SCOPE OF THE MANUAL

This installation & maintenance manual describes the various systematic

procedures for installation, operation and maintenance for the below skids.

Biocide injection package

H2S Scavenger injection package
Offshore methanol injection package
Offshore corrosion inhibitor injection package
Offshore scale inhibitor injection package
Onshore corrosion inhibitor injection package
Onshore scale inhibitor injection package
TEG(Glycol) injection package
MEG oxygen scavenger package
Sodium Carbonate injection package
Sodium Hydroxide injection package
Ammonia Injection package
Oxygen Scavenger Package
New Biocide Injection Package (South Side)
SAFETY PROCEDURES: -
 All safety precautions shall be followed as per the established the plant safety plan.

 Only experienced & skilled technicians shall be engaged for carrying out start-up of the

chemical injection skid.

 Safety guards shall be in place and secured prior to start-up.

 All earthing has to be checked.

 Cable test reports shall be verified prior to energization.

 Appropriate warning signs & tapes shall be placed during start –up.

 Appropriate PPE shall be worn according to the nature of the job.

 Work area shall be maintained neat and clean.

 The Permit to work shall be obtained before the start of work.

 MSDS for chemicals shall be available on site.

GENERAL INFORMATION

Installation Procedure:
 Before starting the installation activities, ensure the foundation location are properly anchored in the skid.
 Check the Level gauges are properly tightened on the Level gauge nozzles provided on the Tank.
 Check the ladder and handrail properly on the skids (Which Ever it is applicable).
 Install the skid with proper alignment in such case that no misalignment of tie-in points will occur in the
skid.
 After the alignment of the base frame is completed, ensure all the foundation are anchored properly &
tightened.
 Connect all tie in Connections.
 Connect all the incoming cables related to Electrical & Instrumentation.

Startup Procedure:
  Before filling the chemical in the storage tank ensure all dust & foreign particles are flushed properly from
tank & pipe spools. Ensure desiccants are also removed from all the tanks.
 Proper PPE to be used while handling the chemicals.
 Connect the hose to the filling tie-in points and confirm the connections are made with suitable
connections
 Check for the rotation of the motor in order to have the efficient flow rate for injection.
 Carry out kick start of the motor for confirm the rotation of the motor is correct.
 Ensure all the process valves are in open condition and all drain valves are closed conditions.
 Ensure all electrical & instruments are powered up and calibrated as per the required range.
 Open the tank outlet valve.
 Open the pump suction isolation valve for the pump which has to be operated.
 Manually adjust the pump stroke to attain the required flow rate.
 Open the inlet isolation valve of the calibration pot to fill into its maximum capacity.
 After filling calibration pot, close the inlet isolation of the calibration pot.
 Close the tank outlet isolation valve
 After closing the tank outlet isolation valve, immediately open the calibration pot inlet valve.
 Calibrate the flow rate as required for injecting the chemical based on the field requirement.
 After calibrating the flow rate. First, open the tank outlet valve and then isolate the calibration pot to have
continuous flow injection.
 Start the injection pump.

SCJEDULED PREVENTIVE MAINTENANCE

 1. Maintenance and servicing routines are strictly adhered Personnel employed should have the
appropriate qualifications and experience.
2. Frequency of operation may decrease the time for maintenance of items of equipment, the customer
is required to formulate individual maintenance time for these items. Refer to the below
maintenance schedule table.

CHECKS TO BE PERFORMED BEFORE COMMISSIONING

I. Calibration Procedure:

 All instruments used for measurement of any parameter shall be calibrated.

 During installation individual instruments’ calibration procedure shall be followed as per the instrument
manuals.
 Calibration check shall be carried out for respective instruments at the specified time interval as per the
maintenance schedule.
 It shall be ensured that the Supplier Calibration/Test report is available for each instrument used in the
system.
 All gauges and transmitters shall be checked for calibration once in every 6 months.

II. Dosing Pump Maintenance:

 Maintenance of the dosing pump to carried out at regular interval as per the pump IOM.
 Isolate the valves in process line and de-energize the pump motor & electrical components
 Disconnect the pump electrically check that the equipment cannot be switched on accidentally.
 Unscrew the plug and drain the oil into a tray. Degrease the plug and screw it into place.
 Isolate the valves for which the pump to be carried out the maintenance.
 Dismantle the pipe spools & instruments for the respective the pumps which to be carried out for
maintenance.
 Remove the pump from the skid by use of the lifting hook provided in the pump
Pump to the positioned in bench for during maintenance.
 If any diaphragm replacement, pump liquid head to be dismantled as per the OEM procedure. Please refer
the IOM of the dosing pump supplied along with dossier.
 Reassembly of the pump, clean the suction and discharge cartridge(check valves)and position the same
with proper alignment in order have free flow of the liquid
 After completing the maintenance of the pump it can be reassembled in the skid and check for proper
alignment of positioning of the pump.
 Assemble the pipe spools with respective valves & instruments in process line with suitable gaskets and
fasteners.
 The above same operation to be carried out for stand by pump or alternative pump in which is available in
the skid.

III. Tank Maintenance Procedure

 Conduct monthly/weekly walk-around of your tank(s)

 Look for stains on steel where leak may be occurring
 Check physically the nozzle welds
 Check associated piping
 Open up your tank a minimum of twice a years and conduct your own visual inspection inside
 Check for weld deterioration and corrosion
 Visually check coating for blisters or cracks
 Keep a record of inspections and results
 If tank has an internal containment liner, check leak monitor weekly
 Check that the level alarms in tote tanks are working properly
IV. Piping Maintenance Procedure:

 Conduct monthly check for the piping and associated fittings.

 Check for weld deterioration and corrosion.
 Check for Rust and leakage.
 Check the joints and bends.
 Gaskets shall be checked for leakages and replaced if found damaged.

V. Pressure Safety Valve Maintenance:

 Pressure safety valve maintenance to be carried out at regular interval

 Isolate the upstream line and downstream line manual valve of the pressure safety valve
 Ensure the valve seal is properly sealed with lock arrangement
 Dismantle the pressure safety valve after the manual valve isolated
 Open the safety valve internal spring and recalibrate as required to set pressure
 After completing the calibration reassemble the valve in process line
 Ensure the new set of gaskets are installed in process line
 For detail dismantle operation of the pressure safety valve, please refer OEM catalogue as attached in
dossier.

VI. Junction Box Maintenance Procedure:

 JB shall be checked monthly

 Loose connections shall be checked in the terminals.
 Wire quality and damages shall be checked.
 Terminal Quality shall be checked.
 JB doors are properly and tightly closed.

APPLICABLE CONDITION MONITORING TECHNIQUES AND MONITORING POINTS

I. Calibration Procedure:

 All instruments used for measurement of any parameter shall be calibrated.

 During installation individual instruments’ calibration procedure shall be followed as per the instrument
manuals.
 Calibration check shall be carried out for respective instruments at the specified time interval as per the
maintenance schedule.
 It shall be ensured that the Supplier Calibration/Test report is available for each instrument used in the
system.
 All gauges and transmitters shall be checked for calibration once in every 6 months.

II. Dosing Pump Maintenance:

 Maintenance of the dosing pump to carried out at regular interval as per the pump IOM.
 Isolate the valves in process line and de-energize the pump motor & electrical components
 Disconnect the pump electrically check that the equipment cannot be switched on accidentally.
  Unscrew the plug and drain the oil into a tray. Degrease the plug and screw it into place.
 Isolate the valves for which the pump to be carried out the maintenance.
 Dismantle the pipe spools & instruments for the respective the pumps which to be carried out for
maintenance.
 Remove the pump from the skid by use of the lifting hook provided in the pump
Pump to the positioned in bench for during maintenance.
 If any diaphragm replacement, pump liquid head to be dismantled as per the OEM procedure. Please refer
the IOM of the dosing pump supplied along with dossier.
 Reassembly of the pump, clean the suction and discharge cartridge(check valves)and position the same
with proper alignment in order have free flow of the liquid
 After completing the maintenance of the pump it can be reassembled in the skid and check for proper
alignment of positioning of the pump.
 Assemble the pipe spools with respective valves & instruments in process line with suitable gaskets and
fasteners.
 The above same operation to be carried out for stand by pump or alternative pump in which is available in
the skid.

III. Tank Maintenance Procedure

 Conduct monthly/weekly walk-around of your tank(s)

 Look for stains on steel where leak may be occurring
 Check physically the nozzle welds
 Check associated piping
 Open up your tank a minimum of twice a years and conduct your own visual inspection inside
 Check for weld deterioration and corrosion
 Visually check coating for blisters or cracks
 Keep a record of inspections and results
 If tank has an internal containment liner, check leak monitor weekly
 Check that the level alarms in tote tanks are working properly

IV. Piping Maintenance Procedure:

 Conduct monthly check for the piping and associated fittings.

 Check for weld deterioration and corrosion.
 Check for Rust and leakage.
 Check the joints and bends.
 Gaskets shall be checked for leakages and replaced if found damaged.

V. Pressure Safety Valve Maintenance:

 Pressure safety valve maintenance to be carried out at regular interval

 Isolate the upstream line and downstream line manual valve of the pressure safety valve
 Ensure the valve seal is properly sealed with lock arrangement
 Dismantle the pressure safety valve after the manual valve isolated
 Open the safety valve internal spring and recalibrate as required to set pressure
 After completing the calibration reassemble the valve in process line
  Ensure the new set of gaskets are installed in process line
 For detail dismantle operation of the pressure safety valve, please refer OEM catalogue as attached in
dossier.

VI. Junction Box Maintenance Procedure:

 JB shall be checked monthly

 Loose connections shall be checked in the terminals.
 Wire quality and damages shall be checked.
 Terminal Quality shall be checked.
 JB doors are properly and tightly closed.

ISOLATION PROCEDURES TO ENSURE SAFE MAINTENANCE ACCESS

 Isolate the valves in process line and de-energize the pump motor & electrical components
  Disconnect the pump electrically check that the equipment cannot be switched on accidentally.

 Depressurize the lines/pumps instruments as applicable and ensure there is no pressure in the system.

 If the maintenance activity has to be carried out in the Operating skid ensure all the isolation valves are

closed and safety lock is in place with respective work permits displayed.

 Unscrew the plug and drain the oil into a tray. Degrease the plug and screw it into place.

 Isolate the valves for which the pump to be carried out the maintenance.

 Dismantle the pipe spools & instruments for the respective the pumps which to be carried out for

maintenance.

 Remove the pump from the skid by use of the lifting hook provided in the pump

Pump to the positioned in bench for during maintenance.

 If any diaphragm replacement, pump liquid head to be dismantled as per the OEM procedure. Please refer

the IOM of the dosing pump supplied along with dossier.

 Reassembly of the pump, clean the suction and discharge cartridge(check valves)and position the same

with proper alignment in order have free flow of the liquid

 After completing the maintenance of the pump it can be reassembled in the skid and check for proper

alignment of positioning of the pump.

 Assemble the pipe spools with respective valves & instruments in process line with suitable gaskets and

fasteners.

 The above same operation to be carried out for stand by pump or alternative pump in which is available in

the skid.

Sub.
Sub Page Volume
sub Description Remarks
Index No. No.
Index
As built Documents

As built/approved
Engineering and design documents, Calculations of Base
drawings and calculations (provided with frame, Lifting beam,
A.
review, appraisal, validate and approval Storage tank,
provisions) Acceleration head loss,
Pulsation dampener.
As built drawings (shall be provided with
B. review, appraisal, validate and approval
provisions)
C. Dosing Pump IOM Manual
D. Dosing Pump Motor IOM Manual
E. Pressure Gauge IOM Manual
F. Pressure Transmitter IOM Manual
G. Flow Transmitter IOM Manual
H. Pressure Safety Valve IOM Manual
I. Strainer IOM Manual
J.
Pulsation Dampener With Charging
Kit IOM Manual
K. LCS/JB IOM Manual