007,00 8,009

7,008,009,012,0 13,014

89 | P a g e

APPENDIX-4.0: PUMP & MOTOR DETAILS Pump No.

Service

205-P-001 A,B,C

205-P-001D,E,F

205-P-027 A,B,C

DISPATCH TO MARKETING VIA PIPELINE TRANSFER & TT LOADING

PIPELINE OFF TAKE VIA PIPELINE TRANSFER

OFF SPEC PUMPING TO FUEL GAS POOL

190 m 3/hr

190 m 3/hr

20 m 3/hr

24.07 kg/cm²g

24.07 kg/cm²g

16.7 kg/cm²g

CAN TYPE CENTRIFUGAL

CAN TYPE CENTRIFUGAL

Rated Capacity(m³/hr) Discharge Pressure(kg/cm²g) Discharge Pressure Shut Off(kg/cm²g)

CAN TYPE CENTRIFUGAL Type Flow Control loop

FV-0002

FV- 9802

FV-0092

Suction Header Size

10''

10''

4''

Discharge Header Size

8''

8''

3''

Rating of Motor(kw)

132

132

7.5

Motor Current (amp)

1493

1493

14

Motor RPM

216

216

1460

4.1 WATER DRAIN POT DETAILS:

ID HEIGHT DESIGN PRESSURE DESIGN TEMPERATURE

205-VT-110 WATER DRAIN POT 1900 mm 4300 mm 3.5 Kg/cm 2g -450C/ 650C

4.2 ETHYL MARCAPTAN PUMP AND VESSEL FACILITY:

CAPACITY @ suction cond. DIFFERENTIAL PRESS DIFFERENTIAL HEAD

205-P-105 ETHYL MERCAPTAN TRANSFER PUMP 0.40 m 3/hr 2.0 Kg/cm 2 23.8 mlc

ID HEIGHT DESIGN PRESSURE

205-VT-105 ETHYL MERCAPTAN STORAGE VESSEL 750 mm 1500 mm 3.5 Kg/ cm 2g

90 | P a g e

DESIGN TEMPERATURE

CAPACITY @ suction cond. DIFFERENTIAL PRESS DIFFERENTIAL HEAD

650C 205-P-043 A/B ETHYL MERCAPTAN DOSING PUMP 15 LPH 15.0 Kg/cm 2 179.0 mlc

APPENDIX-4.3 VAPOUR COMPRESSOR DETAILS 205-A-006 Motor KW 90 RPM 1480 Drive V-Belt Stage Single APPENDIX-5.0: UTILITY SYSTEM S. No

Parameter Pressure (Kg/cm2 g) Temperature (°C)

Minimum Normal SERVICE WATER (WS) 4 6 Ambient Ambient

Pressure (Kg/cm2 g) Temperature (°C)

PLANT AIR (AP) 4 7 40 40

8 50

10.5 65

INSTRUMENT AIR 4.5 7 Ambient 40

8 50

10.5 65

8.3 Ambient

10.5 65

9 65

-

11.5 Ambient

16 65

(Kg/cm2

Pressure g) Temperature (°C)

Maximum

Mech. Design

8 Ambient

10.5 65

N –NITROGEN (Kg/cm2

Pressure g) Temperature (°C)

Pressure (Kg/cm2 g) Temperature (°C)

3 20

8 Ambient

POTABLE WATER 6 FIRE WATER

(Kg/cm2

Pressure g) Temperature (°C)

7 Ambient

7 Ambient

91 | P a g e

APPENDIX-6.0: XZV DETAILS: TAG NO.

SIZE

FULL OPENING/CLOSING TIME (SEC)

SERVICE

INSTRUMENT AIR PRESSURE (Kg/cm2)

XZV- 0001

14”

90

LPG

4.5

XZV- 0002

18''

90

LPG

4.5

XZV- 0023

8”

90

LPG

4.5

XZV-0003

14”

90

LPG

4.5

XZV- 0004

18''

90

LPG

4.5

XZV- 0024

8”

90

LPG

4.5

XZV- 0005

14”

90

LPG

4.5

XZV- 0006

18''

90

LPG

4.5

XZV-0025

8”

90

LPG

4.5

XZV-0188

14”

90

LPG

4.5

XZV- 0190

18''

90

LPG

4.5

XZV- 0189

8”

90

LPG

4.5

XZV- 8603

14”

90

LPG

4.5

XZV- 0192

18''

90

LPG

4.5

XZV- 0191

8”

90

LPG

4.5

XZV-0193

14”

90

LPG

4.5

XZV- 0195

18''

90

LPG

4.5

XZV- 0194

8”

90

LPG

4.5

XZV-1188

14”

90

LPG

4.5

XZV-1190

18''

90

LPG

4.5

XZV- 1189

8”

90

LPG

4.5

XZV-1003

14”

90

LPG

4.5

XZV- 1192

18''

90

LPG

4.5

XZV- 1191

8”

90

LPG

4.5

92 | P a g e

XZV- 1193

14”

90

LPG

4.5

XZV- 1195

18''

90

LPG

4.5

XZV- 1194

8”

90

LPG

4.5

LOCATION

APPENDIX-7.0: MOV AND HOV DETAILS TAG NO.

SIZE

FULL OPENING/CLOSING TIME (SEC)

SERVICE

MOV-0724

12”

90

LPG

MOV-0279

12”

90

LPG

BOOT-3 BATTERY LIMIT MARKETING PIPELINE TRANSFER BOOT-3 BATTERY LIMIT MARKETING PIPELINE TRANSFER

LPG PUMPHOUSE HOV DETAILS

LPG Marketing 250-P-001 A 250-P-001 B LOCATION Pump Main Suction HO Valve P-001A-S-001 P-001B-S-001 Pump IBT Suction HO Valve P-001A-S-002 P-001B-S-002 Pump Main Delivery HO Valve P-001A-D-001 P-001B-D-001 Pump IBT delivery HO Valve P-001A-D-002 P-001B-D-002 LPG Pipeline Off Take 250-P-001 D 250-P-001 E LOCATION Pump Main Suction HO Valve P-001D-S-001 P-001E-S-001 Pump IBT Suction HO Valve P-001D-S-002 P-001E-S-002 Pump Main Delivery HO Valve P-001D-D-001 P-001E-D-001 Pump IBT delivery HO Valve P-001D-D-002 P-001E-D-002 LPG Off-Spec 250-P-027 A 250-P-027 B LOCATION Pump Main Suction HO Valve P-027A-S-001 P-027B-S-001 Pump Main Delivery HO Valve P-027A-D-001 P-027B-D-001

250-P-001 C P-001C-S-001 P-001C-S-002 P-001C-D-001 P-001C-D-002 250-P-001 F P-001F-S-001 P-001F-S-002 P-001F-D-001 P-001F-D-002 250-P-027 C P-027C-S-001 P-027C-D-001

93 | P a g e

LPG TT GANTRY HOV DETAILS

LOCATION Liquid Loading Upstream 3"HO Valve Liquid Loading Downstream 3"HO Valve Liquid Unloading Upstream 3"HO Valve Liquid Unloading Downstream 3"HO Valve Liquid Blowdown Upstream 3"HO Valve Liquid Blowdown Downstream 3"HO Valve Vapour upstream 3"HO Valve Vapour Downstream 3"HO Valve Vapour Blowdown Upstream 3"HO Valve Vapour Blowdown Downstream 3"HO Valve

BAY-01 LLG-B1L-001 LLG-B1L-002 LLG-B1L-003 LLG-B1L-004 LLG-B1L-005 LLG-B1L-006 LLG-B1V-001 LLG-B1V-002 LLG-B1V-003 LLG-B1V-004

LPG LOADING GANTRY BAY-02 BAY-03 BAY-04 LLGLLG-B2- LLG-B3B4-LL-001 L-001 001 LLGLLG-B2- LLG-B3B4-LL-002 L-002 002 LLGLLG-B2- LLG-B3B4-LL-003 L-003 003 LLGLLG-B2- LLG-B3B4-LL-004 L-004 004 LLGLLG-B2- LLG-B3B4-LL-005 L-005 005 LLGLLG-B2- LLG-B3B4-LL-006 L-006 006 LLGLLG-B2- LLG-B3B4-VV-001 V-001 001 LLGLLG-B2- LLG-B3B4-VV-002 V-002 002 LLGLLG-B2- LLG-B3B4-VV-003 V-003 003 LLGLLG-B2- LLG-B3B4-VV-004 V-004 004

BAY-05 LLG-B5L-001 LLG-B5L-002 LLG-B5L-003 LLG-B5L-004 LLG-B5L-005 LLG-B5L-006 LLG-B5V-001 LLG-B5V-002 LLG-B5V-003 LLG-B5V-004

BAY-06 LLGB6-L001 LLGB6-L002 LLGB6-L003 LLGB6-L004 LLGB6-L005 LLGB6-L006 LLGB6-V001 LLGB6-V002 LLGB6-V003 LLGB6-V004

BAY-07 LLG-B7-L-001

LLG-B7-L-002

LLG-B7-L-003

LLG-B7-L-004

LLG-B7-L-005

LLG-B7-L-006

LLG-B7-V-001

LLG-B7-V-002

LLG-B7-V-003

LLG-B7-V-004

LPG TT METERING SKID HOV DETAILS

Master Meter HO Valve Stand-by Meter-01 HO Valve Stand-by Meter-02 HO Valve Stand-by Meter-03 HO

Duty Meter01 LMS-MD1 LMS-S1D1 LMS-S2D1 LMS-S3-

LPG Metering Skid Duty Duty Duty MeterMeter- Meter02 03 04 LMS-M- LMS-MLMSD2 D3 M-D4 LMSLMS-S1LMSS1-D2 D3 S1-D4 LMSLMS-S2LMSS2-D2 D3 S2-D4 LMSLMS-S3LMS-

Duty Meter05 LMS-MD5 LMS-S1D5 LMS-S2D5 LMS-S3-

Duty Meter06 LMSM-D6 LMSS1-D6 LMSS2-D6 LMS-

Duty Meter07 LMSM-D7 LMSS1-D7 LMSS2-D7 LMS-

94 | P a g e

Valve Stand-by Meter-04 HO Valve

D1 LMS-S4D1

S3-D2 LMSS4-D2

D3 LMS-S4D3

S3-D4 LMSS4-D4

D5 LMS-S4D5

S3-D6 LMSS4-D6

S3-D7 LMSS4-D7

LPG BULLETS HOV DETAILS LPG Bullets LOCATION Off-Spec Receipt 4" HO Valve Blending Spillage 10" HO Valve Blended LPG Receipt 12"HO Valve Intter Bullet Transfer 6"HO Valve Pump minimum Flow 4"Line Inter Mound Transfer From Propylene 6"HO Valve Off-Spec Minimum Flow 3"HO Valve Receipt Start-up 3"HO Valve TT Unloading 6"HO Valve Pump Main Suction Upstream 18"HO Valve Pump Main Suction down Stream 18"HO Valve Intter Bullet Transfer Suction Upstream10"HO Valve Intter Bullet Transfer Suction Down stream10"HO Valve Off-Spec Pump Suction Upstream 6"HO Valve Off-Spec Pump Suction Down Stream 6"HO Valve Water Draining Upstream 3"HO Valve Water Draining Down Stream 3"HO Valve

V-003

V-004

V-005

V-007

V-008

V-009

V-012

V-013

V-014

V-003I-001 V-003I-002 V-003I-003 V-003I-004 V-003I-005

V-004I-001 V-004I-002 V-004I-003 V-004I-004 V-004I-005

V-005I-001 V-005I-002 V-005I-003 V-005I-004 V-005I-005

V-007I-001 V-007I-002 V-007I-003 V-007I-004 V-007I-005

V-008-I001 V-008-I002 V-008-I003 V-008-I004 V-008-I005

V-009I-001 V-009I-002 V-009I-003 V-009I-004 V-009I-005

V-012-I001 V-012-I002 V-012-I003 V-012-I004 V-012-I005

V-013-I001 V-013-I002 V-013-I003 V-013-I004 V-013-I005

V-014-I001 V-014-I002 V-014-I003 V-014-I004 V-014-I005

V-003I-006

V-004I-006

V-005I-006

V-007I-006

V-008-I006

V-009I-006

V-012-I006

V-013-I006

V-014-I006

V-003I-007 V-003I-008 V-003I-009

V-004I-007 V-004I-008 V-004I-009

V-005I-007 V-005I-008 V-005I-009

V-007I-007 V-007I-008 V-007I-009

V-008-I007 V-008-I008 V-008-I009

V-009I-007 V-009I-008 V-009I-009

V-012-I007 V-012-I008 V-012-I009

V-013-I007 V-013-I008 V-013-I009

V-014-I007 V-014-I008 V-014-I009

V-003O-001

V-004O-001

V-005O-001

V-007O-001

V-008O-001

V-009O-001

V-012O-001

V-013O-001

V-014O-001

V-003O-002

V-004O-002

V-005O-002

V-007O-002

V-008O-002

V-009O-002

V-012O-002

V-013O-002

V-014O-002

V-003O-003

V-004O-003

V-005O-003

V-007O-003

V-008O-003

V-009O-003

V-012O-003

V-013O-003

V-014O-003

V-003O-004

V-004O-004

V-005O-004

V-007O-004

V-008O-004

V-009O-004

V-012O-004

V-013O-004

V-014O-004

V-003O-005

V-004O-005

V-005O-005

V-007O-005

V-008O-005

V-009O-005

V-012O-005

V-013O-005

V-014O-005

V-003O-006

V-004O-006

V-005O-006

V-007O-006

V-008O-006

V-009O-006

V-012O-006

V-013O-006

V-014O-006

V-003O-007

V-004O-007

V-005O-007

V-007O-007

V-008O-007

V-009O-007

V-012O-007

V-013O-007

V-014O-007

V-003O-008

V-004O-008

V-005O-008

V-007O-008

V-008O-008

V-009O-008

V-012O-008

V-013O-008

V-014O-008

95 | P a g e

Vapour Line 8"HO Valve

V-003V-001

V-004V-001

V-005V-001

V-007V-001

V-008V-001

V-009V-001

V-012V-001

V-013V-001

V-014V-001

96 | P a g e

APPENDIX-8.0: RELIEF VALVE SETTINGS

S.NO

TAG NO

1

PSV-0003

2

PSV-2222

3

PSV-0082

4

PSV-0083

5

PSV-0084

6

PSV-0089

7

PSV-0426

8

PSV-0427

9

PSV-0431

10

PSV-0430

11

PSV-0434

12

PSV-0435

13

PSV-1426

14

PSV-1427

15

PSV-1431

16

PSV-1430

17

PSV-1434

18

PSV-1435

19

PSV-0392

20

PSV-0001

21

PSV-0004

22

PSV-0005

23

PSV-0391

SERVICE V-003 LPG storage bullet V-003 LPG storage bullet V-004 storage bullet V-004 storage bullet V-005 storage bullet V-005 storage bullet V-007 storage bullet V-007 storage bullet V-008 storage bullet V-008 storage bullet V-009 storage bullet V-009 storage bullet V-012 storage bullet V-012 storage bullet V-013 storage bullet V-013 storage bullet V-014 storage bullet V-014 storage bullet 205-P-027 SUCTION COMMON HEADER 205-P-001 A,B,C PUMP IBT COMMON SUCTION HEADER 205-P-001 A,B,C PUMP DISPATCH COMMON SUCTION HEADER 205-P-001 A,B,C MINIMUM FLOW COMMON HEADER 205-P-027 A,B,C

PRESSURE SET POINT (Kg/cm2g)

INLET SIZE (INCH)

OUTLET SIZE (INCH)

RATING

18.5

8

18

300

8

18

300

8

18

300

8

18

300

8

18

300

8

18

300

8

18

300

8

18

300

8

18

300

39

2

2

300

39

2

2

300

39

2

2

300

39

2

2

300

39

2

2

300

18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5

97 | P a g e

24

PSV-0002

25

PCV-0390

26

PCV-0016

27

PSV-5026

28

PSV-5027

29

PSV-5028

30

PSV-5029

31

PCV-1116

32

PSV-0393

33

PSV-5024

34

PSV-5021

35

PSV-5022

MINIMUM FLOW COMMON HEADER 205-P-0001 A,B,C IBT DELIVERY COMMON HEADER BETWEEN 205-P027 A,B,C MINMUM FLOW COMMON HEADER AND SUCTION COMMON HEADER. BETWEEN 205-P001 A,B,C MINMUM FLOW COMMON HEADER AND SUCTION COMMON HEADER. STARTUP RECEIPT COMMON HEADER inter bullet suction header OFF SPEC RECIPT TT UNLOADING HEADER BETWEEN 205-P001 A, B, C MINMUM FLOW COMMON HEADER AND SUCTION COMMON HEADER. PUMP COMMON DELIVERY PUMP COMMON SUCTION PUMP COMMON SUCTION PUMP IBT COMMON SUCTION

39

2

2

300

3

3

300

3

3

300

39

2

2

300

39

2

2

300

39

2

2

300

39

2

2

300

2

2

300

39

2

2

300

39

2

2

300

39

2

2

300

39

2

2

300

NOTE: All PSV outlets are connected to LT Flare.

98 | P a g e

APPENDIX-9.0: INTEGRATION BETWEEN REFINERY AND LPG STORAGE FACILITY

STREAM FCC CCR AVU – C3 PROPANE – ALKYLATION AVU-BUTANE C4 LPG- ALKYLATION PROPANE – PRU SERVICE WATER (WS) PLANT AIR (AP) INSTRUMENT AIR N –NITROGEN POTABLE WATER FIRE WATER

RESPECTIVE BOOT-3 BATTERY LIMIT OPERATING DESIGN 0 PRESSURE (kg/cm²) TEMP ( C) PRESSURE (kg/cm²) 15.5 40 39.2 16.4 40 39.2 15.5 40 39.2 15.5 40 39.2 15.5 40 39.2 15.5 40 39.2 16 40 39.2 15.6 40 39.2 6 Ambient 10.5 7 40 10.5 7 40 10.5 8 Ambient 10.5 6 Ambient 10.5 7 Ambient 16

TEMP (0C) 98 98 98 98 98 98 98 98 65 65 65 65 65 65

APPENDIX-10.0: BULLETS INSTRUMENTATION DETAILS: NAME Servo gauge Radar gauge Pressure transmitter Temperature transmitter Level switch Servo gauge Radar gauge Pressure transmitter Temperature transmitter Level switch Servo gauge Radar gauge Pressure transmitter Temperature transmitter Level switch Servo gauge Radar gauge Pressure transmitter Temperature transmitter Level switch Servo gauge Radar gauge Pressure transmitter Temperature transmitter

TAGE NO. LT-0001 LT-0002 PT-0002 TT-0001 LZT-2001 LT-0004 LT-0005 PT-0005 TT-0002 LZT-2002 LT-0007 LT-0008 PT-0009 TT-0003 LZT-2003 LT-0206 LT-0207 PT-0425 TT-0255 LZT-2007 LT-0206 LT-0209 PT-0429 TT-0256

LOCATION

V-003

V-004

V-005

V-007

V-008

99 | P a g e

Level switch Servo gauge Radar gauge Pressure transmitter Temperature transmitter Level switch Servo gauge Radar gauge Pressure transmitter Temperature transmitter Level switch Servo gauge Radar gauge Pressure transmitter Temperature transmitter Level switch Servo gauge Radar gauge Pressure transmitter Temperature transmitter Level switch

LZT-2006 LT-0210 LT-0211 PT-0433 TT-0257 LZT-2009 LT-1206 LT-1207 PT-1425 TT-1255 LZT-2004 LT-1206 LT-1209 PT-1429 TT-1256 LZT-2005 LT-1210 LT-1211 PT-1433 TT-1257 LZT-2006

V-009

V-012

V-013

V-014

100 | P a g e

APPENDIX-11.0: ALARMS LEVEL (mm) SL.NO BULLET NO.

SERVICE/ AREA

Low Low ALARM, mm

1 V-003 LPG 2 V-004 LPG 3 V-005 LPG 4 V-007 LPG 5 V-008 LPG 6 V-009 LPG 7 V-012 LPG 8 V-013 LPG 9 V-014 LPG PRESSURE (Kg/cm2 g) SNO TAG SERVICE/ LOW LOW AREA ALARM 1 V-003 LPG 5.63 2 V-004 LPG 5.63 3 V-005 LPG 5.63 4 V-007 LPG 5.63 5 V-008 LPG 5.63 6 V-009 LPG 5.63 7 V-012 LPG 5.63 8 V-013 LPG 5.63 9 V-014 LPG 5.63 LPG TRANSFER PUMPS DELIVERY 10 205-PLPG 23.2 001 A/B/C 11 205-PLPG 23.2 001 D/E/F 12 205-BLPG – OFF 15.5 027 SPEC A/B/C APPENDIX-12.0: SAFETY INTERLOCKS EQUIPMENT/LOCA TION

SAFETY INTERLOCKS High level

V003/004/007/008/ 009/012/013/014

High High level Low level Low Low level

Low ALARM, mm

High High ALARM, mm

LOW ALARM 6.2 6.2 6.2 6.2 6.2 6.2 6.2 6.2 6.2

HIGH ALARM 14 14 14 14 14 14 14 14 14

HIGH HIGH ALARM 17 17 17 17 17 17 17 17 17

--

--

31.767

--

--

31.767

--

--

22.3

CAUSE Level>510 0mm Level>520 0mm

High ALARM, mm

EFFECT

REMARK

Alarm ESD valve at the inlet and Alarm

2 out of 3 logic. LI-0001,LI0002,LZT-2001

Alarm. Close ESD valve at the outlet XZV Shutdown LPG transfer pump.p-001A/B/C.

101 | P a g e

Shutdown off-spec LPG transfer pump.p-027A/B/C. Close ESD valve at LPG marketing line. (XZV-0179). Close ESD valve at LPG pipeline-off-take .(XZV-3002). Alarm Close inlet XZV. Alarm.

High High pressure High pressure Low pressure

Alarm Alarm Close ESD valve at the outletXZV. Shutdown LPG transfer pump.p-001a/b/c. Shutdown offspec LPG transfer pump.p-027a/b/c. Close ESD valve at LPG marketing line.(XZV-0179). Close ESD valve at LPG pipeline .(XZV-3002). Alarm. Close ESD valve at vapour balancing line(XZV0023). Alarm.

Low Low pressure

On LPG transfer pump common disc. Header. On LPG transfer pump common disc. Header.

High line pressure.

Shutdown LPG transfer pump(p-0001a/b/c/d/e/f/). alarm

Low pressure alarm.

ESD actuation at LPG tanker loading bays(refin ery end)

Shutdown LPG transfer pumps(p-001a/b/c/d/e/f). shutdown propylene vapour compressor Close ESD valves at LPG transfer bays (XZV-6001, 6002, 6003, 6004, 6006, 6007 6051). Close ESD valve at LPG vapour balancing line(XZV-

102 | P a g e

6005) Alarm. ESD actuation at LPG pipeline offtake.(at refinery end). ESD actuation at LPG marketing terminal.( at refinery end)

Common disc. Header of p001a/b/c. Common disc. Header of p001a/b/c. Individual Disc. Of p001A/B/C/D/E/F/. Individual Disc. Of p001A/B/C/D/E/F/. Ethyl Mercaptan storage vessel Ethyl Mercaptan storage vessel Ethyl Mercaptan storage vessel

On bullet 205-V003/004/005/007/ 008/009/012/013/ 14.

Shutdown LPG transfer pumps(p-0001a/b/c/d/e/f). close ESD valve at LPG transfer pipeline(XZV-3002). ESD signal to pipeline. Alarm. Shutdown LPG transfer pumps(p-0001a/b/c/d/e/f). close ESD valve at LPG marketing line(XZV-0179). Close ESD valve at LPG marketing line(XZV-0104). ESD signal to marketing line. Alarm.

High flow rate

alarm

Low flow indication.

Alarm.

High High pressure.

Shutdown particular LPG transfer pumps. alarm

Low Low pressure.

Shutdown particular LPG transfer pumps. Alarm

High level Low level

Low Low level

High High level.

ESD system should stop the transfer pump first before ESD valve completely closed.

Alarm Alarm Shutdown ethyl Mercaptan dosing pump(p43a/b). Alrm

Shutdown LPG transfer pump(p-001a/b/c/d/e/f). alarm

Pump trip action in case of High High level in the bullet has to take place only if that perticular bullet

103 | P a g e

is getting filled under IBT not normal receipt mode. On off-spec. LPG transfer pump disharge header. On off spec. LPG transfer pump disharge header. Off spec LPG transfer pump discharge header. Off spec LPG transfer pump discharge header. At pump 205-p027A/B/C.

At pump 205-p027A/B/C

High pressure. Low pressure. High flow

Low flow

Shutdown off spec LPG transfer pump(p-027a/b/c). alarm. Alarm

Alarm

Alarm

High High pressure

shutdown off spec LPG pump 205-P-027a. alarm

Low Low pressure

Shutdown off spec LPG pump 205-P-027a. alarm

104 | P a g e

APPENDIX-13.0: FIRE PROTECTION DETAILS

EQUIPMENTS

QUANTITY

DOUBLE HYDRANT

27

HOSE BOX

15

WATER MONITOR

15

DELUGE

6

APPENDIX-14.0: FIRST AID FIRE FIGHTING DETAILS EQUIPMENTS LOCATION 10KG DCP TT GANTRY 75KG DCP TT GANTRY 10KG DCP PUMPHOUSE-5 25KG DCP PUMPHOUSE-6

QUANTITY 4 1 4 2

APPENDIX-15.0: AGDC (ALARM AND GAS DETECTORS COMBUSTIBLE) TAG NO 205-AGDC-0807 205-AGDC-0810 205-AGDC-0814 205-AGDC-0817 205-AGDC-0821 205-AGDC-0825 205-AGDC-0806 205-AGDC-0813 205-AGDC-0816 205-AGDC-0820 205-ADGC-0824 205-AGDC-0827 205-AGDC-0809 205- AGDC-0812 205- AGDC-0815 205- AGDC-0815 205- AGDC-0819 205- AGDC-0823 205- AGDC-0804 205- AGDC-0808 205- AGDC-0811 205- AGDC-0818 205- AGDC-0822 205- AGDC-0826 205- AGDC-0801 205- AGDC-0802 205- AGDC-0803 205- AGDC-0844

LOCATION V-003 DOME-1 V-004 DOME-1 V-005 DOME-1 V-007 DOME-1 V-008 DOME-1 V-009 DOME-1 V-003 DOME-2 V-004 DOME-2 V-005 DOME-2 V-007 DOME-2 V-008 DOME-2 V-009 DOME-2 V-003 OUTLET V-004 OUTLET V-005 OUTLET V-007 OUTLET V-008 OUTLET V-009 OUTLET V-003 MANIFOLD V-004 MANIFOLD V-005 MANIFOLD V-007 MANIFOLD V-008 MANIFOLD V-009 MANIFOLD 205-P-001A MANIFOLD 205-P-001B MANIFOLD 205-P-001C MANIFOLD V-012 DOME-1

REMARKS

105 | P a g e

205205205205205205205205205205205205205205205205205205205205205205205205-

AGDC-0845 AGDC-0846 AGDC-0839 AGDC-0841 AGDC-0843 AGDC-0838 AGDC-0840 AGDC-0842 AGDC-0835 AGDC-0836 AGDC-0837 AGDC-0829 AGDC-0830 AGDC-0831 AGDC-0832 AGDC-0833 AGDC-0834 AGDC-0733 AGDC-0734 AGDC-0735 AGDC-0736 AGDC-0737 AGDC-0738 AGDC-0739

V-013 DOME-1 V-014 DOME-1 V-012 DOME-2 V-013 DOME-2 V-014 DOME-2 V-012 OUTLET V-013 OUTLET V-014 OUTLET V-012 MANIFOLD V-013 MANIFOLD V-014 MANIFOLD 205-P-001D MANIFOLD 205-P-001E MANIFOLD 205-P-001F MANIFOLD 205-P-027A MANIFOLD 205-P-027B MANIFOLD 205-P-001-C MANIFOLD TT gantry Bay-1 TT Gantry Bay-2 TT Gantry Bay-3 TT Gantry Bay-4 TT Gantry Bay-5 TT Gantry Bay-6 TT Gantry Bay-7

15.1 FDAS (FLAME DETECTOR AND ALARM SYSTEM) TAG NO 205-AFDF-0803 205-AFDF-0804 205-AFDF-0805 205-AFDF-0806 205-AFDF-0807 205-AFDF-0808 205-AFDF-0801 205-AFDF-0802 205-AFDF-0812 205-AFDF-0813 205-AFDF-0814 205-AFDF-0809 205-AFDF-0810 205-AFDF-0811 205-AFDF-0707 205-AFDF-0708 205-AFDF-0709 205-AFDF-0710 205-AFDF-0711 205-AFDF-0712 205-AFDF-0713

LOCATION V-003 DOME-2 V-004 DOME-2 V-005 DOME-2 V-007 DOME -2 V-008 DOME-2 V-009 DOME-2 205-P-001A MANIFOLD 205-P-001C MANIFOLD V-012 DOME-2 V-013 DOME-2 V-014 DOME-2 205-P-001D MANIFOLD 205-P-001F MANIFOLD 205-P-027C MANIFOLD TT gantry Bay-1 TT Gantry Bay-2 TT Gantry Bay-3 TT Gantry Bay-4 TT Gantry Bay-5 TT Gantry Bay-6 TT Gantry Bay-7

REMARKS

106 | P a g e

15.2 GAS ALARM BEACON WITH HOOTER-AGB TAG NO LOCATION 205-AGB-0803 PUMPHOUSE-6 205-AGB-0802 SOUTH SDIE OF MOUND-1 205-AGB-0801 PUMP HOUSE-5 205-AGB-0702 WEST SIDE OF TT GANTRY

REMARKS

15.3 MANUAL CALL POINT-MCP TAG NO 205-AFMCP-0803 205-AFMCP-0807 205-AFMCP-0802 205-AFMCP-0801 205-AFMCP-0804 205-AFMCP-0806 205-AFMCP-0805 205-AFMCP-0707

LOCATION ENTRY OF PUMPHOUSE-6 SOUTH SIDE OF PUMPHOUSE-6 EAST SIDE MOUND-1 NORTH SDIE OF MOUND-1 ENTRY OF PUMPHOUSE-5 SOUTHSIDE OF PUMPHOUSE-5 EAST SIDE OF MOUND-2 WEST SIDE OF TT GANTRY

REMARKS

15.4 GAS ALARM SIREN-AGS TAG NO 205-AGS-0803 205-AGS-0802 205-AGS-0801 205-AGS-0702

LOCATION NORTH SIDE OF PUMPHOUSE-6 SOUTH SIDE OF MOUND-1 SOUTH SIDE OF PUMPHOUSE-5 WEST SIDE OF TT GANTRY

REMARKS

15.5 FIRE ALARM BEACON-AFB TAG NO 205-AFB-0801 205-AFB-0804 205-AFB-0802 205-AFB-0803 205-AFB-0702 15.6

LOCATION NORTH SIDE OF MOUND-1 MANIFOLD SOUTH SIDE MOUND-1 SOUTH SIDE OF PUMPHOUSE-5 SOUTH SIDE OF MOUND-2 WEST SIDE OF TT GANTRY

REMARKS

FIRE ALARM SIREN-AFS

TAG NO 205-AFS-0801 205-AFS-0804 205-AFS-0803 205-AFS-0802 205-AFS-0702

LOCATION NORTH SIDE OF MOUND-1 MANIFOLD SOUTH SIDE MOUND-1 SOUTH SIDE OF MOUND-2 SOUTH SIDE OF PUMP HOUSE-5 WEST SIDE OF TT GANTRY

REMARKS

107 | P a g e

APPENDIX-16 SAFETY CHECK LIST FOR LPG ROAD TANKERS Customer: Tank Truck No. Oil Company’s Name. ____________ S. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Date _________Carriers

Check points VALID LICENCE FROM CCOE VALID CERTIFICATE FROM „RTO‟ (R.C. AND F.C) RLW-ULW Licenced capacity. VALID DRIVING LICENCE & HAZARDOUS CHEMICAL DRIVING CERTIFICATE Has suitable spark arrestor of make and design approved by CCOE, Nagpur, properly fixed to exhaust. CONDITION OF EXHAUST PIPE BATTERY CUT-OFF SWITCH/BATTERY ENCLOSURE/INDICATION LIGHTS „U‟ CLAMPS & FOUNDATION BOLTS NO EXPOSED / LOOSE WIRING Carries 2 nos. 10 Kg. DCP extinguishers in easily accessible and removable position with Truck No. date of checking and charging painted on it and 1 no. of 2 Kg CO2 extinguisher in the driver cabin. ENGINE STARTER AND STARTER COVER ANY FLAMMABLE LIQUID / MATERIAL PROPER BONDING FOR CHASSIS, CABIN AND BULLET ROTOGUAGE & PRESSURE GAUGE AND TEMPERATURE GAUGE BONDING / EARTHING WIRE AT LIQUID & VAPOUR CONNECTION PROTECTION AT ROTOGUAGE, LIQUID & VAPOUR VALVES (STOPPER PIN) SAFETY VALVE, DIESEL TANK PROTECTION Height barrier provided as per specifications. ANY OTHER TEMPORARY PLUGGING SPARE WHEEL GENERAL CONDITION OF TANKER AND PROPER HAZCHEM SIGN NO VISIBLE DENT OR CORROSION ON THE BULLET Paint of bullet is not peeling off. TREMCARD INSTRUCTION BOOKLET DETAILING INSTRUCTION ON HANDLING EMERGENCIES ENROUTE STATUTORY TEST CERTIFICATE 43,44,2,18&19 HAND BRAKE OR WOODEN CHOKE Quick closing manifold valve with lever indicating close

OK

Not OK

108 | P a g e

27 28 29

30

31 32 33

and open status. Fuel tank is protected by means of stout guard and fuel tank cap is locked. First aid kit is available. Hazchem sign, name of contractor with address and telephone No. displayed prominently. Vessel identification code includes Radiography PWHT Design Pressure Design Temperature Hydrostatic test pressure First test date and subsequent test dates Water capacity in litres Liquid/vapour lines are adequately anchored and are well protected by means of stout steel guard. Tool box containing Leather hand gloves and heat resistant hand gloves, Safety Goggles , 2 nos. red flags non-metallic tools, wooden plugs of appropriate size and sealing compound. CHECK LIST FROM UNLOADING POINTS

Remarks: VEHICLE GROSS WEIGHT LOADING CAPACITY FORM ‘F’ VALIDITY

I here by declare that there is no accident of bullet

TANKER: LOADING APPROVED / NOT APPROVED / HOLD Reference OISD- 159.

occurred during my period

Driver Signature

109 | P a g e