MCOT 018 Sea Loading Pump Station - SLPS - Operations PDF

Operating Procedure MY SKO O 05 MCOT 018
Sea Loading Pump Station (SLPS) Operations Rev. 0 Sept 2011
Any deviation from this procedure must follow the MANAGEMENT OF CHANGE PROCEDURE
or STANDING INSTRUCTIONS process before any deviation or change may be made.
OPERATING PROCEDURE
Contents
Foreword
Distribution List
Amendment Summary
Preface
Glossary
Reference Documents
Section 1 Introduction
Section 2 Procedure
Appendix A Checklist
Diagram
"UNCONTROLLED WHEN PRINTED"
30/07/2012 9:44 AM PETRONAS CARIGALI SDN BHD Page 1 of 24

FOREWORD
Authority for original issue

Document Author
Issue of this document has been formally authored by:
Name: Mentor Solutions & Resources Sdn Bhd
Position: Technician/ Consultant/ Contractor
Date:
Issue Review
Issue of this document has been formally reviewed by:
Name:
Signature
Position: Production Supervisor/ Field Engineer
Date:
Issue Approval
Issue of this document has been formally approved by:
Name:
Signature:
Position: Head of Production
Date:
Document Custodian
The following person has been assigned as the document custodian:
Name:
Signature:
Position Onshore Installation Manager
Date

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

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

GLOSSARY
CCR Central Control Room

DCS Distributed Control System
DTS Daily Tank Status
EOV Electric Operated Valve
FCV Flow Control Valve
NPSH Net Positive Suction Head
PCMS Process Control and Monitoring System
SLPS Sea Loading Pump Station
RCU Remote Control Unit
REFERENCE
DOC. NO TITLE
MCOT Rejuvenation Project Phase 2 Piping & Instrumentation Diagram (P&ID)

Process Drawing (Rev. No. 6)
MY SKO O 07016 Rev.1 April 2010 MCOT Operating Procedures Manual

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

1 INTRODUCTION
1.1 OBJECTIVE/PURPOSE
1.1.1 This operating procedure outlines activities required to operate SLPS booster pumps, gas
engine driven and electrical driven crude oil pumps for loading operation and inter tank
transfer.
1.2 SCOPE
1.2.1 The procedure applies to MCOT booster and crude oil loading pumps.
1.2.2 The main activities involved are operations of;
• SLPS booster pumps P-1410, P-1420, P-1430 (electric motor, vertical pump)
• Crude oil main loading pump P-1/10/11/1200 (gas engine driven)
1.3 OP CATEGORY
Categories Normal/ Start Up / Shutdown / Checklist Required: Yes/ No

Emergency / Special / Temporary /
and attributes
Abnormal / Decommissioning
1.4 PREREQUISITES
1.4.1 Choice of operating gas engine driven crude loading pumps or combination of pumps must be
planned upfront.
1.4.2 Certified ICE Engine Driver.
1.4.3 Maintain communication with CCR during inter tank operation or loading operations.
1.5 LIMITATIONS
1.6 Shortage of gas supply, instrument air and electrical power.
1.7 ROLES/RESPONSIBILITY
1.7.1 Refer to Section 2: Procedure “Action party”.

1.8 HSE REQUIREMENTS
Hazards and The table below lists job hazards and the precautions that should be taken
precautions for safety, environmental, quality, ergonomics, Good Manufacturing
Practices, etcB before beginning this procedure.
Hazard Precaution
Pressure Ensure proper lineup to avoid high

backpressure conditions
Flammable No hot work during pump running

High Pitch Noise Wear hearing protection
Chemical/Toxic/Thermal burns Avoid crude oil contact with skin.
Loss of Containment Ensure all flanges and connections are

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

required this activity in addition to mandatory PPEs. List any special PPEs required,
PPE Use
Ear muffs/plug Hearing protection during pump running
Tools and The tools and equipment listed below are needed to do this job. List any
Equipment special tools required in addition to hand tools.
Tools and/or Equipment Use
N/A
ESD / N/A
Interlocks

Unit: P-1410/20/30 SLPS BOOSTER Safe

Never Exceed
PUMPS Operating SOL Excursions
Limit(barg)
Area: Sea Loading Pump Station Limit(barg)
Consequence of
Equipment Inst.Tag # H L HH LL Corrective Actions
Deviation
P-1410/20/30 PIAH-1412/22/32 7.3 Alarm will be activated Stop P-1410/20/30 manually, rectify the cause of
the high pressure problem and check P-
1410/20/30/40 integrity before starting them again.
P-1410/20/30 PIAL-1412/22/32 1.2 Alarm will be activated Stop P-1410/20/30 manually, rectify the cause of
the low pressure problem and check P-
1410/20/30/40 integrity before starting them again.
P-1410/20/30 PZALL-1414/24/34 1.05 Pump trips Rectify the cause of the low low pressure problem
(discharge line) There is a potential and check P-1410/20/30/40 integrity before starting
damage to the pumps them again.
P-1410/20/30 PZALL-1415/25/35 0.65 Pump trips Rectify the cause of the low low pressure problem
(suction line) There is a potential and check P-1410/20/30/40 integrity before starting
damage to the pumps them again.

Unit: P-1410/20/30 SLPS BOOSTER Safe

Never Exceed
PUMPS Operating SOL Excursions
Limit (barg)
Area: Sea Loading Pump Station Limit (barg)
Consequence of
Equipment Inst.Tag # H L HH LL Corrective Actions
Deviation
P-1200 PIAH1203 2.5 There is a potential Stop P-1200 manually, rectify the cause of the high
damage to the pump pressure problem and check P-1200 integrity before
starting it again.
P-1 PIAL410 -.05 There is a potential Stop P-1 manually, rectify the cause of the low pressure
damage to the pump problem and check P-1 integrity before starting it again
P-10 PIAL401 -.05 There is a potential Stop P-10 manually, rectify the cause of the low
starting it again
starting it again
(Suction) damage to the pump pressure problem and check P-1200 integrity before
starting it again
(Discharge) damage to the pump pressure problem and check P-1200 integrity before
starting it again
P-1440 PIA 1441 -.05 4.22 -0.72 There is a potential Stop P-1440 manually, rectify the cause of the low
starting it again
P-1450 PIA 1450 -.05 4.22 -0.72 There is a potential Stop P-1450 manually, rectify the cause of the low
starting it again
* Not available in P&ID. The low and high pressures settings are available in CCR1 DCS screen (old set-up). These data will be migrated to CCR2 after MCOT rejuvenation
project which is on-going at this moment of writing this OP.

Section 2
PROCEDURE
Content Page
2.1 SLPS Booster Pumps P1410/1420/1430 ................................................................... 11
2.2 Crude Oil Main Loading Pump P-1/10/11/1200.......................................................... 12
2.3 Crude Oil Main Loading Pump P-1440/1450 .............................................................. 13

2 PROCEDURE
2.1 PREPARATION BEFORE PUMPS START-UP
No. Action Action Party
2.1.1 Check fuel gas system, lubricating system, cooling water system, ICE Driver /
electrical power supply, utility air system (for starting air starter) and Area operator
instrument air system are operational according to pre-startup checklist.
2.2 SLPS BOOSTER PUMPS P1410/1420/1430 START-UP
2.2.1 Line up identified tanks, open tanks side valves and suction EOVs. Panel man 1
/ Area
operator
2.2.2 For crude loading operations, calculate loading time and loading flow rate. Panel man 1
Update MCOT Daily Tank Status (DTS).
2.2.3 Based on required flow rate; line up booster pumps in combination of two Panel man 1 /
pumps or three pumps in parallel at least thirty minutes before loading ICE Driver/
operation. Refer to Appendix A, item 2.1, Figure 1: SLPS Booster pumps Area
Operator
CAUTION:
• FOR LOADING OPERATION, LINE UP CRUDE OIL METERING
PRIOR TO STARTING OF PUMPS.
2.2.4 Carry out the valves checklist as per Appendix A, item 1.1, Table 1. Area operator
2.2.5 Open up respective main loading pump inlet and outlet EOVs either Panel man 1 /
remotely or locally. Area operator
2.2.6 Check pumps electrical power and instrument air system are as per ICE Driver/
requirement. Area operator
2.2.7 Start one booster pump from RCU (CCR). Panel man 1/
ICE Driver/
Area operator
2.2.8 In the event of insufficient pressure or flow, start the second booster pump Panel man 1/
(CCR). ICE Driver/
Area operator
2.2.9 Monitor pump suction, discharge pressure and temperature as per normal Panel man 1/
operating parameters. ICE Driver/
Area operator

2.2.10 Check recycles valves (FCV-1410/1420/1430) operations physically and Panel man 1/
in DCS screen. Valves should be in open position until the main loading Area operator
pumps are started.
2.3 CRUDE OIL MAIN LOADING PUMP P-1/10/11/1200 START-UP
2.3.1 Options to run electric motors, gas driven engines crude loading pumps or Shift
combination of pumps must be planned upfront with shift supervisor Supervisor
2.3.2 Based on required flow rate, line up main loading pumps in combination of ICE Driver/
two pumps or three pumps in parallel at least ten (10) minutes before Area operator
loading operation as per stated in the note below; / Panel man 1
• Refer Appendix A, item 2.2, Figure 2: SLPS pump P-1
2.3.3 Ensure that the clutch lever at “DISENGAGE” position. ICE Driver/
Area operator
2.3.4 Turn selector switch to “OK TO RUN” position at LCP. ICE Driver/
Area operator
2.3.5 Turn selector switch to “LOCAL” position at LCP. ICE Driver/

Area operator
2.3.6 Reset all alarms on LCP until all engine status indicators on panel will turn ICE Driver/
green. Area operator
NOTE:
Low pressure sensors will be locked for 3 minutes and “LOW PRESSURE
LOCKED OUT” indicator will turn green.
2.3.7 Press “ENGINE START” button to start engine at LCP. “ENGINE Area operator
RUNNING” indicator will be illuminated.
2.3.8 Let the engine run idle for 10 minutes. Area

operator/ ICE
Driver
2.3.9 Adjust engine speed accordingly and engage the pump clutch lever. Area
operator/ ICE
Driver

2.3.10 Monitor pump and engine performances and flow rates. Adjust the engine Panel man 1 /
speed accordingly to meet flow rate requirements. Area
operator/ ICE
Driver
2.3.11 Start up the next loading pumps if required and carry out checking and Area
monitoring of operation parameters. operator/ ICE
Driver
CAUTION:
IF ABNORMAL NOISES OR VIBRATION ENCOUNTERED, CARRY OUT
INVESTIGATION AND INFORM CCR.
2.4 SHUTDOWN OF MAIN LOADING PUMP P-110/11/1200
2.4.1 Put gear box oil pressure selector switch to override ICE Driver/
Area operator
2.4.2 Disengage the clutch ICE Driver/

Area operator
2.4.3 Let the engine run idling for 5 minutes ICE Driver/
Area operator
2.4.4 Switch the selector to “STOP” position to stop the engine ICE Driver/
Area operator
2.4.5 Close gas supply manual valve to shut off the engine ICE Driver/
Area operator
2.4.6 Close instrument air supply manual valve ICE Driver/

Area operator
2.4.7 Close cooling water inlet and outlet manual valve ICE Driver/
Area operator
2.4.8 Stop cooling tower fans & pump ICE Driver/

Area operator
2.4.9 Close all opened EOV and valves involved in pre-start up ICE Driver/
Area operator
2.5 SHUTDOWN OF BOOSTER PUMP P-1410/20/30
2.5.1 Inform CCR Panel Operator that P-1410/ 20/ 30 is to be shutdown ICE Driver/
Area operator
2.5.2 Shutdown pump by switching the “Stop” position to SS 1410 or SS 1420 Panel man 1/
or SS 1430 to shutdown P-1410, P-1420 and P-1430, respectively. ICE Driver/

Area operator
2.5.3 Turn RCU selector switch to “OFF” position and lock. ICE Driver/
Area operator

2.6 MOTOR DRIVEN CRUDE OIL MAIN LOADING PUMP P-1440/1450 (AWAITING
TO BE COMMISSIONED)
2.6.1 Base on required flow rate, line up electric motor driven main loading Area operator
pumps in parallel thirty minutes before loading operation.
NOTE:
• Design flow rate: 1363 Kl/hr
• Discharge pressure: 13 bar
• Electric motor : 700 kW
2.6.2 Check booster pumps pressures and flow rates. Open up main loading Panel man 1 /
pumps suction and discharge EOVs either remotely or locally. Area operator
2.6.3 Check pumps electrical power and instrument air system and lubricating Area operator
system according to the pre-startup checklist.
2.6.4 Start electric motor driven pumps one at a time and monitor pump suction Area operator
and discharge pressure and temperature
CAUTION:
• SUCTION VALVES MUST BE FULLY OPEN DURING OPERATION
• PUMP CAN RUN ON CLOSED VALVE BUT ON SHORT PERIOD
NOTE:
• Gas engine driven pumps and electric motor driven pumps have
different discharge heads and preferable to be run in its own cluster.
• If gas engine driven and electric motor driven pumps are required to
run in parallel, adjust gas engine pump speed to met discharge
pressure of electric motor pump to prevent stalling.
2.6.5 Shut off pump from local panel when loading completed. Close suction Panel man 1 /
and discharge EOVs accordingly. Area operator
2.6.6 Close back all pumps/ side suctions valves and EOVs. Panel man 1 /
Area operator
END OF PROCEDURE

Appendix
APPENDIX A
Content Page
1 CHECKLIST ............................................................................................................ 17
1.1 TABLE 1: SLPS BOOSTER PUMPS CHECKLIST ................................................... 17
2 DIAGRAMS ............................................................................................................ 18
2.1 FIGURE 1: SLPS BOOSTER PUMPS P-1410/20/30 ............................................... 18
2.2 FIGURE 2: SLPS PUMP P-1 ..................................................................................... 19
2.3 FIGURE 3: SLPS PUMP P-10 ................................................................................... 20
2.4 FIGURE 4: SLPS PUMP P-11 ................................................................................... 21
2.5 FIGURE 5: SLPS PUMP P-1200 ............................................................................... 22

1 CHECKLIST
1.1 TABLE 1: SLPS BOOSTER PUMPS CHECKLIST
Valve No. Description Open Close
EOV 0101 Crude Inlet to P-1 Close
EOV 0103 Discharge from P-1 Close
EOV 0006 Inlet to Metering Skid Close
20" VG Outlet from Metering Skid Open
16" VG5 Manual valve on S11 (P&ID No. P 0072 1 /6) Close
16" VG5 Manual valve on S11 (P&ID No. P 0072 1 /6) Close
EOV 0014 Crude to S.B.M 5 Close

2 DIAGRAMS
2.1 FIGURE 1: SLPS BOOSTER PUMPS P-1410/20/30

2.2 FIGURE 2: SLPS PUMP P-1






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Operating Procedure MY SKO O 05 MCOT 018

Sea Loading Pump Station (SLPS) Operations Rev. 0 Sept 2011

"UNCONTROLLED WHEN PRINTED"

30/07/2012 9:44 AM PETRONAS CARIGALI SDN BHD Page 1 of 24

Authority for original issue

Name: Mentor Solutions & Resources Sdn Bhd

Position: Technician/ Consultant/ Contractor

Position: Head of Production

Position Onshore Installation Manager

"UNCONTROLLED WHEN PRINTED"

30/07/2012 9:44 AM PETRONAS CARIGALI SDN BHD Page 2 of 24

Rev Description Date Approver Title Name

Rev 0 Original Document

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

"UNCONTROLLED WHEN PRINTED"

30/07/2012 9:44 AM PETRONAS CARIGALI SDN BHD Page 3 of 24

CCR Central Control Room

MCOT Rejuvenation Project Phase 2 Piping & Instrumentation Diagram (P&ID)

"UNCONTROLLED WHEN PRINTED"

30/07/2012 9:44 AM PETRONAS CARIGALI SDN BHD Page 4 of 24

1.1 OBJECTIVE / PURPOSE ............................................................................................. 6

1.2 SCOPEBBB ............................................................................................................... 6

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

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

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

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

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

"UNCONTROLLED WHEN PRINTED"

30/07/2012 9:44 AM PETRONAS CARIGALI SDN BHD Page 5 of 24

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

1.6 Shortage of gas supply, instrument air and electrical power.

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

"UNCONTROLLED WHEN PRINTED"

30/07/2012 9:44 AM PETRONAS CARIGALI SDN BHD Page 6 of 24

1.8 HSE REQUIREMENTS

Pressure Ensure proper lineup to avoid high

Flammable No hot work during pump running

Chemical/Toxic/Thermal burns Avoid crude oil contact with skin.

Loss of Containment Ensure all flanges and connections are

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

Ear muffs/plug Hearing protection during pump running

"UNCONTROLLED WHEN PRINTED"

30/07/2012 9:44 AM PETRONAS CARIGALI SDN BHD Page 7 of 24

Unit: P-1410/20/30 SLPS BOOSTER Safe

"UNCONTROLLED WHEN PRINTED"

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Unit: P-1410/20/30 SLPS BOOSTER Safe

"UNCONTROLLED WHEN PRINTED"

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2.1 SLPS Booster Pumps P1410/1420/1430 ................................................................... 11

2.2 Crude Oil Main Loading Pump P-1/10/11/1200.......................................................... 12

2.3 Crude Oil Main Loading Pump P-1440/1450 .............................................................. 13

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2.1 PREPARATION BEFORE PUMPS START-UP

No. Action Action Party

2.2 SLPS BOOSTER PUMPS P1410/1420/1430 START-UP