PURGING WITH NITROGEN INTRODUCTION: During Plant Survey and work on the compressor cylinders, air may enter into the Equipment and Process System. Before re-commissioning the unit, this air must be purged out from the Process System by either hydrocarbon Gas or Nitrogen. Failure to do this, air/gas mixture when subjected to pressure and temperature can cause an explosion in the system that may result to serious injury to Personnel and damage to equipment. Gas Purging is used only when a small area/volume of equipment or process plant is opened and exposed to atmosphere during maintenance work (ie. Compressor Stage). Nitrogen Purging is necessary only when complete CRU Gas Process Plant is opened and exposed to atmosphere during maintenance work (ie. during Major Survey). Purging is carried out by pressurizing the equipment and piping to 10 Psig {TWO or THREE times) and with repeated depressurizing to atmosphere through safe located and unlit vents. Gas supply for Purging is taken from the nearest available point with sufficient pressure (30 - 40 Psi). Maintenance is responsible to ensure availability of the gas supply at site. Nitrogen supply is obtainable on mobile trailers and advance management have to be made with Maintenance to make it available on time and at sufficient quantity. The quantity or volume of Nitrogen required for purging the ‘CB’ CRU is: 1240. SCF - -670. SCF = 1910 SCF Production & Export Admin Division Page 92The total volume of 1910 SCF covers all vessels, pipelines and compressors within the CRU. This much quantity is for ONE time purge only. If repeated purge is required, this volume of 1,910 SCF has to be multiplied by the number of times, for example: For Two Purge Operation = 2 X 1910 SCF For Three Purge Operation = 3 X 1910 SCF PURGE PREPARATION: Carry out the following preparations and checks with No Fait: 1. Ensure all vehicles and personnel not required during purging period, are well clear of the area. 2. Ensure safe access (ladder) is available to vessel top vents. 3. Check that spades are removed and spectacle flanges are turned to open position. 4. Shut 36” suction valve to C-101. 5. Shut 6” bypass from 2nd stage compressor discharge. 6 Make sure of the following: Vent valves on top of C-101/102/103 and C-104 are shut. Vent valves on gas inlets to E-101/102 and E-103 are shut. C-101 and C-102 manual drains shut. 1™ stage compressor suction and discharge bottle drains are shut. WoTE: If self-drain system is provided on suction bottles to 2” and 3" compressors, make sure isolating valves on related drain lines are closed. 7. Shut C-102 Auto Dump downstream valve and ensure by-pass is closed. 8. Shut C-103 water Auto Dump downstream valve and bypass. 9. Open C-103 LCV bypass. Production & Export Admin Division Page 93,10. Check G-101/102 suction and discharge valves opened and priming valves closed. 11, ©-103/104 extra high Auto Dumps downstream valve & bypass shut. 12. Isolate LP quick drain, (shut upstream valve). 13. Isolate HP quick drain, (shut upstream valve). 14, At C-104 carry out the following: * Isolate Auto Water Dump Valve, (shut downstream and by-pass valves). * Isolate lean gas PRV, (shut downstream and by-pass valves). e Isolate LCV (shut downstream and by-pass valves). 15. Maintenance to connect Nitrogen Trailer (if required) to C-101 manual drain. NOTE: Ensure C-101 vessel is drained out of liquid before connecting the trailer. 16. Open C-101 manual drain valve (after connecting Nitrogen hose). PURGE OPERATION: 1. Open the source valve at the Trailer or Gas Point slowly to introduce Nitrogen/Gas through the Process System. 2. Bar-over the engine manually (5 revolutions) to allow nitrogen to pass through and pressurize the process system to 10 Psig. 3. Ensure that the process system is pressurized to 10 Psig. 4. Close the valve at the Trailer when the pressure is 10 Psig. 5. Open provided vents at various points to vent the Nitrogen/Gas to atmosphere. 6. Open as many vent points as possible to drive out the air from the Process System. 7. Prime G-101 and G-102 pumps. Production & Export Admin Division Page 9410. 11. 12. 13. 14, 15. When the Process System is depressurized, close all vent points. Repeat this pressurizing and depressurizing procedure two more times. Analyze the oxygen content on the various points using a sniffer and confirm that oxygen content is below the maximum acceptable level (4%). If the oxygen content is not yet below the requirement, repeat purge condition until the requirement is satisfied. When purging with Nitrogen/Gas is completed, shut the source valve of the Trailer or Gas Point and C-101 manual drain. Disconnect Nitrogen Trailer or Gas source point. Open 36” suction valve to C-101 to introduce tank vapours into C- 103 and the process system.. Start CRU as per normal start-up procedure. Production & Export Admin Division Page 95PRE START-Up CHECK LisT For every cold-start, after a prolonged shutdown ensure to check the following: A. Plant Area 1. Main Plant production not less than 60,000 Bbis/day. 2. 2™ stage separators pressure not less than 40 Psig. 3. Gas compensating valve up-stream and down-stream isolating valves are open, by-pass shut. 4. LP Header Butterfly valve set to control at 3.0” W.G. 5. Isolating valve on ‘Lean’ gas line at Plant end is open. B. CRU Process System 36” suction valve to C-101 open. C-101 vessel is manually drained and drain valve shut. Nore: If Auto Drain system is provided ensure there is no liquid level in the Seal Drain Drum. Check C-101 pressure is normal 2.5 - 3.0” WG. 6” By-pass valve from 3" stage compressor discharge is open. All four unloaders are screwed out. All vent valves are shut. C-102 manual drains shut and Auto Dump set for correct operation. C-103 Auto Water Dump set for correct operation and ensure in good working order by ‘stroking’ the valve. Valve on circulating line from G-101 discharge to C-103 open. . Suction valve to G-101, open. . €-103 LCV upstream & downstream valves open, by-pass shut. . C-103/104 Extra High Auto Dumps upstream and downstream isolating valves open, by-pass valves shut. Note: If Extra Level Auto Dumps are connected to Main Plant LP Headers, ensure isolating valves at Plant end are OPEN. Production & Export Admin Division Page 9613. 14. 15. 16. 17. 18. 19. 20. C-104 Auto Water Dump set for correct operation and ensure in good working order by ‘stroking’ the valve. C-104 LCV upstream & downstream valves open, by-pass shut. Suction valve to G-102, open. Valve on circulating line from G-102 discharge to C-104, open. Main isolating valve on transit line to Refinery, open. C-104 Lean gas PRV upstream & downstream valves open, by- pass shut. LP/HP Quick drains upstream isolating valves, open. All suction and discharge bottle drains shut, except those on self- drain system if provided. chide Oil Cooling & 1. E101 crude and gas stream inlet/outlet valves fully open. 2. E-102 crude and gas stream inlet/outlet valves fully open. 3. E-103 crude and gas stream inlet/outlet valves fully open. 4. Ensure no spades are in line of E-101/102/103 inlet/outlet crude and gas pipings. Open manual drains at E-101/102/103 to check for cooler tubes leak. Check E-101/102/103 TCV’s (Automatic Temperature Controllers) upstream and downstream isolating valves open, and TCV’s set as follows: > E-101 TCV setat 120 °F. > E-102 TCV set at 100 °F. > E-103 TCV setat 90 °F. Mote: The pressure drop of the crude oil across the cooler (inlet to outlet) should not exceed 25 Psi, otherwise this may put unnecessary load on the pumps and erode the cooler tubes. The pressure can be adjusted by the Trimming valve. This does not apply to CRU’s where ‘HoT OIL’ system is used for cooling. Production & Export Admin Division Page 97D. Scavenge Air System 1. Ensure sand blower is switched ON. 2. Check Water and Mercury manometers are serviceable. €. Fuel System Isolating valve downstream of Engine Gas Scrubber to CRU is open. Isolating valve upstream of Fisher 99 (Big Joe) open. Pressure downstream of Fisher 99 regulator is 40 Psi. Drain out C-109 (CRU Fuel Gas Scrubber). Open fuel gas plug/gate valve. 2a Pen Ensure gas control valve (Governor) is in shut position. F. Engine Lubricating System 41. Ensure underground oil storage tanks are topped up with correct type of oil and air supply available. 2. Check lube oil level at: a) Engine sump. b) Day tank. c) Power & Compressor Cylinder lubricators. 3. Pre-lube pump and Auxiliary lube oil pump suction valves open. 4, Full flow filter inlet valve open. 5. Strainer outlet valve open. 6. Fin Fan cooler is switched ON. 7. Air lock vent on filter open. NOTE: During start-up, keep close watch of this vent. When the Filter is filled up and primed of air lock ie. oil starts oozing out, close the vent valve Production & Export Admin Division Page 98G. Cooling Water System » Ensure underground water tank is topped up, Texteam pump and air supply available. Surge tank water level is at 3/4 sight glass. Surge tank outlet valve to pump open. Water bleeding points shut. H. Starting Air System 1. CRU Starting Air Compressor on Auto. 2. Air vessel pressure 220 Psig. 3. Drain out air vessel (C-107) of any liquid. 4. Air supply open to Auxiliary at Pre-lube oil pumps and Barring jack. 5. Open main Starting Air Gate and Plug Valves, upstream of Starter Motors. |. Control Panel_FT-50 1. Instrument air pressure available, approximately 60 Psig. 2. ‘est Alarm panel lights and Acknowledge. 3. Press Reset button at the Panel to clear out Shutdown indications. Note: Ensure all Alarms, Shutdown and Permissive indications are clear, except those of Class ‘B’ indicators. 4. Electric power switched ON for UV Detectors, G-101 & G-102 pumps. 5. Bar - over the engine, if necessary (for those units not already equipped with the new Air Starter Motor System). Production & Export Admin Division Page 99g valves on Fuel Gas System, Starting Air System and Pre-lubrication Air System. 2. Start the Fin Fan cooler. 3. Check 6” manual circulating valve (6” bypass valve) is open. 4. Check that all four (4 Nos) Unloaders are out. 5. Check Starting Air pressure, Fuel Gas pressure and C-101 Suction pressure are normal. NoTE: Start Air pressure should be between 170 - 190 Psig for Safe Start-up without damaging the Starter Motors. * Pressure more than 220 Psig may damage Starter Motor. © Pressure less than 150 Psig may not be able to crank the engine. K. DCS Control Room 1. Press CRU Reset Push-button at the Operator Console. 2. At the DCS check and ensure the following: « The status of C-103/C-104 level. © Pressure in C-104 vessel. * Lean Gas Pressure Controller and all other Controllers setpoints are correctly set. Production & Export Admin Division Page 100START-UP PROCEDURE ‘AUTOMATIC START’ Ensure CRU ‘RESET’ Push-button is reset at Operator Console (DCS) in the Control Room. REACTION 1. At FT-50 Control Panel turn ‘ACK-RESET’ Knob to RESET position. 1, Check at FT-50 Panel the following PERMISSIVES indicators are ‘ON’. * Unit Shutdown ‘START PERMISSIVE’, * Class ‘B’ Shutdown ‘START PERMISSIVE’ ‘+ Start Air Pressure ‘START PERMISSIVE’. ‘© Fuel Gas Pressure ‘START PERMISSIVE’. * DCS ‘START PERMISSIVE’. Note: Class ‘B’ Shutdowns consists of the following points: > Low Lube Oil Pressure Shutdown. > Jacket Water Low Press Shutdown. > Power Cylinder Low Flow Shutdown. > Compr. Cylinder Low Flow Shutdown. 2. At FT-50 Panel select ‘AUTOMATIC START’ position. 3. Press ‘AUTO-START’ button. Then observe the unit going through the following ‘Automatic Sequence’. a) Pre-Lube Oil Pump Starts. % Class ‘B’ Shutdowns are over-ridden (by- passed) for 180 Seconds. “SEQUENCE PROGRESS’ light comes ‘ON’. a) 90 Secs after Oil Pressure reaches 5 Psi, “CRANK PERMISSIVE’ comes ‘ON’. Production & Export Admin Division Page 101ACTION __ REACTION. b) CRANK ‘ON’. b) Starting Motor cranks the engine for 7 Secs (Purge Time). ¢) IGNITION ‘ON’. ¢) Ignition coils charge spark plugs for 2-Second period and Ignition indication comes ‘ON’. d) Fuet ‘ON’. d) Fuel Shut-Off Valve opens and Fuel Control Valve admits fuel gas at controlled pressure for ‘ight up’. * LP Quick Vent valve closes automatically. At 90 RPM speed: Starter Motors, Auxiliary & Pre-Lube Oil pumps stop. Class ‘B’ Shutdowns over-ride indicators are cleared. Fuel Control Valve allows 10-12 Psig gas flow to the engine to attain Minimum Speed of 165 RPM. e) WARN UP ‘ON’. e) Warn Up Timer is energized for 180 Secs. * Engine remains running on idle speed (165 RPM) during this period. * When Lube Oil temp reaches 110 °F “ACCEL PERMISSIVE’ light comes ‘ON’. f) Unit READY To Loap ‘ON’. f)_ The engine is now ready to increase Speed and for Loading up. Notre: After successful start ensure to: * Close Starter Motors manual isolating valves (Gate & Plug Valves). * Leave open Auxiliary & Pre-Lube Oil Pumps suction valves and Starting air valves of the pumps. Production & Export Admin Division Page 102START-UP PROCEDURE ‘MANUAL START’ Ensure CRU ‘RESET’ Push-button is reset at Operator Console (DCS) in the Control Room. 1. At FT-50 Control Panel turn “ACK-RESET’ Knob to RESET position. | l 1. Check at FT-5O Panel the following PERMISSIVES indicators are ‘ON’. © Unit S/D ‘START PERMISSIVE’. Class ‘B’ S/D ‘START PERMISSIVE’. © Start Air Press. ‘START PERMISSIVE’. Fuel Gas Press. “START PERMISSIVE’. DCS ‘START PERMISSIVE’. NOTE: Class ‘B’ Shutdowns consists of the following points: > Low Lube Oil Pressure Shutdown. > Jacket Water Low Press Shutdown. > Power Cylinder Low Flow Shutdown. > Compr. Cylinder Low Flow Shutdown. 2. At FT-50 Panel select “LOCAL MANUAL’ Start position. Ea 3. Press the ‘PRE-LUBE’ button (SW-5). —__|__ a) Pre-Lube pump starts. b) Indication light on ‘SW-5’ button comes. ON. ) Check the Pump is running and pressure is OK ie. 5 Psig. Nore: Pressure can be checked on Digital Display Module Channel No. 60. Production & Export Admin Division Page 103ACTION 4. Press the ‘CRANK’ button (SW-4). REACTION a) Starter Motors crank the engine. b) Indication light on “SW-4" button comes ON. ¢) Ensure the engine is cranking, d) When engine speed reaches 40 RPM, 7 Seconds Purge Timer is energized. NoTE: Engine Speed can be checked on Digital Display Module Channel No. 1. 5. Press the ‘IGNITION’ button (SW-3), a) Ignition coil is energized to charge the Spark Plugs for 2 Seconds, b) ‘IGNITION’ indication on ‘SW-3’ button comes ON. 6. Press the ‘FUEL’ button a) Fuel Shut Off Valve opens and Fuel Control Valve admits fuel gas at controlled pressure for ‘ight up’. b) Indication light on “SW-2’ button comes ON. c) LP Quick Vent valve closes automatically. d) At 90 RPM speed: Starter Motors, Auxiliary & Pre-Lube Oil pumps stop. e) Fuel Control Valve allows 10-12 Psig gas flow to the engine to attain Minimum Speed of 165 RPM. f) Check on FT-50 Panel that Class ‘B’ Shutdowns over-ride indicators are cleared. g) Ensure ‘WarM-UP’ indication comes ON. h) When engine temperature reaches 110 °F, “ACCEL PERMISSIVE’ indication comes ON. i) Unit ‘Ready to LOAD’ comes ON. NoTE: Engine Lube Oil temp'can be observed on Digital Display Module Channel No. 35. Production & Export Admin Division Page 104LOADING UP (POST START CHECKS) Increase the engine speed to 210 RPM using the ‘raise’ Push-button. Close the 6” By-pass valve slowly. When the By-pass valve is fully closed, put in Unloaders one by one (watch C-101 pressure as you are doing this). MoTE: C-101 Pressure can be observed from Digital Display Module on Channel No. 56. Check engine speed, if necessary increase. When level starts to rise in C-103 prime and start G-101 pump. When level starts to rise in C-104 vessel, prime and start G-102 pump. Manually stroke C-102 Auto Dump Valve and C-103 & C-104 Water Dump Valves to ensure they are in working order. Check the Controllers status on the DCS and ensure that C-103, C-104 levels and C-104 pressure controls are OK. Note: C-104 Pressure can also be checked from FT-5O Digital Display Module Channel No. 59. Production & Export Admin Division Page 105NORMAL SHUTDOWN Take unloaders out. Reduce engine speed slowly to 190 RPM. Press the ‘AUTOMATIC STOP’ Push-button on FT-50 Local Panel and observe the following: * ‘COOLDOWN’ status indication comes ON and the engine run at this idle speed for 2 minutes, to allow the hot parts to cooldown gradually - extending engine life. After cooldown period observe the following sequence of actions taking place automatically: « Fuel Shut-off valve closes. e LP Quick Vent (XV-103) opens (depressurizing C-103 and upstream vessels/equipment). * When engine speed drops below 150 RPM ‘COOLDOWN’ in ation light comes ‘ON’ on FT-50 Panel and the Auxiliary lube oil pump starts and continues to run for 15 Minutes. e At 40 RPM rundown speed, the Igni Switch inside the Relay Box ‘Closes’ to ground the Ignition coils in order to prevent accidental energizing during shutdown. * G-101 and G-102 pumps stop automatically. The ‘CRU’ engine can also be manually shutdown by either of the following methods: a) Shut off fuel gas plug valve at engine side. b) Press the ‘CRU STOP’ Push-button at Operator Console in the Control Room. WoTE: For Manual stop using fuel gas plug valve, Auxiliary lube oil pump will also start automatically when the engine speed drops to 150 RPM during rundown. Inform the Refinery (LPG Plant). If unit is to be shutdown for more than few hours, switch off Fin-Fan cooler. Leave sand Blower in operation. Leave 6” circulating valve shut (otherwise C-104 will remain pressurized through the 6” line if the transit line check valve is passing backwards. This backflow may even overpressurize the crude storage tanks. WOTE: The above procedure is the same if the unit shuts down automatically on fault. Production & Export Admin Division Page 106EMERGENCY SHUTDOWN On emergency the CRU unit can be shutdown from the following points: 1. 2. FT-50 Local Panel ‘ESD’ Push-button. CRU site Area ‘ESD’ Push-button. Control Room at Operator Console: ‘CRU ESD’ Push-button. ‘Total Shutdown’ Push-button. When any of the above stations Push-button is pressed, the unit will shutdown as follows: Fuel Shut-Off Valve closes and the engine runs down to stop. LP Quick Vent (XV-103) opens (depressurizing C-103 and upstream vessels/equipment). HP Quick Vent XV-104) opens (depressurizing C-104 vessel and upstream equipment). Nore: The C-104 Quick Vent will also open in the event of shutdowns caused by: >» UV Fire detectors activation. > Overspeed trip. > FT-50 Panel Processor failure. These events are also considered as emergency shutddown. No ‘COOLDOWN’ Cycle is initiated (ie. no Auxiliaries are allowed to run). At 40 RPM rundown speed, the Ignition system stops and Ignition coils are grounded to prevent accidental energizing during shutdown. G-101 & G-102 pumps stop automatically. Production & Export Admin Division Page 107SHUTDOWN FOR MAINTENANCE For maintenance shutdown the CRU has to be stopped in the same manner as in the Normal Shutdown Procedure described earlier. However, in addition to that, the following steps have to be taken: 1. Ensure 6” circulating valve is shut. 2. Shut 36” suction valve to C-101. 3. Isolate the Lean gas PRV. 4. Isolate C-104 LCV on the transit line. 5. Locked out electric main switches locally and in sub-station. 6. Isolate coolers and drains if necessary. 7. Close isolating valve of LP - HP Quick Drain on common line at the HP flare tie in point. 8. Prepare ‘PERMIT TO WorK’ for Maintenance. 9. Request Maint. to fit spades if the work condition necessitate so. 10. Wash out vessel, carry out gas free test and issue gas free certificate if entry to vessel is required. Wore: i) If CRU Quick drains are connected to HP Flare line, it is also essential to open manual drains of C-102, C-103 & C-104 to pit, so as to be able to depressurize the vessels to zero (0). ii) Issue work permits to Maintenance crew only when the system is completely isolated, purged and working environment is safe. Production & Export Admin Division Page 108