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OPERATING MANUAL

FOR

GAS DEHYDRATION UNIT

(UNIT NO-21/22)

DEEN DAYAL FIELD DEVELOPMENT PROJECT

ONSHORE GAS TERMINAL
GUJARAT STATE PETROLEUM CORPORATION
LIMITED

B 08.08.2012 Issued for Client’s Comments RSK DK TKS

A 16.02.2012 Issued for comments DAYAL DK LKV
Rev No. Date Purpose Prepared by Checked by Approved by

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PREFACE

This operating manual for GDU unit has been prepared by M/s Engineers India Limited for M/s
Gujarat state Petroleum Corporation.

Operating procedures & conditions given in this manual are indicative. These should be treated as
general guide only for routine start-up and operation of the unit. The actual operating parameters
and procedures may require minor modifications / changes from those contained in this manual as
more experience is gained in operation of the Plant.

For detailed specifications and operating procedures of specific equipment, corresponding Vendor's
operating manuals/instructions need to be referred.

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Table of Contents

SECTION-1 ................................................................................................................................. 12
GENERAL ................................................................................................................................... 12
1.1 INTRODUCTION ......................................................................................................... 12
1.2 UNIT CAPACITY ......................................................................................................... 12
1.3 STREAM HOURS AND TURNDOWN CAPABILITY ............................................. 13
1.4 FEED STOCK CHARACTERISTICS ....................................................................... 13
1.5 PRODUCTS ................................................................................................................. 13
1.6 ESTIMATED UTILITY CONSUMPTION .................................................................. 13
1.7 ESTIMATED CHEMICAL CONSUMPTION ............................................................ 14
1.8 BATTERY LIMIT CONDITIONS ................................................................................ 14
1.9 EQUIPMENT LIST ...................................................................................................... 14
SECTION-2 ................................................................................................................................. 17
PROCESS DESCRIPTION....................................................................................................... 17
2.1 PROCESS SUMMARY ............................................................................................... 17
2.2 PROCESS DESCRIPTION ........................................................................................ 17
2.3 UTILITY DISTRIBUTION............................................................................................ 19
2.4 BLOWDOWN SYSTEM .............................................................................................. 20
2.5 INTERLOCK DESCRIPTION .................................................................................... 22
SECTION-3 ................................................................................................................................. 24
GAS – FIRE DETECTION AND FIGHTING .......................................................................... 24
3.1 GAS DETECTION: ......................................................................................................... 24
3.2 Fire Fighting System ...................................................................................................... 25
3.3 USE OF LIFE SAVING DEVICE .................................................................................. 26
3.4 LIST OF HYDROCARBON DETECTORS ................................................................. 27
SECTION-4 ................................................................................................................................. 28
PRECOMMISSIONING ............................................................................................................. 28
4.1 INTRODUCTION ......................................................................................................... 28
4.2 VESSELS INSPECTION ............................................................................................ 29
4.3 PIPING .......................................................................................................................... 31

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4.4 HEAT EXCHANGERS ................................................................................................ 33

4.5 PUMPS.......................................................................................................................... 34
4.6 INSTRUMENTATION ................................................................................................. 36
4.7 CHEMICAL INVENTORY ........................................................................................... 36
4.8 PRELIMINARY OPERATIONS ................................................................................. 36
SECTION –5 ............................................................................................................................... 41
PLANT OPERATING PROCEDURES.................................................................................... 41
5.1 INTRODUCTION .......................................................................................................... 41
5.2 START UP .................................................................................................................... 42
5.3 OPERATING VARIABLES .......................................................................................... 48
5.3.1 NORMAL OPERATING PARAMETER ..................................................................... 48
5.3.2 ALARM AND TRIP SETTINGS .................................................................................. 56
5.3.3 RELIEF VALVE SETTINGS ........................................................................................ 62
5.3.4 List of Control Valve ..................................................................................................... 62
5.3.5 BLIND LIST: .................................................................................................................. 63
5.4 NORMAL SHUTDOWN ............................................................................................... 66
5.5 EMERGENCY SHUTDOWN ...................................................................................... 67
5.6 EMERGENCY PROCEDURES:................................................................................. 68
GENERAL ................................................................................................................................... 68
5.6.1 LOSS OF ELECTRICAL POWER.............................................................................. 69
5.6.2 LOSS OF STEAM ........................................................................................................ 70
5.6.3 LOSS OF COOLING WATER .................................................................................... 71
5.6.4 LOSS OF INSTRUMENT AIR .................................................................................... 71
5.7 SAMPLING PROCEDURE ......................................................................................... 73
SECTION -6 ................................................................................................................................ 76
GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT ......................................... 76
6.1 GENERAL ..................................................................................................................... 76
6.2 CENTRIFUGAL PUMPS ............................................................................................ 76
6.3 POSITIVE DISPLACEMENT PUMPS ...................................................................... 78
6.4 HEAT EXCHANGERS ................................................................................................ 80
SECTION -7 ................................................................................................................................ 82

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SAFETY PROCEDURE ............................................................................................................ 82

7.1 INTRODUCTION ......................................................................................................... 82
7.2 SAFETY OF PERSONNEL ........................................................................................ 82
7.3 WORK PERMIT PROCEDURE................................................................................. 82
7.4 PREPARATION OF EQUIPMENT FOR MAINTENANCE .................................... 85
7.5 PREPARATION FOR VESSEL ENTRY .................................................................. 86
7.6 HAZARDOUS CHEMICAL HANDLING ................................................................... 91
ANNEXURE-I .............................................................................................................................. 92
PROCESS FLOW DIAGRAM................................................................................................... 92
ANNEXURE-II ........................................................................................................................... 935
PIPING AND INSTRUMENTATION DIAGRAM .................................................................. 935
ANNEXURE-III .......................................................................................................................... 103
MSDS OF TEG ......................................................................................................................... 103

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0.1 GLOSSARY AND ABBREVIATIONS

0.1.1 GLOSSARY
API Acronym for “American Petroleum Institute.” A private industry trade
organization that promotes petroleum product exploration, processing,
and sales. This organization also sets various standards which petroleum
processors agree to abide by in their day to day operations, such as
standards and procedures for the measurement and testing of petroleum
products.
API Gravity An arbitrary scale expressing the gravity or density of liquid petroleum
products. The measuring scale is calibrated in terms of degree API. It may
be calculated in terms of the following formula:
°API=(141.5/Specific Gravity 60°F/60°F)-131.5
Auto Ignition This is the temperature at which fuel ignite itself without the help of
Point external spark.
Back pressure Pressure on the discharge side of a pump, valve, fan, vessels or other
piece of equipment that resists a flow from that equipment.
Barrel A standard unit of measurement of liquids in the petroleum refining
industry.
1 barrel=159 liters or 42 U.S. Gallons.
Battery Limit The outer boundaries of the area assigned to a unit.
Bleeder A valve located on the low point of a line, pump or vessel that can be used
to drain equipment or piping. Bleeders are also located in areas of
process equipment or piping. Bleeders are also located in areas of
process equipment from where samples are taken.
Blind A solid metal plate inserted into a line to prevent to flow of process fluids
into that line or other process equipment.
Blowdown A vessel or process that draws process fluids into a “blowdown” vessel to
keep undesirable material from accumulation. For example, a steam
blowdown drum would be used to settle particulates and sediments out of
a steam flow. Blowdown vessels are also used to reduce pressure on a
process circuit or system.
Boiling Point The temperature at which liquid changes to a vapor or the temperature at

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which the vapor pressure of a liquid is equal to the pressure exerted on

the liquid.
Bomb A Small cylindrical pressure vessel that is used to take high pressure
samples of materials that must remain pressurized, such as propane and
butane.
Bottoms Liquid product from the bottom of a distillation or fractionating tower,
usually a hydrocarbon product with a high boiling point.
BPD or BPSD “Barrels per Day” or “Barrels per stream Day” the standard measure of
petroleum product flow in petroleum processing operations. BPSD is
stated as the rating capacity of particular unit or portion or a unit operating
at a constant flow rate.
British Thermal The energy required to heat one pound of water to temperature of 1°F.
Unit or BTU The British Thermal Unit or BTU is typically used in process operations to
compare the relative heating values of various fuels and to rate the
capacity heat exchange equipment.
Channeling Flow through process equipment where most of the fluid flows through
certain portions of the catalyst bed or equipment bypassing other portions.
Charge The raw material feed stream into a process unit or vessel.
Condensate Liquids, which are formed when the vapor phase of a compound turns to
liquid at a temperature below the liquid’s boiling point. The term
condensate usually refers to condensate water products.
Cut-point The temperatures point at which a hydrocarbon boils.
Cx A common numerical designation for hydrocarbon product which has
been separated from heavier product by a distillation process. The higher
the carbon numbers the “heavier” the hydrocarbon product. Such product
designations include:
C1 – Methane
C2 - Ethane
C3 - Propane (Liquid under pressure)
C4 – Butanes (Liquid under pressure)
C5 – Pentanes (Liquid under pressure)
C6 + Hydrocarbon Liquids (Which may contain heavier hydrocarbons)
Note: The designation “C6 + “is used to refer to mixture of hydrocarbons

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which contain C6 and heavier compounds. It is pronounced “C6 plus”

(“See six Plus”) Similarly, “C6 – “ refers to a mixture of all hydrocarbons
which are C6 and lighter and pronounced “C6 minus”
Distillate Liquids, which are formed when the vapor phase of a liquid condenses at
a temperature below the liquid’s boiling point. The term distillate usually
refers to a hydrocarbon product.
Distillation The process of heating petroleum oil to a vaporization point and
condensing of various components of the crude within specific boiling
point ranges.
Draw Off A connection which allows liquid to flow from the side or bottom of a
vessel.
End Point Also known as “Final Boiling Point”. On a laboratory distillation, it is the
temperature at which the last drop of sample is driven off.
Entrainment Liquid droplets or coke particles carried up a distillation tower by rising
vapors.
Final Boiling The maximum temperature at which a liquid completes it boiling process
Point or FBP and fully transforms into its vapor phase.
Flash Point Flash point of a fuel is the minimum temperature at which application of a
test flame causes the vapor above the sample to ignite it. A minimum
limits on flash point because of fire hazard consideration. The flash point
has no significance on performance of engine.
Flash Zone The zone in a distillation tower where pressure falls suddenly in relation to
the pressure of the feed being introduced, causing the feed to flash into its
vapor phase.
Flue Gas Gases from the combustion of fuel. The heating potential having been
substantially spent, they are discarded to the flue or stack. They consist
primarily of CO2, CO, O2, N2 and water vapour.
Fraction A hydrocarbon product which has been separated from heavier
hydrocarbons by its boiling point range.
Fractional The process of heating petroleum oil to a vaporization point and
Distillation condensing out various components of the crude within specific boiling
point ranges. (cut points)
Inert gas Will not support combustion. In GSPC OGT inert gas is generally nitrogen

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and carbon dioxide.

Initial Boiling On a laboratory distillation, it is the temperature at which the first drop of
Point distillate drops from the distillation flask.
Light Ends Hydrocarbon products which remain in their gaseous phase at
atmospheric pressure. Generally regarded as hydrocarbons, which are in
the C5 range.
Live Steam Steam, which comes directly from a boiler or steam generator, as
opposed to steam which, has been exhausted from equipment.
Overhead Vapor or liquid product that is removed from the top of a distillation,
fractionation or stripping tower.
Pump Around The process of removing heat from a hydrocarbon liquid by pumping it
from a process tower or vessel, cooling the liquid, and returning the liquid
to the vessel, usually at a different level from where the liquid was
removed.
Reflux The process of removing heat from a fractionation tower by partially
condensing the overhead hydrocarbon vapor and returning the liquid to
the top of the tower. The returning reflux flows downward through the
tower, controlling the tower temperature and absorbing a greater fraction
of the heavier components for removal at the tower bottom.
Safety Valve A valve pre-set to release excessive pressure on a vessel or system.
Side Stream A hydrocarbon product removed from the side of distillation tower or
process vessel.
Split Range The use of two control element in parallel to provide finer control over a
Control process than could be accomplished with a single controller. In practice,
one control element is much larger than the other is. The smaller control
element provides control over the lower 10 to 20% of the control range
while the larger controller provides control over the higher end of the
control range.
Steam A process, which uses steam to release lighter fractions of a hydrocarbon
Stripping from a heavier hydrocarbon liquid by lowering the hydrocarbon partial
pressure.
Threshold The highest concentration of toxic substance in air which an individual can
Limit Value or be exposed to for an eight hour workday without apparent adverse health

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TLV effects.
Vapor Pressure The internal pressure a liquid exerts against itself by the vapor phase
molecules of a liquid or solid.
Viscosity Viscosity is a measure of a fluid’s resistance to flow. Fuel viscosity affects
the shape of the fuel spray. High viscosity can cause poor atomization
resulting large droplets and high spray penetration. This causes poor
fuel/air mixing and combustion. In some cases, the fuel then wash the
lubrication off cylinder walls, causing excessive wear. Low fuel viscosity
result in a spray that is too soft and does not penetrate far enough into the
combustion chamber, which causes poor combustion. Low fuel viscosity
can lead to excessive injection pump plunger leakage and fuel metering
inaccuracies.

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0.1.2. ABBREVATIONS
1. API American Petroleum Institute
2. ASTM American Society For Testing Material
3. BFW Boiler Feed Water
4. BPSD Barrels Per Stream Day
5. CBD Closed Blowdown
6. CPP Captive Power Plant
7. CPU Condensate Polishing Unit
8. CSU Condensate Stabilization Unit
9. DDE Deen Dayal East
10. DDN Deen Dayal North
12. DDW Deen Dayal West
13. DPDU Dew Point Depression Unit
14. EP End Point
15. GDU Gas Dehydration Unit
16. GSPC Gujarat State Petroleum Cooperation
17. GSU Gas Sweetening Unit
18. HC Hydrocarbon
19. HP High Pressure
20. IBP Initial Boiling Point
21. KOD Knock Out Drum
22. LP Low Pressure
23. LPG Liquefied Petroleum Gas
24. MMSCFD Metric Million Standard Cubic Feet per Day
25. O/H Overhead
26. OGT Onshore Gas Terminal
27. PLQP Process cum Living Quarter Platform
30. TEG Tri-Ethylene Glycol
31. TL Tangent Length
32. TPH Tones Per Hour
33. WC Water Column
34. WHP Well Head Platform

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SECTION-1
GENERAL
1.1 INTRODUCTION
Gujarat State Petroleum Corporation Ltd (GSPC) is the operator of the Deen Dayal Field (Block
KG-OSN/2001/03) situated offshore from the Yanam – Kakinada coast of Andhra Pradesh,
India.GSPC has discovered a significant reserve of gas in the Deen Dayal West (DDW) area
with the KG #8 exploration well located 15km offshore in 60 meters of water. The reservoir is
characterized by high temperature and high pressure.The initial Deen Dayal Field Development
is expected to consist of a Well Head Platform (WHP), Process cum Living Quarter Platform
(PLQP), multiphase pipeline to shore and an Onshore Gas Terminal (OGT). The pipeline route
will be via the Goutami Godavari River estuary to avoid encroaching on the Corangi Sanctuary.

The basis for the Integrated Field Development Strategy is to initiate the development of the
Deen Dayal Complex by building a production hub in the DDW area. As other fault blocks (Deen
Dayal North (DDN), Deen Dayal East DDE)) are explored and delineated, production pipelines
resulting from development of these areas will be routed through the DDW production Hub. All
production gas from the Deen Dayal complex will be gathered together at the DDW production
Hub and exported to the Onshore Gas Terminal at Mallavaram, East Godavari, Andhra Pradesh
via a common export pipeline (upto pipeline max capacity) after dehydration at process
platform.

The initial gas quantity expected at OGT is 50 MMSCFD corresponding to production from two
wells. This is expected to progressively increase to 600 MMSCFD from the off-shore field.
Accordingly, it has been decided to design OGT for a train throughput of 100 MMSCFD to
provide operational flexibility for turndown scenario. Two identical trains are provided with a
provision for adding two more trains of identical capacity in the future.

1.2 UNIT CAPACITY

GDU capacity is as per GSU outlet corresponding to 100 MMSCFD of slug catcher gas to GSU
inlet per train.

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1.3 STREAM HOURS AND TURNDOWN CAPABILITY

The facilities (GDU) are capable of operating at 33 percent of design feed capacity, while
maintaining the designated product specification. Numbers of Stream days per year are 365.
2 Trains of identical capacity are provided.

1.4 FEED STOCK CHARACTERISTICS

The feed to GDU is sweetened gas from GSU (Gas sweetening unit) with the following
characteristics

H2S content : 4 ppm (max)

CO2 content : < 3% by volume in sales gas.

1.5 PRODUCTS
The product from GDU is dehydrated Gas and is sent to DPDU. Product characteristics are:
Permissible total TEG loss from unit : 13.4 lt/MMSCM, max
Permissible moisture content of the outlet gas : 112 kg/MMSCM
GDU design will account for conditions in DPDU to meet HC Dew point and water Dew point
may have to lower below above specification to avoid hydrate formation in DPDU.

1.6 ESTIMATED UTILITY CONSUMPTION

Service Total consumption (1 train excluding common facilities)

Cooling Water 7.8 (m3/hr)

DM Water 5.0 * (m3/hr)
Service Water 21/22.6 * (m3/hr)
HP Steam 0.42 (T/hr)
LP Steam 0.25* (T/hr)
Condensate 0.42 (T/hr)
Power 36.2+ 4.0* (KW)

Fuel Gas 60/-20(Kg/hr)

Instrument Air 85 (Nm3/hr)
Plant Air 230* (Nm3/hr)
Nitrogen 60.0*
(*) indicates intermittent service

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1.7 ESTIMATED CHEMICAL CONSUMPTION

Chemical Quantity Initial Requirement
TEG (Tri-Ethylene Glycol) 27.5 Tons/year 40.0 tons
Charcoal* 1.5 Tons/Year (typical value) 0.5 tons

* Charcoal requirement indicated above is for combined GDU & GSU unit. Recommended
quantity will be finalized based on vendor inputs.

1.8 BATTERY LIMIT CONDITIONS

Feed Stream Source Temperature (°C) Pressure (Kg/cm2g)

Gas Sweetening Unit

Sweetened Gas 40.0 103.8
(GSU)

Product Stream Destination Temperature (°C) Pressure (Kg/cm2g)

Dehydrated Gas DPDU 40.3 101.8

1.9 EQUIPMENT LIST

Design Design
Internal
Item No. Item Description TL-TL Temperature, Pressure
Diameter
°C (Kg/cm2 g)
COLUMNS
21/22-C-101 Glycol Absorber 1400 mm 9000 mm 65 115.6
Glycol
21/22-C-102 792 mm --- 240 3.5
Regenerator
Glycol Stripping
21/22-C-103 18 “NB 2800 mm 240 3.5
column

VESSELS

21/22-V-101 Feed Gas KOD 2800 3950 65 115.6

Glycol Filter
21/22-V-102 -- -- 65 115.6
Separator
21/22-V-103 Rich Glycol 1200 3400 65 9.5

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Design Design
Internal
Item No. Item Description TL-TL Temperature, Pressure
Diameter
°C (Kg/cm2 g)
Degassing Drum
Glycol Sump
21/22-V-104 900 3800 65 1.5
Drum
Lean Glycol
21/22-V-105 1100 3300 150 3.5
Surge Drum
Glycol Reboiler
21/22-V-106 18”NB 1800 270 36
Condensate Pot

Heat Exchangers:
Shell Side Tube Side
Op. Op.
Item Op. Op.
Item No. Temp. Temp.
Description Fluid Press. Fluid Press.
(in/out) (in/out)
°C Kg/cm²g °C Kg/cm²g
21/22-E- Lean Glycol Cooling Lean
33 / 43 4.5 86.3 / 45 108.1
101 Cooler Water TEG
21/22-E-
Lean / Rich
102 Rich 50.38/ Lean 197.9 /
Glycol 4.8 0.12
(Plate & TEG 167 TEG 81.6
Exchanger
Frame)
21/22-E- Rich 160 / HP 233.7 /
Glycol Reboiler 0.07 29.5
103 TEG 204 Steam 233.7
21/22-E- Glycol Reflux C-102 104 / Rich
0.02 40 / 50.4 4.8
104 Condenser O/H 87.8 TEG

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Pumps
Rated Discharge Shut-off
Item No. Item Description Type Capacity Pressure Pressure
(m³/hr) (Kg/cm²g) (Kg/cm²g)
21/22-P-101 Lean Glycol
Reciprocating 3.1 108.1 120
A/B Injection Pump
Glycol Transfer
21/22-P-102 Centrifugal 4.0+MCF 9.5 19.5
Pump
21/22-P-103 Glycol Drain Pump Centrifugal 2.0 3.0 8.0

21/22-P-104 Fresh Glycol Pump Air Driven 1.5 3.0 4.5

Tanks:

Diameter Height Design Design Pressure

Item No. Item Description
(mm) (mm) Temp, °C (Kg/cm2 g)
Full of Liquid + 25
21/22-T-
Lean Glycol Tank 4100 2700 65 mm WC and 50 mm
101
WC Vacuum

Package Item:
Design Design Pressure
Item No. Item Description Types of Filters
Temp, °C (Kg/cm2 g)
1. 21/22-G-101A/B:
Cartridge Filter
21/22-LZ- Glycol Filtration 2. 21/22-G-102 A/B:
65 0C 9.5 Kg/cm2g
101 Package Charcoal Filters
3. 21/22-G-103 A/B:
Cartridge Filters

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SECTION-2
PROCESS DESCRIPTION

2.1 PROCESS SUMMARY

The removal of water from Sweet Gas is made by contacting the gas with Triethylene Glycol
solution. The sweetened gas is at a pressure of 103.8 Kg/cm2g & temperature of 40 °C and is
dried to 52 Kg/MMNm3 at the battery limits conditions. Each train consists of two sections
Absorption section and regeneration section

2.2 PROCESS DESCRIPTION

Absorption Section: - Sweet gas from Gas Sweetening Unit (GSU) enters the dehydration unit
and is routed to feed gas KOD 21/22-V-101 under flow control (FIC-1101). The entrained or
condensed liquids are removed in Feed Gas KOD. The entrained or condensed liquids from
21/22-V-101 are routed to ABD Header under level control. The gas is then fed to Glycol
Absorber (21/22-C-101) where it is contacted with lean tri-ethylene glycol solution (99.7 %Wt).

This column is provided with packed bed where gas flows upward through bed of the glycol
contactor for counter current contact with Tri-ethylene Glycol. Glycol absorber column is
provided with demister pad to prevent the carryover of glycol along with the gas. Dehydrated
gas exits from the top of Glycol contactor is scrubbed for any glycol carryover in the Glycol filter
separator (21/22-V-102) and then sent to downstream hydrocarbon dew point depression units
(DPDU).

Rich Glycol is drawn-off under level control off the bottom from the absorber and Glycol Filter
Separator (21/22-V-102) and is routed to the regeneration section.

Regeneration Section: - Rich Glycol received from Absorption Section enters Degassing Drum
21/22-V-103 where the absorbed light hydrocarbons are released and sent under pressure
control to fuel gas network. 21/22-V-103 is equipped with Heavy Hydrocarbon skimming lines.
The Degassed Glycol leaving 21/22-V-103 enters the Glycol Filtration Package (21/22-LZ-101)
consisting of Cartridge Filters 21/22-G-101 A/B followed by Charcoal Filter 21/22-G-102 A/B.
Another Cartridge Filters 21/22-G-103 A/B provided at downstream of Charcoal Filters.

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Before entering the still column to be regenerated, glycol is preheated in two steps. Firstly, in a
heating coil at top of the regeneration column, providing the desired overhead reflux which is
controlled by the 3 ways overhead temperature control valve and secondly in the Glycol/Glycol
Exchangers (21/22-E-102, Plate Heat Exchanger Type), by the regenerated glycol.

The glycol regeneration column 21/22-C-102 fitted with 5 trays is top mounted on the reboiler
21/22-E-103. The bath temperature is controlled at 204 Deg C by the action on the steam flow
rate to the reboiler.

Lean TEG leaving 21/22-E-103 is afterwards stripped by dry fuel gas in the packed stripping
column 21/22-C-103 to reach the final concentration of 99.7 % Wt. Then, it returns to the glycol
surge drum 21/22-V-105, after being cooled to 116.3 Deg C in the Glycol / Glycol exchanger
21/22-E-102. From the surge drum, it is pumped by the reciprocating pumps 21/22-P-101A/B to
the Lean Glycol cooler 21/22-E-101 for cooling the lean glycol to 36.4 Deg C and further sent
back to the absorber 21/22-C-101.

Lean Glycol Storage Section: - Initial fresh Glycol is filled into Lean Glycol tank either by Road
tankers or Drums using Glycol Loading Pump 21/22-P-105.
During normal operation, fuel gas from DPD unit is relieved and then passed through the
reboiler hot bath before being injected at bottom of the stripping column 21/22-C-103. During
start-up, Dry fuel gas/Nitrogen needed for the glycol stripping is available from the treated gas
leaving the dried gas filter separator 21/22-V-102, which is relieved and then passed through
the reboiler hot bath before being injected at bottom of the stripping column 21/22-C-103.
A lean glycol storage tank 21/22-T-101 and its attached pump 21/22-P-102 allow glycol transfer
and make-up.
A glycol sump drum 21/22-V-104 is provided for collecting TEG drips and drains from various
sources throughout the unit. The solution is returned to the lean glycol tank via the sump pump
21/22-P-103.This pump starts automatically in case of high level in the drum.

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2.3 UTILITY DISTRIBUTION

2.3.1. HP STEAM
HP steam from CPP is supplied at a normal pressure of 30.0 Kg/cm2g. From the main
header the HP steam is supplied to GDU through a 3” header. The continuous requirement
for HP steam in GDU is 0.42 TPH (per train).

2.3.2. LP STEAM
LP steam from CPP is supplied at a pressure of 5.0 Kg/cm2 g. There is no continuous
requirement for LP steam in this unit, only intermittent requirement of 0.25 TPH is
anticipated.

2.3.3. PURE CONDENSATE

Pure condensate is being collected from GDU & GSU and sent to the CPP unit through 6”
main pure condensate header.

2.3.4. FUEL GAS

The fuel gas system in the OGT complex is consists of:-
− CPP fuel gas header collecting fuel gas from Slug Catcher.
− Stripping gas header collecting fuel gas from DPDU.
− LP fuel gas header collecting fuel gas from GSU and GDU.
Stripping gas shall be used in GDU as well as in flare system for assisting flaring. LP fuel
gas shall be used for flare system (For pilot burner, purging etc).

2.3.5. RAW WATER

Service water from treated water reservoir (Raw water) is supplied through a header (4”-
WS-90-1401-A93A). From the main header the service water is supplied to GDU/DPDU
through a 2” header. There is no continuous requirement for service Water in these units
only intermittent requirement of about 5.0 m3/hr in each unit is anticipated.

2.3.6. DM WATER
DM water from DM plant is supplied through a header (4”-WDM-90-1501-A11K). From the
main header the DM water is supplied to GDU through a 2” header. DM water is used for
dilution of Glycol in the Lean Glycol Tank. As the dilution of glycol is batch operation so

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there is no continuous requirement for DM Water in these units only intermittent requirement
of about 5.0 m3/hr in each unit is anticipated.

2.3.7. COOLING WATER

Cooling water to GDU is supplied from cooling tower. 3” cooling water supply header in each
GDU supplies cooling water to Lean Glycol cooler (21/22/22-E-101). The continuous
demand for cooling water in GDU is 7.8 m3/hr.

2.3.8. PLANT AIR

Plant air is required for cleaning, blowing and operating pneumatic tools. Plant air from
Compressed air system is supplied through a header (4”-AP-90-1701-A3A). From the main
header the Plant Air is supplied to GDU 1/2 through a 3” header.

2.3.9. INSTRUMENT AIR

Instrument air is required for operation of various instruments and also for the purging of
some control panels. Instrument air from Compressed air system is supplied through a
header (4”-AI-90-1701-A3A). From the main header the Instrument Air is supplied to GDU
1/2 through a 4” header.

2.3.10. FLARE SYSTEM

Flares are provided to safely combust relief valve discharges and normal process vents. The
flare system is designed to prevent over pressure and safe disposal of discharged
hydrocarbon vapours / liquids during startup, shutdown and emergency. Relieving gases are
sent through an elevated stack from a closed collection system and burnt at the top by
means of pilot burners, which are at the top of the flare stack. These burners burn
continuously to avoid any vapors leaving the stack un-burnt. 24” Flare header from the units
are connected to main flare header (24”-FL-90-1901-A4A) in OSBL area.

2.4 BLOWDOWN SYSTEM

2.4.1. OILY WATER SEWER
Oily water sewer is provided to collect following:
a) Hydrocarbon process waste from equipment drains.
b) Blow down from process equipment.

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c) Spill material during sampling.

2” drains from various equipments are provided in the OWS. Drained streams received
through OWS funnels etc. are routed to ETP through a combined header. Contaminated rain
water from the unit paved area is also routed to OWS System. All equipments having CBD
connections are normally provided with OWS connection.
Care should be taken that at no time any spark reaches vapour space of OWS funnels. This
may result in explosion immediately there or elsewhere in network wherever explosive
mixture of air and hydrocarbon vapours is present in appropriate concentration for
explosion.

2.4.2. COMMON CLOSED BLOWDOWN SYSTEM

Those hydrocarbon streams that are either free of water or only slightly contaminated with
water are received in closed blow down (CBD) header, routed to CBD drum (11-V-111)
located in Gas Sweetening Unit (GSU). Such hydrocarbon streams are generated especially
during shut down periods when equipments such as vessels, drums, pumps etc. and
systems are drained under gravity to clear hold up oil. The hydrocarbon in the CBD vessel
should be received at a temperature well below flash point of lightest component present
inside. CBD network helps reducing amount of hydrocarbon loss. Uncontaminated
hydrocarbons from equipment draining is collected and routed to CBD Drum via CBD
headers, covering entire unit. CBD drum is an underground vessel, placed horizontally.
Drain point from each equipment is terminated on this underground header. Temperature in
CBD tank is maintained by cooling water circulation through internal coil if necessary. CBD
drum is floating with flare.

2.4.3. GLYCOL DRAIN SYSTEM

The equipments containing glycol are drained to glycol drain system. The drain lines are
routed to Glycol Sump Drain (21/22-V-104). The vessel is provided with glycol drain pump
which has an auto-start / stop facility on high level and low level in the vessel detected by
LT-1605 with LAH/LAL-1605. The material from Glycol Sump drain is pumped out to Lean
Glycol Tank.

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2.5 INTERLOCK DESCRIPTION

S. No. Interlock No Actuated By Action Taken

1. 21/22-I-01 21/22-LALL-1208 Close 21/22-UV-1201
2. 21/22-I-02 21/22-LALL-1103 Close 21/22-UV-1102
3. 21/22-I-03 21/22-LALL-1206 Close 21/22-UV-1202
21/22-I-04 21/22-FAL-1201 a. Trip pump 21/22-P-101 A/B
4. b. Close 21/22-UV-1101
c. Close 21/22-UV-1203
5. 21/22-I-05 21/22-TAHH-1506 Close 21/22-UV-1501
6. 21/22-I-06 21/22-LALL-1209 Close 21/22-UV-1204
7. 21/22-I-07 21/22- LALL-1305 Close 21/22-UV-1301
8. 21/22-I-08 21/22-LALL-1604 Stop pump 21/22-P-102
9. 21/22-I-09 21/22-LALL-1703 Trip pump 21/22-P-101A/B
10. 21-I-10 Unit Shut Down a. Activate PV-1204
91-I-3101 b. Close 21/22-UV-1101
91-I-3103 c. Close 21/22-UV-1102
d. Close 21/22-UV-1201
e. Close 21/22-UV-1202
f. Close 21/22-UV-1203
g. Close 21/22-UV-1204
h. Close 21/22-UV-1501
i. Trip Pump 22-P-101 A/B
j. Trip Pump 22-P-102
k. Trip Pump 22-P-103

11. 22-I-10 Unit Shut down a. Activate PV-1204

91-I-3102 b. Close 22-UV-1101
91-I-3103 c. Close 22-UV-1102
d. Close 22-UV-1201
e. Close 22-UV-1202
f. Close 22-UV-1203
g. Close 22-UV-1204

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S. No. Interlock No Actuated By Action Taken

h. Close 22-UV-1501
i. Trip Pump 22-P-101 A/B
j. Trip Pump 22-P-102
k. Trip Pump 22-P-103

12. 21/22-I-11 21/22-LSH-1605 Start pump 21/22-P-103

21/22-LSL-1605 Stop pump 21/22-P-103

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SECTION-3
GAS – FIRE DETECTION AND FIGHTING
3.1 GAS DETECTION:
The unit handles hydrocarbon liquids and gases which can cause fire and explosion if
conditions for the same are favorable. Direct contact of hydrocarbons with any source of
ignition or fire such as spark or open flame should be avoided. Sparks or open fire should not
be allowed in the operating area while the unit is operating or has potential of hydrocarbon
leakage. Even during shutdown, when an open flame work is absolutely essential, this should
be allowed with the permission of the authorized person after suitable precautions have been
taken. Approved safety & work permit systems should be strictly followed.
(i) Improper earthing of equipment may produce static charges. All equipment
must be provided earthing connections as per standards.
(ii) The drain/vent valves and sample points on hot and heavy products and steam
lines are likely to get plugged, if the lines are not in constant use. Such valves
should be crack opened for a few minutes under personal supervision and only
after the liquid flow has started, the opening of the valves should be adjusted as
required.
(iii) Leakage of hydrocarbons from equipment and pipe joints are undesirable and
must be reported to the immediate supervisor without delay.
(iv) The set pressure of relief valves should never be altered without prior permission
of the authorized persons in writing.
Wherever block valves are provided for isolation of relief valves, these valves
should be kept opened all the times as per stipulations in P&IDs.
(v) The closure of block or control valves which isolate exchangers or piping from
relief protection devices can subject the equipment to possible overpressure due
to thermal expansion of the blocked fluid. The expansion may be caused by heat
from the atmosphere or adjacent hot equipment. In order to prevent such over
pressurizing, some suitable drains/vents or other valves connected with some
closed system in the network should be left opened, to take care of such
expansion.

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(vi) Poor Housekeeping in the operating area is a potential cause of accidents.

Spillage of oil etc. is very dangerous. Maintain a high standard of housekeeping
in the work area.
(vii) Releasing equipment for maintenance without properly preparing it e.g.
blinding/isolating & making it hydrocarbon free, electrical isolation etc. should be
avoided as this can also result in major accidents.

3.2 Fire Fighting System

The operating personnel should be fully conversant with Fire Fighting system provided in the unit.
All of them should have adequate fire fighting training and will serve as an auxiliary Fire Squad in
the event of a fire breakout. It will be the primary responsibility of unit personnel to fight the fire at
the very initial stage and, at the least, localize it.
Major Fire fighting facilities provided in the unit comprise the following:

i) Fire Water System

Water is most important fire fighting medium. Water is used for fire extinguishment, control,
equipment cooling & exposure protection of equipment/personnel from heat radiation.
An elaborate fire water distribution network is provided around unit. Fire Water Hydrants/Monitors
are provided around unit, which give coverage to most of equipment.

ii) Foam System

For containing large Hydrocarbon fires, foam systems are useful. They have inherent blanketing
ability, heat resistance and security against burn back. Low expansion foam is used for
hydrocarbon oil fire. Foam can be applied over burning oil pool with the help of foam tenders/foam
delivery system.

iii) Portable Fire Extinguishers

Fire should be killed at the incipient stage. Portable fire extinguishers are very useful in fighting
small fires. All extinguishers in the unit must be located in specified places only. The operating
crew should be acquainted with exact location of the extinguishers. They also must know most
suitable type, which, when and how to use an extinguisher. For example, electrical fires should be
put out with CO2 or dry power extinguishers; water and foam should not be used. The used
extinguishers should be checked and restored by fire station personnel.

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iv) Fire Signal

Break Glasses have been provided at strategic locations of unit to see fire alarm in fire station. If a
fire is sighted, glass of window should be smashed, causing fire alarm switch to actuate. This is an
emergency call & should be periodically tested for proper functioning.

v) Steam Smothering
LP Steam hose connections have been provided at every convenient point inside unit. Steam
lances of standard 15M length can be fitted with these hose stations. Where ever hydrocarbon
leakage is detected which is likely to catch fire, Steam blanketing may be done. Apart from diluting
combustible hydrocarbons, steam prevents atmospheric oxygen from taking part in combustion,
thus help in extinguishing fire. However, steam should never be applied on large pool of
hydrocarbon fire. Direct application of steam on burning oil may result in spillage of burning
hydrocarbon & spread of fire. Similarly use of fire water on hot oil surfaces may cause sputtering &
spread of fire.

3.3 USE OF LIFE SAVING DEVICE

Safety of the personnel should the prime concern. Life saving device is to be used for personnel
protection. Important life saving devices which are required to be used are given below:

Head protection: - Safety helmets shall be worn by all personnel at all times in the plant for protection
of the head. They may be removed when inside rooms or buildings which do not have overhead or
other hazards.
Eye and face protection: - Safety glasses, goggles or face shields shall be worn while performing
work, which could result in eye or face injury.
Hand Protection: - Proper hand protective gloves should be worn.
Foot protection: - Safety shoes are to be worn for foot protection.
Ear protection: - Whenever personnel are required to be work in noisy areas proper ear protection
device such as ear plug etc, is to be used.

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Breathing apparatus: - Whenever persons are required to work or enter an area of high
toxic/aromatic/hydrocarbon vapor concentration, wear appropriate respiratory protection, such as
self-contained breathing apparatus or an air mask with an external air supply.

3.4 LIST OF HYDROCARBON DETECTORS

S. No. Detector Tag No. Location Service

1. 21/22-AI-1401 Near Rich Glycol Degassing Drum Hydrocarbon
2. 21/22-AI-1501 Near Glycol Regeneration Column Hydrocarbon
3. 21/22-AI-1202 Near Glycol Absorber Hydrocarbon

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SECTION-4
PRECOMMISSIONING

4.1 INTRODUCTION
As the new unit nears completion, there is a large amount of preparatory work, which should be
performed by the operating crew. A planned check of the unit will not only set the foundation of
a smooth start-up, but will also provide a firm basis for acquainting operators with the
equipment. Start-up is a critical period and the operator must know exactly the operation of all
equipments.
− Some of the pre-commissioning works can be carried out simultaneously along with
construction. But, care in the organization of this work is necessary so that it will not
interfere with construction work. It is most important to plan schedule and record with
checklists and test schedules all the preliminary operation and to co-ordinate the
construction program.
Once contractor completes work, sections of the unit should be checked out by both GSPC and
EIL personnel in those areas. Immediately punch lists that indicate the deviations from the EIL
design specifications, should be written following inspection of those areas, and distributed to
the contractor.
Inspection of the plant can be basically divided into the following areas:
− Vessels
− Piping
− Exchanger
− Pumps
− Compressors
− Instrumentation
− Catalyst/Chemicals Inventory and its storage

A discussion and lists of the major points that must be examined in the inspection of these
areas follows:

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4.2 VESSELS INSPECTION

The actual installations must be compared against the drawings to assure that the vessels will
function as intended. The column internals must conform exactly to the design specifications if
good distribution is to be attained. Particular attention must be paid to the following details:

4.2.1. Specification Check

1. Review design specifications with the vendor drawings to verify agreement on:
− Pressure, temperature, and vacuum ratings.
− Shell metallurgy, thickness, and corrosion allowance.
− Nozzle size and orientation; flange rating, type and finish.
− Type of lining, thickness and material.
− Stress relieving and/or heat treatment.
− Foundation design for full water weight.
2. Confirm that the vessel has been hydrostatically tested.
3. Verify that all code plate information on the vessel is correct.

4.2.2. Internal Inspection

A. Column
− Inlet nozzle, metallurgy, type, size, opening sizes, freedom to expand.
− Tray spacing; levelness, orientation and dimensions of weirs, downcomers,
accumulators, drawoff and trap trays, seal pans, distributors, baffles, nozzles, tray
contact devices; metallurgy of trays, contact devices, clips, bolts, nuts and gaskets;
freedom of movement of valve caps or other contact devices; number, size, and
distribution of tray contact devices or perforated plate holes; proper fit of all internals and
proper welding of support rings or other support devices; liquid tightness of drawoff
trays, seal pans and accumulators, all bolting and clips tightened.
− Thermowells: orientation, length, and metallurgy.
− It must be verified that sufficient quantities of bolts, washers and hold downs of the
proper size and metallurgy are available to reassemble any disassembled portions of the
reactor internals.

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B. Other Vessels
1. Mesh blankets and outlet screens: size, location, levelness, suitability of fit (no
bypassing allowed), metallurgy of blanket, support, tie wires, and grids.
2. Vortex breakers: type, size, and orientation.
3. Baffles: size, type , orientation, levelness.
4. Instrument nozzles: location, orientation, cleanliness, thermowell length and metallurgy.
5. Inlet distributors: type, size, orientation, levelness, freedom to expand, wetted area.
6. Non-fired reboilers: location, orientation, proper supports.
7. Packing: type, size, support, installation.
8. Internal ladders and other devices: location, size, orientation, properly secured.

C. General
− The vessel should be clean (free from trash) and should not have excessive mill
scale.

4.2.3. External Inspection

1. Manways and nozzles: location, size, flange rating and finish, metallurgy, with proper
gaskets, nuts and bolts.
2. Ladders and platforms: correctly positioned, secure and free to expand.
3. Insulation and steam tracing: provided as specified and has expansion joints as required.
4. Vessel grounded correctly.
5. Correct vessel elevation.
6. Valves and instrumentation: easily accessible from grade or platform.
7. Piping:
− Adequate supports and guides for all connecting lines.
− Level and pressure instrument connections drain to a safe location.
− Vents to atmosphere or blowdown provided as specified.
− Relief valves have been bench tested.
− Check valves exist on utility line connections where hydrocarbon backup could
occur.
− Connections available for steaming/purging of the vessel.
8. Fireproofing of structure and supports is complete.
9. Instrumentation:

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− Level glass floats center positioned correctly with respect to vessel tangent line, and
are readable from grade or platform.
− Through-view level glasses have rear light for illumination.
− Flange ratings, metallurgy, size, etc. are all correct.

4.3 PIPING
The unit must be constructed in accordance with Piping and Instrumentation Diagrams (P&ID's),
including all details, elevations, dimensions, arrangements, and other notes on the P&ID's. One
must be able to startup, shutdown and conduct normal operations on the unit as envisioned in
the licensor design. Also, piping for special procedures such as dry-out, special materials
preparation, regeneration and/or alternative flow schemes may have been incorporated into the
unit's design, and the unit should be able to operate in all of these modes with piping as
designed and constructed.
If the unit is connected to other process facilities, adequate means must be provided to receive
feed from or send products to these facilities without contamination of these streams, and
minimize as much as possible the effects of upsets of other process units especially where
contamination of feed or product stream might occur. Check all tankage interconnections to
minimize the possibility of stream contamination outside of the battery limits.
Check that adequate means of measuring flows, pressures, and temperatures, and sampling of
all process streams has been provided.
The following items must be checked to ensure conformity to the design specifications:
1. Flanges: rating, facing, and metallurgy; type (typically, 2" and smaller are socket weld, 2½"
and larger are weld neck flanges).
2. Gaskets: type; metallurgy (materials of retainer, jackets, winding, filler, etc.); thickness, ring
size, etc.
3. Fittings, connections and couplings: rating and metallurgy.
4. Valves: rating and metallurgy (body, trim, seats, etc.); packing; seat inserts; bonnet gaskets;
grease seals; socket-weld or flange type, rating and facing; installed in correct direction of
flow; lubricant provisions; gear operators; extended bonnets; stops; ease of operation.
5. Bolting: stud or machine bolts; bolt and nut metallurgy; bolt size.
6. Pipe: metallurgy, thickness; seamed or seamless; lining.
7. Tubing: size and thickness; metallurgy; seamed or seamless.
8. Gauge glasses:

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− Through-view types should have rear-mounted lights.

− Design pressure and temperature.
− Special materials of construction.
− Drains to safe location.
− Visible from grade (or platform, if required).
9. Pressure relief valves:
− Size and style.
− Lever requirement.
− Inlet/outlet flange material, facing and rating.
− Set pressure - must be bench tested.
− Metallurgy of nozzle, disc, spring, etc.
− Type (pilot operated, balanced, etc.).
− Inlet/outlet block valves car-sealed open; valve stems installed in horizontal or below.
10. General:
a. Utility systems within the battery limit should follow all relevant pipe class specifications in
the same detail required for process lines.
b. Package systems (modular units, etc.) shown on the EIL P&ID should follow all relevant
pipe class specifications in the same detail required for other process lines.
c. Expansion: review the physical installation to ensure that no expansion problems will occur
when the unit gets hot and that:
− Column overhead, reflux, feed and other lines are free to expand.
− Rotating equipment will not be pulled out of alignment.
− Sufficient expansion loops have been provided on long hot lines.
− Pipe shoes are free to move in one direction, and are resting on supports of sufficient
size that the shoe will not fall off the support.
d. High point vents and low point drains should be installed where necessary.
e. Spectacle blinds should be provided where required.
f. Car-sealed valves should be locked in proper position.
g. Spring hangers should have locking pins removed (after hydrotesting) and necessary
adjustments should be made for hot/cold position after startup.

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4.4 HEAT EXCHANGERS

4.4.1. Specification Check
The design specifications should be reviewed with the vendor drawings to check:
1. Metallurgy of shell, tubes, tubesheet, channel cover, baffle, header box, etc.
2. Tube size and thickness: number of shell and tube passes and direction of flowing streams;
max/min allowable velocities.
3. Design temperature, pressure and pressure-drop ratings.
4. Nozzle size, flange type, rating, facing and metallurgy; vent and drain connections.
5. Design differential pressure between shell and tube sides of the exchanger.

4.4.2. Field Inspection

In the field the following items should be checked:-
1. Name plate verifies specifications.
2. Flange size, rating, facing and gaskets.
3. Insulation for heat retention and personnel protection.
4. Exchanger properly grounded.
5. Tubular exchangers:
a. Elevation
b. Slot length of sliding plates adequate for expansion. Exchanger should not be tied
down at both ends. Check that sliding ends of multi-shell exchangers make sense
with regard to expansion of exchangers and connecting pipe.
c. Piping symmetry for parallel exchangers.
d. Non-condensable vents in steam service or in totally condensing systems.
e. Water coolers; inlet at bottom of exchangers; inlet/outlet block valves with a thermal
relief valve inside the outlet block valve; vent and drain connections inside the block
valves.
f. Witness a shell/tube differential pressure test, if possible (especially important in
feed/effluent exchangers). When leak testing piping and equipment, ensure that the
design shell/tube differential pressure is not exceeded.

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4.5 PUMPS
A. Centrifugal Pumps
4.5.1. Specification Check
The design specifications should be reviewed against the pump curves and data given by the
vendor to confirm agreement on the following:
a. Head and capacity.
b. Pressure and temperature rating.
c. Speed.
d. NPSH requirement.
e. Pump type, materials of construction, flange ratings, seals, bearings, number of
stages, lubrication and cooling systems, etc.
f. Type of driver.
g. Balancing lines for multistage pumps must have flanged joints (not unions).

4.5.2. Field Inspection

The following items should be checked in the field:
a. Sight flow indicators, inlet/outlet shutoff valves on cooling water lines.
b. Thermometers/pressure gauges for gland seal and flushing oil manifolds.
c. Restriction orifices (if required) present in seal flush manifold piping.
d. Pedestals on pumps operating over 500°F (260°C) should be water cooled.
e. Cooling water to mechanical seals on pumps operating over 250°F (121/22°C).
f. Proper direction of rotation.

B. Reciprocating Pumps
The vendor information should be checked against the specifications to verify agreement on the
following:
1. Head and capacity (minimum, normal, maximum).
2. Materials of construction (body/glands, plungers, diaphragms, packing, internal check
valves).
3. Cooling/lubrication systems.
4. Pressure, temperature ratings.
5. Relief valve setting must be bench tested.
6. Pump speed and stroke.

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7. Pulsation suppression devices, if required.

Means for calibrating the pump flow rate should be investigated.

C. General
The following items should be checked for all pumps:
1. Piping to be arranged to permit removal or replacement of pump and driver.
2. Piping independently supported from pump; pump will not be pulled out of alignment when
lines get hot; no vapor pockets in piping.
3. Suction strainer easily removed for cleaning; strainers fit well so no bypassing can occur;
strainers have been installed.
4. Discharge pressure gauge readable from discharge block valve.
5. Suction/discharge valves easily accessible and operable, and near to the pump.
Accessibility of auxiliary piping and controls.
6. Check that NPSH requirements have been met.
7. Warm-up lines provided across discharge check valve when pumping hot fluids.
8. Base plate grouting complete.
9. Steam tracing and insulation provided on suction/discharge lines, pump casing, and process
seal flush lines, as required.
10. Minimum flow bypasses (with restriction orifice), if required.
11. All seal oil, warm-up, etc. lines have flanged connections and valves to permit removal of
pump.
12. Lubrication and cooling systems operate correctly.
13. Adequate means for venting and draining the pump casing are available.
14. Vacuum service pumps must have a discharge vent back to the system to allow filling the
pump with liquid.
15. Pumps and drivers are aligned correctly.
16. Check valves are of proper type and installed in the correct direction.
17. All drains from pumps and associated piping and instrumentation should be routed to a safe
location.

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4.6 INSTRUMENTATION
All personnel on site should check to ensure that the instrumentation is provided as specified;
that it is functional; and that a minimum of instrumentation problems will occur when the unit is
commissioned. Some of the basic items which must be checked include the following:
1. Instrument type, range, and size.
2. Materials of construction and rating of instrument, accessories, and connecting
piping, flanges, and valves.
3. Accessibility of instrument for routine checks and maintenance; rigidly mounted.
4. Installation according to correct drawing details.
5. Accessories (pulsation dampeners, filter/regulators, diaphragm seals, excess flow
checks, seal pots).
6. Location of local indicators so they are readable from grade platform or controller
assembly, as required.
7. Process requirements of flow, temperature, pressure, differential pressure, specific
gravity, etc.
8. Controller type, number of modes, chart type, range, cascades.
9. Power requirements of voltage, frequency; emergency power supply and
connections.
10. Calibration of controllers, transmitters, analyzers, special instrumentation.
11. Control valve, block and bypass valve sizes for control valve assemblies.

4.7 CHEMICAL INVENTORY

It must be verified that the proper type and quantity of chemicals are on site and stored properly.

4.8 PRELIMINARY OPERATIONS

The preparation of the unit for startup must start as soon as construction of the various sections
of the unit is completed. Careful attention to detail will assure that a smooth startup can be
conducted and a safe operation is achieved. Pre-startup activities must be carefully planned and
should consist of the following items:
1. Vessel Inspection
2. Flow Check
3. Hydrostatic Pressure Test
4. Water Flushing and Pump Break-in

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5. Utility Systems
6. Instruments
7. Tightness Test

1. Vessel Inspection
Inspection of the vessels can be undertaken as soon as the EIL person arrives on site. Refer to
the previous section on Pre-commissioning for a more detailed discussion on vessel inspection.

2. Flow Check
The actual arrangement of lines, vessels, pumps, etc., must conform to the Piping and
Instrumentation (P&ID) drawing. As soon as construction is completed, and if possible even
before, the unit must be carefully checked against the P&ID. This has been discussed in the
previous section on Pre-commissioning.

3. Hydrostatic Pressure Test

A hydrostatic pressure test must be carried out in order to assure that the unit will be able to
withstand the normal operating pressures and temperatures. One exception to this rule is the
reactor, which can be excluded since it has already been shop tested. Special metallurgical
considerations must be taken into account whenever such a vessel is pressured at low
temperatures.
The unit can be divided into convenient sections for hydrotesting. In any given section, the
pressure test applied should be equal to the allowable test pressure of the lowest rate
equipment in the circuit.
The water used for the test must be at a temperature of at least 75 °F (25 °C), and when used in
the reactor circuit on austenitic stainless steel equipment, it must contain less than 50 wt-ppm
chlorides. Before any testing is done, all orifice plates must be removed from the lines, and relief
valves blinded off.
A temporary connection may have to be installed to assure that both sides of the exchanger are
pressured to the same level if the reactor is not included in the test. Before the pressure test is
concluded, the effluent exchangers must be tested at the design differential pressure to assure
that no cross leakage exists.

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The test pressure must be held until it is assured that the unit is tight and all leaks have been
eliminated. In addition to process lines, utility lines (steam, air, etc.) should also be tested. It is
recommended that the pressure tests be carried out at the lower of the following two values:
1. 130 percent of the operating pressure of the lowest rated equipment in the circuit.
2. 50 psi (3.5 kg/cm2) lower than the lowest shop test applied to any item on the circuit.

4. Water Flushing and Pump Break-In

The water left over from hydrostatic testing can be used to flush the lines and break in the
pumps. Before proceeding with water flushing, all orifice plates must be removed (if no already
done so), control valves rolled out to prevent the accumulation of dirt under the seats, and fine
mesh screens installed in all pump suctions. An effort should be made to run as many of the
pumps and use as many of the lines as possible to collect and remove all trash, solids, slag, etc.
left over from construction. Remember, when pumping water with centrifugal pumps intended
for hydrocarbon service, the suction valve must be fully open and the discharge throttled to
avoid overloading the motor. All pumps and drivers must be properly aligned by qualified
personnel, and the lubrication and cooling systems placed in service before any attempt is
made to run them. It is recommended that whenever possible the drivers be run prior to being
coupled to the pumps.
While running the pumps, the bearing should be checked often for signs of overheating and
vibration. An operator should be nearby to shut down a pump at the first indication of
cavitations. Suction strainers should be pulled and cleaned as often as needed until no more dirt
accumulates in them. In flushing through a reboiler be sure to do so one pass at a time to
ascertain that the tubes are clear. Do not flush into any exchanger until the lines leading to them
have been flushed clean.
The water left after hydrotesting can be drained out under pressure, and this will remove most of
the foreign material. High pressure steam can also be used to blow through the lines. This
procedure is especially recommended for the charge heaters and effluent condensers to assure
that all passes are clear. Advantage should also be taken of the compressor run-in period when
the air pumped by the compressors can be used effectively to blow through the heater tubes
and exchangers.

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5. Utility Systems
The various utility lines should be tested and placed into service as soon as the construction
schedule allows. Pressure tests should be carried out on the steam, condensate, air, fuel gas,
fuel oil, flare etc. The steam lines should be warmed up gradually to prevent damage by water
hammer. At the same time, all steam traps and condensate lines should be placed into service.
Scale and construction debris can be conveniently removed from the steam lines by blowing
them as long as necessary with steam. The other utility lines can be cleaned by blowing with
steam or air, or by water flushing if possible. All utility lines, with the exception of fuel and flare,
can be put into service as soon as the construction schedule allows.

6. Instruments
All instruments should be checked as soon as possible so that any malfunctions or other faults
can be detected early. The instrument checkout should include the following items:
1. Pressure test of instrument air lines
2. Control valve action and calibration
3. Positioner calibration
4. Board calibration and loop check
5. Thermocouple calibration and identification
6. Level instrument calibration
7. Thermometers, pressure gauges, etc.

All orifice plate bores should be measured, recorded and compared with required sizes. The
orifice plates should also be checked to see if they were counter-bored wherever required. After
hydro-testing and water flushing have been completed, the orifice plates can be installed. DCS
Site Acceptance Test to be completed as per vendor procedure. Discrepancy found should be
rectified before plant start up.

7. Tightness Test
The purpose of this test is to check the tightness of flanges, joints, manholes etc. (except pumps
and control instruments). This operation can be integrated with steam purging activity aimed at
expelling air prior to introducing hydrocarbon into the unit.
− Drains at low points will be opened; after draining is over, these will be closed. Vent will be
opened; pressure gauges will be installed on each circuit.

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− Steam is progressively admitted where connections are available. Circuits which do not have
direct admission of steam will be supplied through hoses.
− The temperature of the whole installation is increased slowly and free expansion of lines is
checked. The condensed water is drained while the temperature of the circuit rises.
− When temperature is steady, vents are progressively closed in order to get the desired
pressure by keeping a vent slightly opened. A steam make-up is maintained. All joints will be
checked for leaks. If leaks are detected, system will be depressurised, leaks attended and the
system retested.

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SECTION –5
PLANT OPERATING PROCEDURES

5.1 INTRODUCTION
Start up and normal operating procedures are described in this section. Start up and shutdown are
the most critical periods in operation. It is then that the hazardous possibilities for fire and explosion
are greatest. The hazards encountered most frequently in start up and shut down of units are
accidental mixing of air and hydrocarbons and contacting of water with hot oil. Other hazards
primarily associated with start up are pressure, vacuum and thermal and mechanical shocks.
These can result in fires, explosions, destructive pressure surges and other damages to unit as
well as injury to personnel.
Fires occur when oxygen and fuel vapour or mists are mixed in flammable proportions and come in
contact with an ignition. They may run out of control or touch off devastating explosion. Pressure
surge from unplanned mixing of water and hot oil may cause damage of equipment and/or loss of
valuable production. Extensive, costly down time on process unit may result. Fires usually follow if
the explosion bursts lines or vessels.
Preparation for start-up begins with a complete review of the start up procedure by the operating
crew.
The main objectives of the start-up procedure are:
− To provide a safe and reliable way of getting the unit on stream.
− To protect the high pressure, high temperature equipment during the critical period of
initial pressuring and heating up.
A successful start-up of the unit requires that the unit be clean and the equipment perform
reliably. Pre-start-up activities usually include hydrostatic testing of pressure vessels and piping,
heater refractory dryout, inspection and testing of rotary equipment. The installation of column
internals should be carefully supervised and inspected to ensure proper assembly according to
specifications. The pre-start-up activities and overall start-up critical path should be carefully
planned.
After the unit has been started up and lined out, the focus shifts to reaching and maintaining a
state of optimum operation. This state of optimum operation can be achieved by establishing a
few general operating rules and being aware of potential problems which can occur. First, a
means of judging performance must be defined.

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Secondly, a list of operating variables is established. Using these operating variables, an

approach to operating the unit is outlined with respect to the performance indicators. This
procedure establishes a logical method for operating the plant, increasing yields and ensuring
longer operating cycles.

5.2 START UP
Start up of the unit involves the following consecutive phases:
− Preparation of the unit
− Removal of air from the unit by inert gas / steaming
− Tightness testing
− Glycol filling and circulation in the system
− Slow Pressurisation with gas
− Heating Media (HP Steam) line up to Reboiler
− Stripping Gas flow to Glycol stripping column
− Stabilisation of the unit.

5.2.1. PREPARATION
Prior to actual commissioning of the plant it should be established that all preparatory works
have been successfully completed and all equipment are ready to function. Ensure that;
− Blinds are installed as per master blind list. Each removal and insertion of a blind
should be noted and installed by the operator incharge.
− All vessels, piping, equipment are pressure tested, flushed and ready for service.
− All rotating equipment such as pumps, motors etc. have undergone functional test
successfully.
− All instruments have been checked and calibrated. Control should be on manual.
− All safety valves are in position after setting and testing. Isolating valves will be left in
lock open position. Spare valves should be kept isolated.
− All utility headers are charged.
− Flare, closed blow down, sewer and flushing oil systems are in operable condition.
− All related units are informed of the start-up plan.
− All pre-commissioning activities are completed.
− Fuel gas blinds are removed and headers charged.

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Tightness test will form part of pre-commissioning activities for the first start up. For subsequent
start ups the tightness test can be done in conjunction with the step of elimination of air.

5.2.2. INERT GAS / STEAM PURGING AND TIGHTNESS TESTING

Steam connections are given at appropriate places to remove air from equipment and pipes.
Water to coolers and condensers is isolated. Low point drains of pipes and equipment are
opened to remove condensate. High point vents are opened for air removal. Steaming is done
till O2 content of the system reduces to less than 0.5%. For leak testing vents and drains are
throttled, pressure is built upto 1.0 kg/cm2 g and system checked for any leaks. Leaks are
attended after depressurising.
For carrying out the removal of air with Nitrogen / Inert gas provide connections and appropriate
locations. Pressurise the system with N2 / Inert gas. Care should be taken to avoid the
overpressurization in the Glycol Regeneration section. The system should be pressurised to 1.0
kg/cm2 (g) and then depressurised to flare. Continue pressurisation and depressurisation to flare
till the O2 content in the system reduces to less than 0.5%. Once the O2 content is reduced to
the desired level the system is ready to be commissioned. For leak testing vents and drains are
throttled, pressure is built upto 1.0 kg/cm2 g and system checked for any leaks. Leaks are
attended after depressurising.

5.2.3. BACKING IN FUEL GAS

If steaming is used for air freeing then steam is cut off slowly and fuel gas is backed in. Avoid
pulling in vacuum during this period. This may cause entry of air in the system and damage
vessels which are not designed for vacuum. It is advisable to back in fuel gas section wise.
After all the sections have been floated on fuel gas, water is drained from low point drains.
Positive pressure in the system will facilitate draining of residual water. Removal of water from
the system is an important step for smooth start up.

5.2.4. COMMISSIONING OF UTILITIES

Prior to commissioning of each utility, the utilities section concerned for generation & distribution
should be informed about commissioning of the utility & it’s expected maximum, normal &
minimum consumption.

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5.2.4.1. Steam

The steam network consisting of LP steam header & connected lines should be checked
individually for mechanical completion. The steam header is common with SRB one.
Steam charging of header is done.

a) Warming-up

i. All equip. should be disconnected from steam lines to avoid entry of flushed
material.

ii. Drop all steam traps. Steam traps and bypass lines are to be blown alternately.

iii. Check supports of fixed points, anchors and expansion loops. Temporary welds
on sliding supports are to be removed.

iv. Open all drains & vents on the lines in the unit.

v. Isolate instruments, remove orifice plates and control valves to avoid damage by
exceeding design temperature and/or plugging by flushed material.

vi. Crack open the steam block valves and allows the steam to flow very slowly in
identified & prepared network. This will allow slow warm up of the system and
steam will get condensed. Condensate draining from opened low point drains
should be monitored. As the header temperature rises gradually & steadily, less
& less steam will condense. Precautions are to be taken during warming up.
Slow warm up and condensate draining of header avoids temperature shocks
and water hammer, which may cause serious damage to lines and equipment.

b) Steam Blowing

After header is sufficiently warmed up, open the battery limit valve gradually and
monitor local PI and DCS values to ascertain full charging of header. After steam is
available at battery limit of plant at full operating pressure & temperature and
steam network is warmed up; blow it completely from battery limit with a strong
flow of steam in order to clear the lines of debris and scales. Steam trap inlet lines

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should also be cleared. All the networks should be steam blown in above manner
to ensure the cleanliness.

c) Charging The Header

After satisfactory blowing of all steam networks, close the battery limit valve and
restore all piping, equipment, instruments and steam traps. Steam header inside
plant b/1 should be warmed up once again. Line supports should be checked after
full charging of the header. All steam traps are to be taken in line and the proper
functioning of each one to be ensured.
During cooling period, vents & drains of the lines should be opened so that line is
not subjected to vacuum resulting from steam condensation.

5.2.4.2. Cooling Water & Service Water

All equipment connected with cooling water network should either be disconnected at
inlet or the inlet flange should be opened slightly to insert a thin metallic sheet so that
flushed material does not enter the equipment .Vents at high points in cooling water line
should be opened to expel air from equipment and piping .Control valves & orifice plates
should also be removed. After preparing the net-work, it should be flushed with a strong
water flow. Fire water may be used for this purpose in first startup or when service water
is also not available.

After thorough flushing of all net-works, the dropped instruments (control valves, orifice
plates etc.) and equipment should be remounted and lines should be charged to full
operating pressure.

Functional correctness of all the local instruments e.g. PI, TI etc. should be established
at this stage. Quality of circulating cooling water should also be checked to see that it is
in accordance with design stipulations. Passivation of water circuits should also be
carried out as per requirement of SMMS group of EIL.

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5.2.4.3. Instrument Air, Plant Air and Nitrogen Header

Network shall be blown through completely from the battery limit with strong air flow in order
to clean and dry the lines. All joints and connections shall be checked for tightness with
soap solution. Header & branch lines will be blown through with a high flow rate of air.
During all tests the instruments & control valves should be isolated from the system. All
headers must be charged with noting pressure and temperature of concerned stream.
Note: Nitrogen circuits will be blown with Instrument Air and finally displaced with Nitrogen.

5.2.5. START UP
Following Step by Step Instructions are to be followed for Start Up:-

1) Ensure all utilities are charged.

2) Ensure GSU plant is ready to route sweet Gas to GDU. Inform Shift In-charge of GSU
that GDU is about to take GSU product.
3) Charge all water coolers with cooling water.
4) Addition of initial charge of 100 % TEG (triethylene glycol) should begin by filling the
Glycol Storage Tank from road tankers or TEG drums, using the Fresh Glycol Pump
(21/22-P-104). Once the level in the Lean Glycol Tank is about 50%, start the Glycol
Transfer Pump (21/22-P-102) and fill Lean Glycol Surge Drum (21/22-V-105). Keep
21/22-E-102 side isolation valve closed.
5) At 50% level in Lean Glycol Surge Drum (21/22-V-105) start the Lean Glycol Injection
Pump (21/22-P-101 A/B) which will fill the piping and the tube side of Lean Glycol
Cooler (21/22-E-101), the displaced air or inert gas should be vented from the 2” vent
provided on the vessels and pump strainer drain valves. Close the drain valves and
vents the air / inert gas is completely displaced.
6) As the level in the Glycol Storage Tank falls, continue to transfer the fresh Glycol to
tank from the storage drums.
7) Establish the glycol level in the Glycol Absorber (21/22-C-101). When the normal liquid
level at the absorber bottom is reached, commence the return of Glycol to the
Regeneration section. This may require pressurisation of Glycol Absorber through FG
connection provided.

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8) Slowly open LV-1201 and start filling the regeneration section. This will cause
successive filling of Rich Glycol Degassing Drum (21/22-V-103), Glycol filter Package
(21/22-LZ-101), Glycol Reflux condenser (21/22-E-104), Lean Rich Glycol Exchanger
(21/22-E-102), Glycol reboiler (21/22-E-103), Glycol Stripping Column (21/22-C-103),
and Lean Glycol surge drum (21/22-V-105). Lean Rich Glycol Exchanger (21/22-E-102)
should be
9) Once all the liquid levels are normal stop the Glycol Transfer pump (21/22-P-102) and
Lean Glycol Injection Pump (21/22-P-101 A/B).
10) During filling operation it may be necessary to periodically stop the Glycol Transfer
pump (21/22-P-102) and Lean Glycol Injection Pump (21/22-P-101 A/B) to permit
restoration of minimum liquid level in the Lean Glycol Tank (21/22-T-101). The filling
operation should also be used as an opportunity to test the operation of all the pumps
and level instruments in the system.
11) Pressurise Glycol Absorber (21/22-C-101) slowly with sweetened gas by opening
bypass valve of FV-1101. Allow the pressure in Glycol Absorber to increase to
operating pressure slowly. Pressurisation to operating pressure should be at a slow rate
not exceeding 2 Kg/cm2 per minute. Close the inlet valve when operating pressure is
reached. Caution during initial pressurisation will go a long way in ensuring safety of the
packing in the Glycol Contactor.
12) The Glycol Transfer pump (21/22-P-102) and Lean Glycol Injection Pump (21/22-P-101
A/B) should then be restarted. Normal TEG levels at the Glycol Absorber bottom and
other equipments holding TEG should be rechecked.
13) Slowly open the bypass valve of FV-1101 at the inlet of Feed Gas KOD (21/22-V-101)
to slowly start the gas flow through the system. Full flow of gas should be established in
approx one hour.
14) Once the gas flow has actually begun, HP steam to reboiler should be started slowly.
The reboiler temperature should then be raised to its normal operating level using the
automatic temperature control provided.
15) As dehydrated gas from Glycol Absorber O/H becomes available the flow of stripping
gas to the Glycol stripping column should be started. The pressure in the stripping gas
supply line will be automatically controlled by self actuated pressure control valve PCV-
1301.

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16) The stripping gas flow rate is controlled by throttling globe valve and flow indicator FI-
1501 to achieve the desired dew point of outlet gas. Dew point of the gas may be
monitored by online instrument AI-1201.
17) Note: - Care must be taken not of use excessive stripping gas as this would overload
Glycol Still and refluxing arrangement.
18) As the system operation begins to stabilize, check the individual equipment items for
proper pressure, temperature, liquid levels, flow rate etc.
19) once plant get stabilised and product gets on spec, inform DPDU that dehydrated gas
could be routed to DPDU

5.3 OPERATING VARIABLES

It is important that the operation of unit be conducted to produce products of desired quality. At
the same time appropriate controls should be exercised on certain parameters to prolong the life
of the equipment. The following discussion gives guidelines about affect of the variables and
measures to be taken to achieve desired results.

5.3.1 NORMAL OPERATING PARAMETER

S. No. DESCRIPTION TAG No. UNIT VALUE INDICATION
TYPE
1. 21/22-FI/FIC/FQ-
Flow of Feed Sweet 90914.3 / Local/DCS/
1101(Case-I / Kg/hr
Gas 92537.3 DCS
Case-II)
2. Sweet Gas Inlet DCS
21/22-PI-1101 Kg/cm2g 103.8
pressure
3. Sweet Gas Inlet Local
21/22-PI-1103 Kg/cm2g 103.8
pressure
4. Feed Gas KOD Local
21/22-PI-1102 Kg/cm2g 102.9
pressure
5. Sweet Gas Inlet o
21/22-TI-1101 C 40.0 DCS
Temperature
6. Sweet Gas Inlet o
21/22-TI-1102 C 40.0 Local
Temperature
7. Level of Feed Gas 21/22-LIC-1101 mm 300-600 DCS

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S. No. DESCRIPTION TAG No. UNIT VALUE INDICATION

TYPE
KOD
8. Level of Feed Gas Local
21/22-LI-1102 mm 300-600
KOD
9. Level of Feed Gas Local
21/22-LI-1103 mm 300-600
KOD
10. Flow of Lean Glycol 21/22-FI-
m3/hr 2.5 Local/DCS
to Absorber 1201/1201A
11. Dehydrated Gas DCS
21/22-PIC-1204 Kg/cm2g 101.8
Pressure
12. Dehydrated Gas
21/22-PI-1203 Kg/cm2g 101.8 Local
Pressure
13. Glycol Absorber
21/22-PI-1205 Kg/cm2g 102.4 DCS/Local
Pressure
14. Dehydrated Gas
21/22-PI-1206 Kg/cm2g 101.8 DCS
Pressure
15. Dehydrated Gas
21/22-PI-1208 Kg/cm2g 101.8 Local
Pressure
16. Stripping Gas header
21/22-PI-1207 Kg/cm2g 101.8 Local
Pressure
17. Glycol Absorber 21/22-PDI-1201 Kg/cm2g 0.3 DCS
2
18. Filter Separator 21/22-PDI-1202 Kg/cm g 0.6 DCS
19. Glycol Absorber Top o
21/22-TI-1201 C 40.5 DCS
Temperature
20. Glycol Absorber o
21/22-TI-1202 C 39.6 DCS
Bottom Temperature
21. Temperature of
o
Dehydrated Gas from 21/22-TI-1203 C 40.3 Local
Glycol filter Separator
22. Temperature of
o
Dehydrated Gas from 21/22-TI-1204 C 40.3 DCS
Glycol filter Separator

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GSPC, Onshore Gas Terminal
Page 50 of 105

S. No. DESCRIPTION TAG No. UNIT VALUE INDICATION

TYPE
23. Level of Glycol
21/22-LI/LIC-1201 mm 200-850 Local/DCS
Absorber Bottom
24. Level of Glycol
21/22-LI-1205 mm 200-850 Local
Absorber Bottom
25. Level of Glycol
21/22-LI-1208 mm 200-850 DCS
Absorber Bottom
26. Filter Separator
21/22-LI/LIC-1202 mm 200-556 Local/DCS
Bottom Level
27. Filter Separator
21/22-LI-1204 mm 200-556 Local
Bottom Level
28. Filter Separator
21/22-LI-1206 mm 200-556 DCS
Bottom Level
29. Filter Separator Top
21/22-LI/LIC-1203 mm 2460-2816 Local/DCS
Level
30. Filter Separator Top
21/22-LI-1207 mm 2460-2816 Local
Level
31. Rich Glycol
21/22-PI-1301 Kg/cm2g 7.5 DCS
Degassing Drum
32.
Rich Glycol
21/22-PI-1302 Kg/cm2g 7.5 Local
Degassing Drum

33. Temperature of Rich

o
Glycol Degassing 21/22-TI-1301 C 40.1 Local
Drum
34. Level of Degassing
Drum (H/C 21/22-LIC-1301 mm 200 / 700 DCS
Condensate Side)
35. Level of Degassing
Drum (H/C 21/22-LI-1303 mm 200 / 700 Local
Condensate Side)
36. Degassing Drum 21/22-LI/LIC-1302 mm 400 / 600 Local/DCS

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GDU Rev. A
GSPC, Onshore Gas Terminal
Page 51 of 105

S. No. DESCRIPTION TAG No. UNIT VALUE INDICATION

TYPE
(Rich TEG Side)
37. Degassing Drum
21/22-LI-1304 mm 400/600 DCS
(Rich TEG Side)
38. 21/22-PDI-1401 DCS
Glycol Cartridge Filter Kg/cm2g 0.1
A/B
39. 21/22-PDI- Local
Glycol Cartridge Filter Kg/cm2g 0.1
1402A/B
40. 21/22-PDI-1403 DCS
Glycol Cartridge Filter Kg/cm2g 0.1
A/B
41. 21/22-PDI-1404 Local
Glycol Cartridge Filter Kg/cm2g 0.1
A/B
42. 21/22-PDI-1405 DCS
Glycol Charcoal Filter Kg/cm2g 0.2
A/B
43. 21/22-PDI- Local
Glycol Charcoal Filter Kg/cm2g 0.2
1406A/B
44. Flow of Stripping Gas
21/22-FIC/FI-
to 21/22-C-103 Kg/hr 60.0 DCS/Local
1501/1501A
through 21/22-E-103
45. Flow of HP Steam to
FI-1502 Kg/hr 276 DCS
Glycol Reboiler
46. Pressure of Stripping
Gas to Glycol 21/22-PI-1501 Kg/cm2g 2.0 DCS
Reboiler
47. Pressure of Glycol
21/22-PI-1502 Kg/cm2g 0.07 Local
Reboiler
48. Pressure of HP
Steam to Glycol 21/22-PI-1503 Kg/cm2g 29.5 DCS
Reboiler
49. Pressure of Glycol
Reboiler Condensate 21/22-PI-1504 Kg/cm2g 29.5 Local
Pot

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GDU Rev. A
GSPC, Onshore Gas Terminal
Page 52 of 105

S. No. DESCRIPTION TAG No. UNIT VALUE INDICATION

TYPE
50. Differential Pressure
of Glycol Stripping 21/22-PDI-1506 Kg/cm2g 0.03 DCS
Column
51. Regenerator Top o
21/22-TIC-1501 C 92.16 DCS/Local
Temperature
52. Glycol Reboiler o
21/22-TIC-1502 C 204.0 DCS/Local
Temperature
o
53. Stripping Gas C
21/22-TI-1503 28.0 DCS
Temperature
o
54. HP Steam Inlet C
21/22-TI-1504 233.7 DCS
Temperature
55. Glycol Reboiler o
21/22-TI-1505 C 204.0 Local
Temperature
56. HP Condensate o
21/22-TI-1508 C 233.7 Local
Temperature
57. Level of Glycol
Reboiler Condensate 21/22-LI-1503 mm 150-1500 Local
Pot
58. Level of Glycol
Reboiler Condensate 21/22-LI/LIC-1504 mm 150-1500 Local/DCS
Pot
59. Level of Glycol
21/22-LI-1501 mm 0-1200 Local
Reboiler
60. Level of Glycol
21/22-LI-1502 mm 0-1200 DCS
Reboiler
61. Flow of Pure TEG for
21/22-FR/FQ-1601 m3/hr 1.5 DCS/DCS
Make Up
62. Pressure of Glycol
21/22-PI-1601 Kg/cm2g Atm DCS
Sump Drum
63. Discharge Pressure of
21/22-PI-1602 Kg/cm2g 3.0 Local
Glycol Drain Pump

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GDU Rev. A
GSPC, Onshore Gas Terminal
Page 53 of 105

S. No. DESCRIPTION TAG No. UNIT VALUE INDICATION

TYPE
64. Discharge Pressure of
21/22-PI-1603 Kg/cm2g 9.5 Local
Glycol Transfer Pump
65. Lean Glycol Tank o
21/22-TI-1601 C Ambient Local
Temperature
66. Level of Lean Glycol
21/22-LI-1601 mm 0- 2800 Local/DCS
Tank
67. Level of Lean Glycol
21/22-LI-1602 mm 0-2700 DCS
Tank
68. Level of Lean Glycol
21/22-LI-1603 mm 0-2700 DCS
Tank
69. Level of Glycol Sump mm DCS
21/22-LI-1606 150 / 450
Drum
70. Pressure of Rich TEG
21/22-PI-1701 Kg/cm2g 4.8 Local
to 21/22-E-102
71. Pressure of Rich TEG
21/22-PI-1702 Kg/cm2g 4.6 Local
from 21/22-E-102
72. Pressure of Lean
21/22-PI-1704 Kg/cm2g 0.12 Local
TEG to 21/22-E-102
73. Pressure of Lean
TEG from 21/22-E- 21/22-PI-1705 Kg/cm2g 0.02 Local
102
74. Discharge Pressure
of Lean Glycol
21/22-PI-1707 Kg/cm2g 108.1 Local
Injection Pump
21/22-P-101A
75. Discharge Pressure
of Lean Glycol
21/22-PI-1708 Kg/cm2g 108.1 Local
Injection Pump
21/22-P-101B
76. Pressure of Lean
21/22-PI-1709 Kg/cm2g 108.1 Local
TEG at inlet of 21/22-

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Page 54 of 105

S. No. DESCRIPTION TAG No. UNIT VALUE INDICATION

TYPE
E-101
77. Pressure of cooled
Lean TEG from 21/22-PI-1710 Kg/cm2g 107.4 Local
21/22-E-101
78. Flow of Cooling
21/22-FR-1701 m3/hr 8.8 DCS
Water Supply
79. Differential Pressure
across Rich TEG side
21/22-PDI-1703 Kg/cm2g 0.2 DCS/Local
of Lean Rich Glycol
Exchanger
80. Differential Pressure
across Lean TEG side
21/22-PDI-1706 Kg/cm2g 0.1 DCS/Local
of Lean Rich Glycol
Exchanger
81. Temperature of Rich
o
TEG to Lean Rich 21/22-TI-1701 C 48.6 DCS
Glycol Exchanger
82. Temperature of Rich
o
TEG to Lean / Rich 21/22-TI-1702 C 48.6 Local
Glycol Exchanger
83. Temperature of Rich
o
TEG from Lean / Rich 21/22-TI-1713 C 167 Local
Glycol Exchanger
84. Temperature of Rich
o
TEG from Lean / Rich 21/22-TI-1704 C 167 DCS
Glycol Exchanger
85. Temperature of Lean
o
TEG to Lean Rich 21/22-TI-1711 C 197.1 Local
Glycol Exchanger
86. Temperature of Lean o
21/22-TI-1710 C 197.1 DCS
TEG to Lean Rich

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GDU Rev. A
GSPC, Onshore Gas Terminal
Page 55 of 105

S. No. DESCRIPTION TAG No. UNIT VALUE INDICATION

TYPE
Glycol Exchanger
87. Temperature of Lean
o
TEG from Lean Rich 21/22-TI-1709 C 78.9 DCS
Glycol Exchanger
88. Temperature of Lean
o
TEG from Lean Rich 21/22-TI-1709 C 78.9 Local
Glycol Exchanger
89. Temperature of Lean o
DCS
21/22-TI-1712 C 78.9
Glycol Surge Drum
90. Temperature of Lean
o
TEG to Lean Glycol 21/22-TI-1715 C 83.8 DCS
Cooler
91. Temperature of Lean
o
TEG to Lean Glycol 21/22-TI-1715 C 83.8 Local
Cooler
92. Temperature of Lean
o
TEG from Lean 21/22-TI-1718 C 48.0 DCS
Glycol Cooler
93. Temperature of Lean
o
TEG from Lean 21/22-TI-1720 C 48.0 Local
Glycol Cooler
94. Temperature of
Cooling Water Return o
21/22-TI-1714 C 43 Local
from Lean Glycol
Cooler
95. Level of Lean Glycol
21/22-LI-1701 mm 150-900 DCS
Surge Drum
96. Level of Lean Glycol 150 -900
21/22-LI-1702 mm Local
Surge Drum
97. Level of Lean Glycol
21/22-LI-1703 mm 150- 900 DCS
Surge Drum

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GDU Rev. A
GSPC, Onshore Gas Terminal
Page 56 of 105

S. No. DESCRIPTION TAG No. UNIT VALUE INDICATION

TYPE
98. Level of Lean Glycol
21/22-LI-1704 mm 200-800 DCS
Surge Drum

5.3.2 ALARM AND TRIP SETTINGS

S.
DESCRIPTION TAG NO. UNIT ALARM VALUE
No
Low Flow Alarm of Sweetened
1. 21/22-FAL-1101 Kg/hr 86368.58/87910.435
gas from GSU to KOD
High Flow Alarm of Sweetened
2. 21/22-FAH-1101 Kg/hr 95460/97164.16
gas from GSU to KOD
Low Level Alarm of Feed Gas
3. 21/22-LAL-1101 mm 400
KOD
Low Level Alarm of Feed Gas
4. 21/22-LAL-1103 mm 400
KOD
Low-Low Level Alarm of Feed 21/22-LALL-
5. mm 300
Gas KOD 1103
High Level Alarm of Feed Gas
6. 21/22-LAH-1101 mm 550
KOD
High Level Alarm of Feed Gas
7. 21/22-LAH-1103 mm 550
KOD
Low Level Alarm of Glycol
8. 21/22-LAL-1201 mm 425
Absorber
Low-Low Alarm Level of Glycol 21/22-LALL-
9. mm 200
Absorber 1208
High Level Alarm of Glycol
10. 21/22-LAH-1201 mm 800
Absorber
High Level Alarm of Glycol
11. 21/22-LAH-1208 mm 850
Absorber
Low Level Alarm of Glycol Filter
12. 21/22-LAL-1203 mm 2588
separator Top

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GDU Rev. A
GSPC, Onshore Gas Terminal
Page 57 of 105

S.
DESCRIPTION TAG NO. UNIT ALARM VALUE
No
Low-Low Level Alarm of Glycol 21/22-LALL-
13. mm 2538
Filter separator Top 1209
High Level Alarm of Glycol Filter
14. 21/22-LAH-1203 mm 2738
separator Top
Low Level Alarm of Glycol Filter
15. 21/22-LAL-1202 mm 328
separator Bottom
High Level Alarm of Glycol Filter
16. 21/22-LAH-1202 mm 478
separator Bottom
Low-Low Level Alarm of Glycol 21/22-LALL-
17. mm 278
Filter separator Bottom 1206
High Level Alarm of Glycol Filter
18. 21/22-LAH-1206 mm 478
separator Bottom
Low Flow of Lean Glycol Cooler to 21/22-FAL-
19. Kg/hr 2.3
Glycol Absorber 1201A
High Differential Pressure Alarm
21/22-PDAH-
20. between Glycol Absorber and Kg/cm2g 103
1202
Glycol Filter Separator
Low Pressure Alarm of Glycol
21. 21/22-PAL-1206 Kg/cm2g 100
Filter Separator overhead stream
High Pressure Alarm of Glycol
22. 21/22-PAH-1206 Kg/cm2g 104
Filter Separator overhead stream
Low pressure Alarm of Glycol
23. 21/22-PAL-1205 Kg/cm2g 100
Absorber
High pressure Alarm of Glycol
24. 21/22-PAH-1205 Kg/cm2g 104
Absorber
High Differential Pressure across 21/22-PDAH-
25. Kg/cm2g 103.5
Packed Bed of Glycol Absorber 1201
High Dew Point Alarm of Glycol
26. 21/22-AAH-1201 Kg/MMSm3 40
Filter Separator overhead stream
High-High Dew Point Alarm of 21/22-AAHH- Kg/MMSm3
27. 50
Glycol Filter Separator overhead 1201

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GDU Rev. A
GSPC, Onshore Gas Terminal
Page 58 of 105

S.
DESCRIPTION TAG NO. UNIT ALARM VALUE
No
stream
High Dew Point Alarm of Glycol
28. 21/22-AAH-1202 Kg/MMSm3 40
Filter Separator overhead stream
High-High Dew Point Alarm of
21/22-AAHH- Kg/MMSm3
29. Glycol Filter Separator overhead 50
1202
stream
Low Level Alarm of Rich Glycol
30. Degassing Drum (Rich Glycol 21/22-LAL-1302 mm 425
side)
High Level Alarm of Rich Glycol
31. Degassing Drum (Rich Glycol 21/22-LAH-1302 mm 575
side)
Low Level Alarm of Rich Glycol
32. Degassing Drum (Rich Glycol 21/22-LAL-1304 mm 375
side)
High Level Alarm of Rich Glycol
33. Degassing Drum (Rich Glycol 21/22-LAH-1304 mm 575
side)
Low Level Alarm of Rich Glycol
34. Degassing Drum 21/22-LAL-1301 mm 250
(H/C Condensate side)
High Level Alarm of Rich Glycol
35. Degassing Drum 21/22-LAH-1301 mm 650
(H/C Condensate side)
Low-Low Level Alarm of Rich
21/22-LALL-
36. Glycol Degassing Drum mm 200
1305
(H/C Condensate side)
High-High Level Alarm of Rich
21/22-LAHH-
37. Glycol Degassing Drum mm 700
1301
(H/C Condensate side)
38. High Pressure Alarm of Rich 21/22-PAH-1301 Kg/cm2g 9

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Page 59 of 105

S.
DESCRIPTION TAG NO. UNIT ALARM VALUE
No
Glycol Degassing Drum
Low Pressure Alarm of Rich
39. 21/22-PAL-1301 Kg/cm2g 6
Glycol Degassing Drum
High Differential Pressure Alarm 21/22-PDAH-
40. Kg/cm2g 8
across 21/22-G-101A 1401A
High Differential Pressure Alarm 21/22-PDAH-
41. Kg/cm2g 8
across 21/22-G-101B 1401B
High Differential Pressure Alarm 21/22-PDAH-
42. Kg/cm2g 8
across 21/22-G-101A 1403A
High Differential Pressure Alarm 21/22-PDAH-
43. Kg/cm2g 8
across 21/22-G-101B 1403B
High Differential Pressure Alarm 21/22-PDAH-
44. Kg/cm2g 8
across 21/22-G-101A 1405A
High Differential Pressure Alarm 21/22-PDAH-
45. Kg/cm2g 8
across 21/22-G-101B 1405B
High Differential Pressure Alarm 21/22-PDAH-
46. Kg/cm2g 0.5
across 21/22-C-103 1506
High-High Temperature Alarm of 21/22-TAHH- o
47. C 206
Glycol Reboiler 1506
High Temperature Alarm of Glycol o
48. 21/22-TAH-1502 C 150
Reboiler
Low Temperature Alarm of Glycol o
49. 21/22-TAL-1502 C 205
Reboiler
High Temperature Alarm of Glycol o
50. 21/22-TAH-1501 C 77
Regenerator Vent
Low Temperature Alarm of Glycol o
51. 21/22-TAL-1501 C 100
Regenerator Vent
High Flow Alarm of Stripping Gas
52. 21/22-FAH-1501 Kg/Hr 63
to Glycol reboiler
Low Flow Alarm of Stripping Gas
53. 21/22-FAL-1501 Kg/Hr 57
to Glycol reboiler

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Page 60 of 105

S.
DESCRIPTION TAG NO. UNIT ALARM VALUE
No
Low Level Alarm of Glycol
54. 21/22-LAL-1502 mm 850
Reboiler
High Level Alarm of Glycol
55. 21/22-LAH-1502 mm 1100
Reboiler
Low Level Alarm of Glycol
56. 21/22-LAL-1504 mm 200
Reboiler Condensate Pot
High Level Alarm of Glycol
57. 21/22-LAL-1504 mm 1400
Reboiler Condensate Pot
Low Level Alarm of Lean Glycol
58. 21/22-LAL-1601 mm 1100
Tank
High Level Alarm of Lean Glycol
59. 21/22-LAH-1601 mm 2100
Tank
Low Level Alarm of Lean Glycol
60. 21/22-LAL-1603 mm 1050
Tank
High Level Alarm of Lean Glycol
61. 21/22-LAH-1602 mm 2150
Tank
Low-Low Level Alarm of Lean 21/22-LALL-
62. mm 1000
Glycol Tank 1604
High Level Alarm of Glycol Sump
63. 21/22-LAH-1606 Kg/cm2g 450
Drum
Low Level Alarm of Glycol Sump
64. 21/22-LAL-1606 Kg/cm2g 150
Drum
High Level Alarm of Glycol Sump
65. 21/22-LAH-1605 Kg/cm2g 400
Drum
Low Level Alarm of Glycol Sump
66. 21/22-LAL-1605 Kg/cm2g 200
Drum
Low Level Alarm of Lean Glycol
67. 21/22-LAL-1701 mm 200
Surge Drum
High Level Alarm of Lean Glycol
68. 21/22-LAH-1701 mm 800
Surge Drum
69. High-High Level Alarm of Lean 21/22-LAHH- mm 900

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GDU Rev. A
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Page 61 of 105

S.
DESCRIPTION TAG NO. UNIT ALARM VALUE
No
Glycol Surge Drum 1701
Low-Low Level Alarm of Lean 21/22-LALL-
70. mm 150
Glycol Surge Drum 1703
High Level Alarm of Lean Glycol
71. 21/22-LAH-1704 mm 800
Surge Drum
Low Level Alarm of Lean Glycol
72. 21/22-LAL-1704 mm 200
Surge Drum
High Differential Pressure Alarm
21/22-PDAH-
73. Rich TEG side across 21/22-E- Kg/cm2g 0.3
1703
102
High Differential Pressure Alarm
21/22-PDAH-
74. Lean TEG side across 21/22-E- Kg/cm2g 0.2
1706
102
High Temperature Alarm of Rich o
75. 21/22-TAH-1701 C 35
TEG to 21/22-E-102
Low Temperature Alarm of Rich o
76. 21/22-TAL-1701 C 55
TEG to 21/22-E-102
High Temperature Alarm of Rich o
77. 21/22-TAH-1704 C 155
TEG from 21/22-E-102
Low Temperature Alarm of Rich o
78. 21/22-TAL-1704 C 175
TEG from 21/22-E-102
High Temperature Alarm of Lean o
79. 21/22-TAH-1709 C 90
TEG from 21/22-E-102
Low Temperature Alarm of Lean o
80. 21/22-TAL-1709 C 65
TEG from 21/22-E-102
Low Flow Alarm of Cooling water
81. 21/22-FAL-1701 m3/hr 8.3
Supply to 21/22-E-101
High Temperature Alarm of Lean o
82. 21/22-TAH-1718 C 95
Glycol from 21/22-E-101
Low Temperature Alarm of Lean o
83. 21/22-TAL-1718 C 35
Glycol from 21/22-E-101

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5.3.3 RELIEF VALVE SETTINGS

Set Pressure
Sr. No. PSV No. Location Basis
Kg/cm2g
21/22-PSV-1201 /
1 Glycol Absorber 115.6 External Fire
1202
21/22-PSV-1301 / Rich Glycol Degassing Block
2 9.5
1302 Drum Discharge
21/22-PSV-1303 / PCV-1301
3 Stripping Gas 4
1304 Failure
4 21/22-PSV-1401 A/B 21/22-G-101 A/B 9.5 Fire Case
5 21/22-PSV-1402 A/B 21/22-G-102 A/B 9.5 Fire Case
6 21/22-PSV-1403 A/B 21/22-G-103 A/B 9.5 Fire Case
Glycol Reboiler
7 21/22-PSV-1501 36.0 Fire Case
Condensate Pot
21/22-PSV-1701 / Lean Glycol Injection Vendor to Blocked
8
1702 Pumps provide Discharge
Tube rupture
9 21/22-PSV-1704 21/22-E-101 shell side 8.0
case

5.3.4 List of Control Valve

Sr. No. Tag No. Description Failure Position
1. 21/22-FV-1101 Sweet Gas Feed line to Feed Gas KOD Fail Open
Condensate from Feed GAS KOD to ABD
2. 21/22-LV-1101 Fail Close
Header
3. 21/22-LV-1201 Rich TEG from Glycol Absorber Fail Close
Rich TEG from Glycol Filter Separator
4. 21/22-LV-1202 Fail Close
Bottom
5. 21/22-LV-1203 Rich TEG from Glycol Filter Separator Top Fail close
Dry Gas to HP Flare from Glycol Filter
6. 21/22-PV-1204 Fail Open
Separator
H/C condensate from Rich Glycol
7. 21/22-LV-1301 Fail Close
Degassing Drum

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Sr. No. Tag No. Description Failure Position

8. 21/22-TV-1501 Rich TEG to Glycol Reflux Condenser Fail Close
9. 21/22-TV-1502 HP Steam to Glycol Reboiler Fail Close
10. 21/22-LV-1504 Condensate to GSU condensate Header Fail Close
11. 21/22-LV-1502 Rich TEG to Glycol Regenerator Fail Close

5.3.5 BLIND LIST:

It is desired to prepare blind list during pre-commissioning activity, commissioning
activity and then further shutdown and start ups. It is very useful before feed in to
review status of blind as per master blind list. Sometime due to much pressure on
commissioning team and lots of simultaneous activities it was found blind was left
inserted and feed was charged, leading to accident fortunately no casualty was
observed. But it is objective of commissioning manager to conduct safe start up. it is
recommended to include to verification of blind position before each activity and
updation of blind register. Blind register is Excel sheet where record of date and time
with person involved for every removal and insertion of blind is made during entire life
of unit. Hence the blind list for GDU is as follows:

BLIND POSITION
Sr. BLIND
LOCATION LINE NO. NORMAL START SHUT
No. SIZE
OPERATION UP DOWN

1 12" SWEETENED 12"-P-21/22-1101- Open Open Close

GAS FROM GSU E16A
TO KOD (V-101)
2 2" DRAIN TO ABD 2"-P-21/22-1103- Open Open Close
E16A
3 2" UC 2"-FG-21/22-1104- Close Open Close
E16A
4 3" DRAIN TO OWS 2"-D-21/22-1102- Close Close Open
E16A
5 2" PSV TO HP 6(H)"-P-21/22-1202- Close Open Close
FLARE E16A
6 2" UC 2"-FG-21/22-1203- Close Open Close
E1A

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BLIND POSITION
Sr. BLIND
LOCATION LINE NO. NORMAL START SHUT
No. SIZE
OPERATION UP DOWN

7 2" DRAIN TO 2"-P-21/22-1204- Close Open Close

GLYCOL SUMP E1A
DRUM
8 2" DRAIN TO OWS 2"-P-21/22-1204- Close Open Close
E1A
9 12" DEHYDRATED 12"-P-21/22-1207- Open Open Close
GAS TO DPDU E1A
10 12" DEHYDRATED 12"-P-21/22-1202- Open Open Close
GAS TO HP E1A
FLARE
11 12" DEHYDRATED 12"-P-21/22-1202- Open Open Close
GAS TO HP E1A
FLARE
12 2" DRAIN TO 2"-P-21/22-121/224- Close Open Close
GLYCOL SUMP E1A
DRUM
13 2" DRAIN TO OWS 2"-P-21/22-121/224- Close Close Open
E1A
14 2" STRIPPING GAS 2"-P-21/22-1131- Open Open Close
A1A
15 2" STRIPPING GAS 2"-P(H)-21/22-1307- Close Open Close
TO LP FLARE A1A
16 2" V-103 TO HP 6"(H)-P-21/22-1304- Close Open Close
FLARE A1A
17 1.5" V-103 DRAIN TO 1.5"-D-21/22-1308- Close Close Open
OWS (3 No.) A1A
18 2" V-103 DRAIN TO 2"-P-21/22-1307- Close Close Close
GLYCOL SUMP A1A
19 2" V-103 DRAIN TO 2"-P-21/22-1309- Close Close Close
CBD A1A
20 2" V-103 DRAIN TO 2"-P-21/22-1310- Open Open Close
CBD A1A

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BLIND POSITION
Sr. BLIND
LOCATION LINE NO. NORMAL START SHUT
No. SIZE
OPERATION UP DOWN

21/22 2" RICH TEG 2"-RT-21/22-1311- Open Open Close

A1A
22 2" FILTER TO H-FL-21/22-1420- Close Close Close
FLARE A1A
23 2" FILTER TO FILTER / OWS / Close Close Close
FILTER/GLYCOL SUMP (23 NOs
SUMP/ OWS Blind)
24 3" HP STEAM TO 3"-SH-21/22-1517- Open Open Close
GLYCOL A1A-B2A-IH
REBOILER
25 2" TO GLYCOL 4"-RT-21/22-1505- Close Open Close
SUMP DRUM A1A-IS
26 2" TO OWS 6"-P-51-1402-A1A- Close Close Open
IH
27 2" GLYCOL 2"-D-21/22-1501- Close Open Close
REBOILER TO A1A
SUMP DRUM
28 2" GLYCOL 2"-D-21/22-1501- Close Close Open
REBOILER TO A1A
OWS
29 2" TEG FROM 2"-LT-21/22-1601- Close Close Close
TANKER TO A1A
TANK
30 2" DRUM PUMP TO 2"-LT-21/22-1609- Close Close Close
TANK A1A
31 2" LEAN TEG 1.5"-LT-21/22-1605- Close Close Close
A1A
32 3/4" GLYCOL 2"-DT-21/22-1602- Close Close Close
TRANSFER A1A
PUMP CASING
DRAIN
33 2" TANK DRAIN TO 2"-LT-21/22-1606- Close Close Close

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BLIND POSITION
Sr. BLIND
LOCATION LINE NO. NORMAL START SHUT
No. SIZE
OPERATION UP DOWN

SUMP DRUM A3A

34 2" TANK DRAIN TO 2"-LT-21/22-1606- Close Close Open
OWS A3A
35 4" VALVE PIT 4"-DT-21/22-5701- Open Open Close
A1A
36 2" GLYCOL SURGE 2"-DT-21/22-1702- Close Close Close
DRUM DRAIN TO A1A
SUMP DRUM
37 2" GLYCOL SURGE 2"-DT-21/22-1702- Close Close Open
DRUM DRAIN TO A1A
OWS
38 2" GLYCOL 2"-DT-21/22-1703/ Close Close Close
INJECTION 1704-A1A
PUMP DRAIN TO
SUMP DRAIN
39 2" GLYCOL 2"-DT-21/22-1703/ Close Close Open
INJECTION 1704-A1A
PUMP DRAIN TO
OWS

5.4 NORMAL SHUTDOWN

While shutting down the unit care should be taken not to admit air into the system until all
hydrocarbon vapours have been removed. All related units including utilities should be informed
about the shutdown plan. Closed blow down should be emptied out and should be kept in a
position to receive drainings / flushings from equipment.

The Shutdown procedure for gas dehydration system is given below, the shutdown of the gas
dehydration system should be in conjugation with changes in the operation of other systems.
1. Slowly decrease the gas flow to the Glycol Absorber through FV-1101.
2. Once the gas flow to Glycol Absorber has stopped, close shutdown valves UV-1101 and
UV-1203.

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3. Slowly start reducing the temperature of Glycol by closing flow of HP steam to reboiler.
4. Once the gas flow has stopped and system depressurized continue the glycol circulation
till the temperature reduces to 80 oC.
5. The flow of stripping gas to Glycol Stripping column has also stopped.
6. Stop the Glycol injection pump (21/22-P-101 A/B).
7. Stop Glycol transfer Pump (21/22-P-102).
8. Allow sometime for Glycol hold up in the Glycol Absorber to drain to bottom.
9. Continue to allow spent glycol to flow on the level control from bottom of the Glycol
Absorber back to regeneration system.
10. After liquid hold up has drained from the Glycol Absorber close block valves in the outlet
line and close UV-1201.
11. Depressurize the system by first closing all the inlet and outlet block valves and then
releasing the gas to HP Flare through PV-1204.
12. After the Glycol Absorber pressure falls to the minimum operating pressure of the HP
Flare, the remaining gas can be released through vent.

5.5 EMERGENCY SHUTDOWN

When the safe routing operation is interrupted emergency procedures are sometimes required
to overcome the potential hazards. If continuation of unit operations on limited basis is
impractical the unit must be shut down as safely as possible.
The emergency procedures attempt to overcome the hazard of a quick shut down. Emergency
can result from equipment failure and from interruption of utilities. Certain features have been
designed into the plant to minimise the likelihood of emergencies. These includes spare pumps,
exchangers etc. Operators should be thoroughly familiar with emergency procedures and
understand the reasons for each work. Good judgment must be exercised as no written
procedure can completely cover all details or problems that can arise in an emergency.
Judgment is more likely to be exact if prior thought and planning have been made.
As during emergency there is no time, emergency procedure must be learnt before hand.
During emergency or fire shutdown, the gas dehydration system can be shutdown using
interlock I-10. This interlock will cause the following event to take place.
a. Unit Depressurisation by opening 21/22-PV-1204
b. 21/22-UV-1101 in the inlet sweetened gas line will close thereby stopping the flow of
sweetened gas.

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c. 21/22-UV-1102 in the Feed Gas KOD drain line will close (if open).
d. 21/22-UV-1201 in the Glycol Absorber bottom line will close thereby stopping the flow of
glycol to regeneration section.
e. 21/22-UV-1202 in the Glycol Filter separator bottom outlet line will close (if open) there
by stopping the glycol flow to regeneration section.
f. 21/22-UV-1203 in the dehydrated gas to DPDU will close, to prevent any backflow from
downstream unit.
g. 21/22-UV-1204 in the Glycol Filter separator side outlet line will close (if open) there by
stopping the glycol flow to regeneration section.
h. 21/22-UV-1501in the HP steam line to Reboiler will close, thereby stopping the flow of
HP steam to reboiler.
i. Shutdown of Glycol Injection Pump 21/22-P-101 A/B, thereby stopping the flow of lean
glycol.
j. Shutdown of Glycol transfer Pump 21/22-P-102, thereby stopping the flow of lean glycol
flow to surge drum.
k. Shutdown Glycol Drain Pump 21/22-P-103 (if running).

5.6 EMERGENCY PROCEDURES:

GENERAL
In a process plant, sometime during start up/shut down, leak cases, control valve failure,
non-adherence to operating procedure, results in abnormal situation which may have
normal to serious adverse affects. Operating emergencies develop when, for some
uncontrolled situation, normal operation is not possible. Emergencies resulting from
failure of equipment, loss of Feed, instrumentation failure, usually require an immediate
shutdown of the plant. The sudden loss of electrical power, instrument air or other
utilities could also cause a plant shutdown. However, in some cases, the plant may be
kept on stream until the fault is corrected. Certain features have been designed in the
plant to minimize the severity of an emergency like detectors, various types of alarms
and trips, interlock system, emergency push buttons.

Certain features may be adopted to ensure these situations could be avoided or if arises
could be carefully controlled. These features include before taking up any job, job safety
analysis to be done, adherence to standard operating procedure, clarity about standard

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operating conditions, toxic gas release management plan, safety guidelines, regular
emergency control plan drills, etc..

In an emergency, as the nature and degree of emergency can vary from time to time.
However, the following procedures detail the work to be performed for personnel and
equipment safety, during the various possible emergency situations. The following steps
are only a general guide for the operating crew, as special problems may arise at
different times, when human judgment, patience and presence of mind determine the
success of the corrective action taken. The operating crew should be thoroughly familiar
with the emergency procedures and understand the reason of each move. They should
always intention to avoid personal injury, minimize loss of production and save plant
property from damage during such situations.

5.6.1 LOSS OF ELECTRICAL POWER

Effect:
The following pumps, driven by electrical motors (with running indication on DCS), will
stop:

21/22-P-101 A/B Lean Glycol Injection Pump

21/22-P-102 Glycol Transfer Pump

21/22-P-103 Glycol Drain pump

21/22-P-104 Fresh Glycol Pump

On tripping of Lean Glycol Injection Pump, 21/22-I-4, interlock will actuate which will
close 21/22-UV-1101, 21/22-UV-1203.
Actions to be taken:

Depending on situation, following actions should be taken as early as possible:-

• Open 21/22-PV-1204(Through ESD) to depressurize the unit to HP Flare. This will

actuate interlock 21-I-10 which will close 21/22-UV-1101, 21/22-UV-1102, 21/22-UV-

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1201, 21/22-UV-1202, 21/22-UV-1203, 21/22-UV-1204, 21/22-UV-1501 and trip pumps

21/22-P-101 A/B, 21/22-P-102 and 21/22-P-103.

• Close isolation valves on HP Steam supply to the Glycol Reboiler and open condensate
drain valve. Close Respective LV on condensate line.

• Close discharge valves of all centrifugal pumps.

• Observe level in respective vessels.

• Inform all related units about power failure.

• When power supply is resumed establishes Glycol circulation as per routine start-up
procedure and gradually take regenerator in line and then take feed in.

5.6.2 LOSS OF STEAM

This will badly affect Glycol Regeneration process which may affect glycol quality and
leading to wastage of glycol wastage.

Effects:

• No HP steam supply to Glycol reboiler. Glycol regeneration will stop.

• Due to loss of condensate, the Pure Condensate Recovery will stop.

Actions to be taken:

• If steam failure is for a short duration, close 121/22-UV-1501 and close isolation valve
of steam line and LV in condensate line and open drain in condensate line.

• Continue normal Glycol circulation circulation through all absorber and regenerator.

• if steam failure is for longer duration, then Open 21/22-PV-1204(Through ESD) to

depressurize the unit to HP Flare. This will actuate interlock 21-I-10 which will close
21/22-UV-1101, 21/22-UV-1102, 21/22-UV-1201, 21/22-UV-1202, 21/22-UV-1203,
21/22-UV-1204, 21/22-UV-1501 and trip pumps 21/22-P-101 A/B, 21/22-P-102 and
21/22-P-103. inform DPDU regarding same.

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• After supply is restored, recharge steam header and open condensate pot LPD and
keep draining till live steam start coming out.
5.6.3 LOSS OF COOLING WATER

Effect: Loss of cooling water will heat the pump as BCW will also be not available, so

pump cannot be kept running as there is chance of bearing getting ceased.

Cooling water failure of the following coolers will take place:

(i) 21/22-E-101: Lean Glycol Cooler

Hot Lean Glycol will go to absorption section

Actions to be taken:

• Cut off steam supply to the regenerator reboiler manually and closed condensate LV and
open LPD to start draining condensate pot.

• Start venting to acid flare from regenerator to maintain pressure if required.

• Initiate immediate shut down as we will not be able to use pumps. Emergency shut down
could be initiated by Opening 21/22-PV-1204(Through ESD) to depressurize the unit to
HP Flare. This will actuate interlock 21-I-10 which will close 21/22-UV-1101, 21/22-UV-
1102, 21/22-UV-1201, 21/22-UV-1202, 21/22-UV-1203, 21/22-UV-1204, 21/22-UV-1501
and trip pumps 21/22-P-101 A/B, 21/22-P-102 and 21/22-P-103. Inform DPDU regarding
same.

• Open cooling water outlet side vent on all coolers/condensers.

• When cooling water supply is resumed, bring back the unit in service

5.6.4 LOSS OF INSTRUMENT AIR

In the event of loss of instrument air, the pneumatic instruments will not indicate/record
the correct operating parameters. All the control valves will return to their fail safe
positions as indicated in table below:

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Sr. No. Tag No. Description Failure Position

1. 21/22-FV-1101 Sweet Gas Feed line to Feed Gas KOD Fail Open
Condensate from Feed GAS KOD to ABD
2. 21/22-LV-1101 Fail Close
Header
3. 21/22-LV-1201 Rich TEG from Glycol Absorber Fail Close
Rich TEG from Glycol Filter Separator
4. 21/22-LV-1202 Fail Close
Bottom
5. 21/22-LV-1203 Rich TEG from Glycol Filter Separator Top Fail close
Dry Gas to HP Flare from Glycol Filter
6. 21/22-PV-1204 Fail Open
Separator
H/C condensate from Rich Glycol
7. 21/22-LV-1301 Fail Close
Degassing Drum
8. 21/22-TV-1501 Rich TEG to Glycol Reflux Condenser Fail Close
9. 21/22-TV-1502 HP Steam to Glycol Reboiler Fail Close
10. 21/22-LV-1504 Condensate to GSU condensate Header Fail Close
11. 21/22-LV-1502 Rich TEG to Glycol Regenerator Fail Close

If the instrument air failure is of small duration (for few minutes) it is possible to keep the
unit on stream by taking the various controls on bypass and checking the temperatures,
pressures and levels locally. The control valves should be operated manually by the
hand wheels provided or the bypass globe valves should be adjusted which ever may be
the case.
Remember it is not advisable to operate plant on such manual mode for longer duration
as the controlling of various parameters become difficult and also it is unsafe. Hence, it
is always advisable to take shut down following normal shutdown procedure in case of
instrument air failure.
Emergency shut down could be initiated by Opening 21/22-PV-1204(Through ESD) to
depressurize the unit to HP Flare. This will actuate interlock 21-I-10 which will close
21/22-UV-1101, 21/22-UV-1102, 21/22-UV-1201, 21/22-UV-1202, 21/22-UV-1203,
21/22-UV-1204, 21/22-UV-1501 and trip pumps 21/22-P-101 A/B, 21/22-P-102 and
21/22-P-103. Inform DPDU regarding same.

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5.7 SAMPLING PROCEDURE

Control tests provide the information to the operating staff for making necessary adjustments to
get the maximum output and “on-spec” quality products. The control tests are to be made at all
steps to monitor the intermediate and final products whether or not they are at the desired
specification. Samples are taken and analyzed at regular intervals such that the operation of the
plant are monitored and any deviation (from specification will indicate some mal-operation /
malfunction of the plant which can be spotted and rectified in time without undue loss of time
and product. Sometimes, samples are taken to find out the effect of certain changes brought
about in the operating conditions. The samples are to be taken with great care so that the
samples are representative samples. The frequency of sampling, the type of analysis and points
where samples are to be taken are generally specified by the process licensor. During
guarantee tests some additional samples can be taken at higher frequencies, which will be
specified, in the technical procedures prior to test run. The following guidelines should be
followed while collecting samples.

a) Liquid Sampling Procedure (Non-Flashing Type)

i. The person taking samples should wear proper or appropriate safety clothing like face
shields, aprons, rubber gloves etc. to protect face, hands and body.
ii. Whenever hot samples are taken, check cooling water flow in the sample cooler is
circulating properly.
iii. Sample points usually have two valves in series. One gate valve for isolation (tight shutoff)
and other globe valve for regulating the flow. Open gate valve first and then slowly open the
globe valve after properly placing the sample containers. After the sampling is over, close
the globe valve, first and then the gate valve. Then again open the globe valve and drain the
hold up between the gate and globe valve in case of congealing liquid.
iv. Sample valve should be slowly opened, first slightly to check for plugging. If the plugging is
released suddenly, the liquid will escape at a dangerously uncontrolled rate. Never tap the
line to release the plugging. Call the maintenance gang to properly unplug the line. In case
of congealing type samples, sample point should be equipped with copper coil type steam
tracer. It should be ensured that steam-tracing line is functioning normally.
v. The operator taking the sample should be careful to stand in a position such that the liquid
does not splash on him and he has unobstructed way out from the sample point in case of
accident.

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vi. While taking dangerous toxic material for sampling, it will act as an observer for safety.
Proper gas mask is to be used. It is advisable to stand opposite to wind direction in case of
volatile toxic liquid.
vii. Sample should be collected in clean, dry and stoppered bottle. In case of congealing
samples use clean dry ladle.
viii. Rinsing of the bottle should be thorough before actual collection.
ix. Before collecting, ensure that the line content has been drained and fresh sample is coming.
x. Gradually warm up the sample bottle / metallic can by repeated rinsing before collecting the
sample.
xi. Stop the bottle immediately after collection of sample.
xii. Attach a tag to the bottle indicating date, time, and name of the product and tests to be
carried out.
xiii. A few products suffer deterioration with time.
xiv. For example, the colour of the heavier distillates slowly deteriorates with time. So these
samples should be sent to laboratory at the earliest after collection.
The samples after collection should be kept away from any source of ignition to minimize fire
hazard.

Volatile samples (e.g. naphtha) should be collected in bottles and kept in ice particularly for
some critical test like RVP.

b) High Pressure Hydrocarbon Liquid Samples (Flashing Type)

i. The person taking sample should use personal protection appliances like apron, gas mask
and hand gloves to protect himself.
ii. Ensure that sample bomb is empty, clean and dry.
iii. Connect the sample bomb inlet valve to the sample point with a flexible hose.
iv. Open the inlet and outlet valves of the sample bomb. Hold the sample bomb. Hold the
sample bomb outlet away from person. Keep face away from hydrocarbon vapour and
stand in such a way that prevalent wind should blow hydrocarbon vapour away. Open the
gate valve of sample point slowly till full open. Then slowly cracks open the regulating
valve. One should be careful at the time of draining, because chance of icing is there. As a
result, the formation of solid hydrates is a continuing process, which leads to the plugging
of valves.

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v. When all the air in the hose and bomb are displaced as seen by the hydrocarbon vapour
rising from the outlet of sample bomb close the sample outlet valve. Allow a little quantity of
liquid to spill to make sure that the bomb is receiving liquid. Frosting will be an indication of
liquid spillage.
vi. Allow liquid hydrocarbon to fill the bomb. When the bomb is full up to the specified level,
close both the valves on sample point. Close inlet valve on the sample point.
vii. Carefully disconnect the hose from the sample bomb. To allow for some vapour space in
the bomb for thermal expansion in case of overfilling, crack open the outlet valve of bomb
and discharge a small part of the liquid. Close outlet valve.
viii. Closed sampling facilities are provided at some locations where it is not desirable to waste
the costly product or if the material is toxic. For filling the sampling bomb, pressure drop
across a control valve is usually utilized or across pump discharge & suction. Air is expelled
from the bomb after it is connected to upstream of control valve or pump discharge side.
The sample is then collected and bomb is detached after closing valves on both sides.
ix. Send sample bomb to laboratory for analysis. Protect the bomb from heat exposure.

c) Gas Sample

For collection of gas sample, which are not under high pressure and temperature, rubber
bladders are used. For the operations under vacuum or low pressure, aspirator is used. For
representative sample, purge the bladder 3 to 4 times with the gas and then take the final
sample. Use of 3 ways valve with bladder / aspirator will facilitate purging and sampling.
Sample bombs are to be used for taking gas samples from high pressure and high
temperature source. Procedure mentioned under high-pressure liquid sampling (flashing
type) is to be used.
However Routine Sample Schedule and sampling frequency for GDU unit to be decided by
client based upon operational requirement

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SECTION -6
GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT

6.1 GENERAL
This section covers the general procedure for operation and trouble shooting of commonly used
equipment like pumps, heat exchangers and furnace etc. For specific information and more detail
refer to vendor's manuals.

6.2 CENTRIFUGAL PUMPS

6.2.1. Start-up
− Inspect and see if all the mechanical jobs are completed.
− Establish cooling water flow where there is such provision. Also open steam for seal
quenching in pumps having such facilities.
− Check oil level in the bearing housing, flushing may be necessary if oil is dirty or contains
some foreign material.
− Rotate the shaft by hand to ensure that it is free and coupling is secure. Coupling guard
should be in position and secured properly.
− Open suction valve. Ensure that the casing is full of liquid. Bleed, if necessary, from the
bleeder valve.
− Energize the motor. Start the pump and check the direction of rotation. Rectify the direction
of rotation if it is not right.
− Check the discharge pressure. Bleed if necessary to avoid vapour locking.
− Open the discharge valve slowly. Keep watch on the current drawn by the motor, if
ammeter is provided. In other cases check at motor control centre.

In some pumps a by-pass has been provided across the check valve and discharge valve to keep
the idle pump hot. In such pumps, the by-pass valve should be closed before starting the pump. It
should be ensured that casing of these pumps are heated up sufficiently prior to starting of the
pump to guard against damage of the equipment and associated piping due to thermal shock.

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6.2.2. Shutdown
− Close discharge valve fully.
− Stop the pump
i. If pump is going to remain as standby and has provision for keeping the pump hot, proceed as
follows:
− Open the valve in the by-pass line across the discharge valve and check valve.
− The circulation rate should not be so high to cause reverse rotation of idle pump and also
overloading of the running pump.
ii. If pump is to be prepared for maintenance, proceed as follows:
− Close suction and discharge valves.
− Close valve on check valve by-pass line, if provided.
− Close cooling water to bearing, if provided. Also shut off steam for seal quenching, if
provided.
− Slowly open pump bleeder and drain liquid from pump if the liquid is very hot allow
sufficient time before draining is started. Ensure that there is no pressure in the pump.
Also drain pump casing.
− Blind suction and discharge and check valve by-pass line and flare connection if any.
− Cut-off electrical supply to pump motor prior to handling over for maintenance.

6.2.3. Trouble Shooting

i. Pump not developing pressure
− Bleed to expel vapor/air
− Check the lining up in the suction side.
− Check the suction strainer.
− Check the liquid level from where the pump is taking suction.
− Check the pump coupling and rotation.
− Get the pump checked by a technician.
ii. Unusual Noise
− Check the coupling guard if it is touching.
− Check for proper fixing of fan and fan cover.,
− Check for pump cavitation.
− Get the pump checked by a technician.

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iii. Rise of Bearing Temperature

Generally the bearing oil temperature upto 80 oC or 50 oC above ambient whichever is lower, can
be tolerated.
− Arrange lubrication if bearing is running dry or oil level is low.
− Adjust cooling water to the bearing housing, if there is such provision.
− Stop the pump, if temperature is too high, call the pump technician.
iv. Hot Gland
− Adjust cooling water if facility exists.
− Slightly loosen the gland nut, if possible.
− Stop the pump and hand over to maintenance.
− Arrange external cooling if pump has to be run for sometime.
v. Unusual Vibration
− Check the foundation bolts.
− Check the fan cover for looseness.
− Stop the pump and hand over to maintenance.
vi. Leaky Gland
− Check the pump discharge pressure.
− Tighten the gland nut slowly, if possible.
− Prepare the pump for gland packing or adjustment/replacement of mechanical seal as the
case may be.
vii. Mechanical Seal Leak
− Stop and isolate the pump and hand over to maintenance.

6.3 POSITIVE DISPLACEMENT PUMPS

6.3.1. Start-up
i. Check if all mechanical jobs are completed.
ii. Flush and renew oil in pump gear box.
iii. Check whether suction strainer is installed.
iv. Check for proper lining up including the pressure safety valve in the discharge. Open suction
valve fully.
v. Check that the motor shaft is reasonably free and coupling secured. Coupling guard should be
in position.

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vi. Energize motor. Open discharge valve. Start the motor and check direction of rotation. Stop
and rectify if direction of rotation is wrong.
vii. Adjust the pump stroke and run the pump at different settings. Watch discharge pressure and
check the rate of pumping using the flow meter or by taking suction from the calibration pot. In
case the pump is provided with a pressure controller adjust it to obtain the required discharge
pressure.
viii. Care should be taken to avoid dry running of pump and back flow of liquid. Bleed if necessary
to expel vapour /air.
ix. Check for unusual noise, vibrations, rise of temperature of both motor and gears.

6.3.2. Shutdown
− Stop the pump.
− Close the suction and discharge valves.
− Drain the liquid if maintenance jobs are to be carried out on the pump.

6.3.3. Trouble Shooting

i. Insufficient Discharge Pressure
− Check the lining up in the suction side.
− Check the functioning of the safety valve and pressure control valve on discharge to
suction.
− Check the strainer on the suction side.
− Check for insufficient liquid level in the tank.
− Check the pump coupling and rotation.
− Get the pump checked by pump technician.
ii. High Discharge Pressure
− Check the line up on the discharge side.
− Check pressure control valve opening.
iii. Leak Gland
− Check for normal pump discharge pressure.
− Tighten the gland nut slowly if possible.
− Hand over the pump for replacing gland packing.
iv. Unusual Vibrations

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− Check the foundation bolts.

− Check motor fan cover for looseness.
− Stop the pump and hand over to maintenance.

6.4 HEAT EXCHANGERS

GENERAL
The unit has a number of heat exchangers. Suitable valve arrangement for bypassing and
isolation is provided wherever necessary to offer the required operational flexibility.

The exchangers have been provided with draining and flushing connections. The coolers and
condensers have been provided with TSV's on the cooling water side to guard against possible
rise of pressure due to faulty operations with the safety release to atmosphere. Temperature
gauges or thermo wells have been provided at the inlet and outlet of exchangers. Where water is
the cooling medium, no temperature measurement is provided for water inlet temperature which is
the same as cooling water supply header temperature.

EXCHANGERS
Shell and Tube type heat exchangers can be broadly classified into following types: -
− Water Coolers/condensers
− Steam heaters (reboiler)
− Exchangers

Start-up /shut down procedures for each unit shall vary slightly from case to case. However,
general start-up /shut-down procedures are discussed in the following paragraphs.

6.4.1. Start-Up
After the heat exchanger has been pressure tested and all blinds removed, proceed as follows:
i. Open cooling medium vent valve to displace non-condensable (air, fuel gas, inert gas etc.)
from the system. Ensure the drain valves are capped. For high pressure system, drain
valves should be flanged. This activity is not required if gas is the medium.
ii. Open cooling medium inlet valve. Close vent valve when liquid starts coming out through it,
then open cold medium outlet valve and fully open the inlet valve also. Where cold medium
is also hot, warming up of cold medium side gradually is also essential.

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iii. Open hot medium side vent valve to displace non condensable (air, fuel inert gas etc.).
Check that the drain is closed and capped. This activity is not required if gas is the medium.
iv. Crack open hot medium inlet valve. When liquid starts coming out from the vent valve,
close it. Open hot medium inlet valve and then open the outlet valve fully. In case of steam
heaters, initially the condensate shall be drained to sewer till pressure in the system builds
up to a level where it can be lined up to the return condensate header.
v. In case by passes are provided across shells and tube side, gradually close the bypass on
the cold medium side and then the bypass across the hot medium side.
vi. Check for normal inlet and outlet temperatures. Check that TSVs are not popping.
vii. The operation of inlet and outlet valves should be done carefully ensuring that the
exchangers are not subjected to thermal shock.
viii. In case of coolers/condensers, adjust the water flow to maintain the required temperatures
at the outlet.
ix. For avoiding fouling, velocity of water should be at least 1 m/sec in a cooler/condenser.

6.4.2. Shutdown

Shut down of an exchanger, coolers, condenser is considered when the equipment is to be

isolated for handling over to maintenance while the main plant is in operation. The following is the
suggested procedure for isolation of the piece of equipment

i. Isolate the hot medium first. In case both hot and cold medium are from process streams,
exchanger shall remain in service till the hot stream has cooled down enough.
ii. In case of a cooler, adjust cooling water flow to the cooler which is in line so that product
temperature is within allowable unit.
iii. Isolate the cold medium next.
iv. Drain out the shell and tube sides to OWS/Sewer/Closed blow down system as applicable.
In case flushing oil connection is given flush the exchanger to CBD. Ensure that the CBD drum
has sufficient level to receive the flushing of the exchanger
v. Depressurize the system to atmosphere/flare/blow down system as applicable.
vi. Purge/flush if required. This is particularly important in congealing services.
vii. Blind inlet and outlet lines before handing over the equipment for maintenance.

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SECTION -7
SAFETY PROCEDURE

7.1 INTRODUCTION
Safety of personnel and equipment is very important. Ignorance of the details of the unit or the
techniques of safe and efficient operation reduces the margin of safety of personnel and subjects
the equipment to more hazardous conditions. All the operating and maintenance crew therefore
must be fully familiar with the equipment and materials being handled in the unit, and recognize the
hazards involved in handling them and the measures taken to ensure safe operations. Since unit
operates at high pressure, so keeping that in mind, pertinent safety guidelines to be adopted.

7.2 SAFETY OF PERSONNEL

General safety rules which shall be practiced and enforces for all personnel who enter the unit are
summarized below:
a. Safety helmets and boots shall be worn by all personnel at all times in the plant. They may be
removed when inside rooms or buildings which do not have overhead or other hazards.
b. Smoking shall be permitted only in specified areas which are clad as non-hazardous and are
pressurized through a ventilation system. Failure of the ventilation system automatically
cancels the smoking privilege until the system is repaired, inspected and authorized operation.
c. Each employees assigned to work in the unit shall know where the safety and fire suppression
equipment is located and how to operate this equipment.
d. Safety glasses, goggles or face shields shall be worn while performing work which could result
in eye or face injury.
e. Operations personnel golden rule:
Do not open or close any valve without first determining the effect.
Note: - Treat each piece of equipment or piping as if it is under pressure.

7.3 WORK PERMIT PROCEDURE

A work permit system must be issued by the appropriate operations group before commencing
any maintenance work affecting the operation of the unit. The work permit is issued for “Hot”
and “Cold” work. The “Hot” work permit must include as a minimum, a precise description and
mode of execution of “Hot” works, the equipment to be used, the expected time during which
“Hot” works is scheduled to start and expected completion, an exact location of the “Hot “ works

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and precautions to be taken. identification of location in field is to be made in advance and it

should be highlighted by adopting marking, wrapping red tap, etc. this should be recorded to
avoid unintended hot work on undesirable pipeline at piperack.

Unit areas are generally identified as hazardous areas as far as the threat of fire is concerned.
Therefore, in order to carryout works within these areas, a written work permit is required. The
work permit, when approved, indicates that a specific work can be carried out in safe conditions
provided that all safety precautions are observed.

a) Permit for “Hot” work

Permits of hot works are required for any work involving the use of or generation of heat sufficient
to ignite flammable substances. Typical sources of ignition are:
− Electric and gas welding
− Any machine capable of producing a spark
− Not explosion-proof electrical equipment
− Internal combustion engines
− Ferrous tools, both hand operated and pneumatic or other type

b) Permits for Cold-Work

Permits for cold-work are required for any work not involving the use of a local ignition source.
Typical examples of cold-work are:
− Disconnecting of lines for the insertion of blinds etc.
− Opening of any equipment such as vessels, filters, etc.

c) Entry permits
Entry permits are required for entering enclosed spaces such as vessels, sewer, pits, trenches,
etc. The use of any tool or machinery, which could provide a source of ignition, is forbidden.
Also, prior to entry it should be ensured that area is well ventilated and the oxygen content in air
is about 21/22% by volume. Fresh air flow is to be ensured in the enclosed space through out
the duration of work. A gas test for H2S and flammable gases should also be performed before
entry. A person should also be on alert outside the enclosed space for rescue in case of
emergency. Procedure for carrying out work and rescue plan shall be formulated before
commencement of work.

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d) Guidelines for release of permits

− The equipment item, on which works have to be carried out, shall be clearly indicated.
During the shutdown of any system, permits covering the whole section with above
mentioned item shall be issued, if possible. The type of work permitted shall be clearly
indicated.
− The date and the period of validity of the permit shall also be indicated. If the work does not
get over within the period of validity of the permit, the permit can be extended provided that,
at each start of the works the safety conditions are checked again and signed by the
operator in-charge and by safety officer. Beyond this extended period, a next permit will
have to be issued. The explosiveness test and the check of toxic gases shall be performed
always at the last moment before each start of the work and subsequently every time the
work is resumed or whenever doubts arise.
− The validity of the permit can be cancelled at any moment by the operator or by safety
officer; in case they deem that the conditions are not safe.
− The conditions to be complied with shall include special precautions, such as the use of
protective clothing, breathing apparatus, safety equipment and the tools to be used etc.
− No one shall be allowed to enter the vessel or other enclosed spaces without suitable
protective clothing and until the vessels or the enclosed spaces become safe for entry by
means of proper isolation, proper ventilation and suitable check of the atmosphere inside
and availability of rescue person outside the enclosed equipment.

If welding or hot work is to be done ensure that:-

− Fire fighting system is ready
− Close the neighbouring surface drains with wet gunny bags
− Keep water flowing in the neighbouring area to cool down any spark.
− Responsible operation supervisor should be present at the place of hot work till the first
torch is lighted.

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7.4 PREPARATION OF EQUIPMENT FOR MAINTENANCE

a) Process Equipment: Towers, Vessels etc.
Before opening any equipment, it should be purged to render the internal atmosphere non-
explosive and breathable. Operations to be carried out are: -
− Isolation with valves and blinds.
− Draining and depressurization.
− Replacement of vapours or gas by steam, water or inert gas.
− Take care about instrument tapping.
− Washing of towers and vessels with water.
− Ventilation of equipment.
− Opening of top manhole.
− Testing of inside atmosphere with explosive meter.
− Complete opening if inside atmosphere is satisfactory.
− Analyze the atmosphere inside for O2 content and any poisonous gas.

Note: Open a vent on the upper part of the vessel to allow gases to escape during filling and to
allow air inside the vessel during draining. Ensure proper ventilation inside the vessel by
opening all manholes. For hydrocarbon or other gases, pressurize the vessel with N2 or gas
and fill in the liquid and drain under pressure. This is to avoid hydrocarbon going to
atmosphere.
b) Precautions before Handing Over Equipment
Following items should be checked by a responsible operating supervisor before the equipment is
handed over for maintenance after it has been purged.
− Ascertain that equipment is isolated by proper valves and blinds.
− Ascertain that there is no pressure of hydrocarbons in the lines, vessels and equipment.
− Purge the system with N2 first and later by air and check for O2 content at vent and drain to
ensure that the vessel is full of air.
− Check that steam injection lines and any inert line connections are disconnected or
isolated from the equipment.
− Provide tags on the various blinds to avoid mistakes. Maintain a register for blinds.
− Check for pyrophoric iron and if existing, keep this wet with water.
− Keep the surrounding area cleaned up.

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− Get explosive meter test done in vessels, lines, equipment and surrounding areas.
If welding or hot work is to be done, also:
− Keep fire fighting devices ready for use nearby.
− Close the neighbouring surface drains with wet gunny bags.
− Keep water flowing in the neighbouring area to cool down any spark bits etc.
− Keep stem lancers ready for use.

After the above operations have been made, a safety permit should be issued for carrying out the
work. A responsible operating supervisor should be personally present at the place of hot work till
the first torch is lighted. Hot work should be immediately suspended if instructed by the supervisor
or on detecting any unsafe condition. When people have to enter a vessel for inspection or other
work, one person should stand outside near the manhole of the vessel for any help needed by the
persons working inside. The person entering the vessel should have tied on his waist a rope to
enable pulling him out in case of urgency. Detail procedure for preparation for vessel entry is given
in next sub-section.

7.5 PREPARATION FOR VESSEL ENTRY

The most common potential hazards in vessel entry are:
− Unit Checkout Prior to Start-up
− Turnaround Inspections
− Reactor Loading
− Reactor Unloading
The precautions apply equally to entry into all forms of vessels, including those enclosed areas
which might not normally be considered vessels. Examples include: Reactors, Columns,
Separators, Receivers, Clay Treater, Fired heaters, Sumps

Positive Vessel Isolation

Every line connecting to a nozzle on the vessel to be entered must be blinded at the vessel.
This includes drains connecting to a closed sewer, utility connections and all process lines. The
location of each blind should be marked on a master piping and instrumentation diagram
(P&ID), each blind should be tagged with a number and a list of all blinds and their locations
should be maintained. One person should be given responsibility for the all blinds in the unit to
avoid human errors.

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The area around the vessel manways should also be surveyed for possible sources of
dangerous gases which might enter the vessel while the person is inside. Examples include
acetylene cylinders for welding and process vent or drain connections in the same or adjoining
units. Any hazards found in the survey should be isolated or removed.

Vessel Access
Safe access must be provided both to the exterior and interior of the vessel to be entered. The
exterior access should be a solid, permanent ladder and platform or scaffolding strong enough
to support the people and equipment who will be involved in the work to be performed.

Access to the interior should also the strong and solid. Scaffolding is preferred when the vessel
is large enough. The scaffolding base should rest firmly on the bottom of the vessel and be
solidly anchored. During vessel access activity, a safety observation plan to be made to ensure
proper safety measures are being adopted.

If the scaffolding is tall, the scaffolding should be supported in several places to prevent sway.
The platform boards should be sturdy and capable of supporting several people and equipment
at the same time and also be firmly fastened down. Rungs should be provided on the
scaffolding spaced at a comfortable distance for climbing on the structure.

If scaffolding will not fit in the vessel a ladder can be used. A rigid ladder is always preferred
over a rope ladder and is essential to avoid fatigue during lengthy periods of work inside a
vessel. The bottom and top of the ladder should be solidly anchored. If additional support is
available, then the ladder should also be anchored at intermediate locations. When possible, a
solid support should pass through the ladder under a rung, thereby providing support for the
entire weight should the bottom support fail. Only one person at a time should be allowed on
the ladder.

When a rope ladder is used, the ropes should be thoroughly inspected prior to each new job.
All rungs should be tested for strength, whether they are made of metal or wood. Each rope
must be individually secured to an immovable support. If possible, a solid support should pass
through the ladder so that a rung can help support the weight and the bottom of the ladder

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should be fastened to a support to prevent the ladder from swinging. As with the rigid ladder,
only one person should climb the ladder at a time.
Wearing of a Safety Harness
Any person entering a vessel should wear a safety harness with an attached safety line. The
harness is not complete without the safety line. The harness should be strong and fastened in
such a manner that it can prevent a fall in the event the man slips and so that it can be used to
extricate the man from the vessel in the event he encounters difficulty. A parachute type harness
is preferred over a belt because it allows an unconscious person to be lifted from the shoulders,
making it easier to remove him from a tight place such as an internal manway. A minimum of one
harness for each person entering the vessel and at least one spare harness for the people
watching the manway should be provided at the vessel entry.

Providing a Manway Watch

Before a person enters a vessel, there should be a minimum of two people available outside of
the vessel, one of whom should be specifically assigned responsibility to observe the activity of
the people inside of the vessel. The other person must remain available in close proximity to
the person watching the manway so that he can assist the person or go for help, if necessary.
He must also be alert for events outside of the vessel which might require the people inside to
come out of the vessel, for example, a nearby leak or fire. These people should not leave their
post until the people inside have safely evacuated the vessel.

A communication system should be provided for the man way watch so that they can quickly
call for help in the event that the personnel inside of the vessel encounter difficulty. A radio,
telephone, or public address system is necessary for that purpose.

Providing Fresh Air

The vessel must be purged completely free of any H/C gases and inventoried with fresh air
before permitting anyone to enter. The responsible department, usually the safety department,
must test the atmosphere within the vessel for toxic gases, oxygen and explosive gases before
entry. This must be repeated every 4 hours while there are people inside the vessel. Each point
of entry and any dead areas inside of the vessel, such as receiver boots or areas behind
internal baffles, where there is little air circulation should be checked.

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Fresh air can be circulated through the vessel using an air mover, a fan, or, for the cases where
moisture is concern, the vessel can be purged using dry certified instrument air from a hose or
hard piped connection. When an air mover is used, make certain that the gas driver uses plant
air, not nitrogen, and direct the exhaust of the driver out of the vessel to guarantee that this gas
does not enter the vessel. When instrument air is used, it must be confirmed that a check of the
supply header is made to ensure that it is properly lined up and that there are no connections
where nitrogen can enter the system (nitrogen improperly used as a backup for instrument air
by some refiners). The fresh air purge should be continued throughout the time that people are
inside of the vessel. The responsible control room should be informed that instrument air is
being used for breathing so that if a change to nitrogen is required the people are removed from
the affected vessel.

A minimum of one fresh air mask for each person entering the vessel and at least one spare
mask for the hole watcher should be provided at the vessel entry. These masks should
completely cover the face, including the eyes, and have a second seal around the mouth and
nose. When use of the mask is required, it must first be donned outside of the vessel where it is
easy to render assistance in order to confirm that the air supply is safe. Each mask must have a
backup air supply that is completely independent of the main supply. It must also be
independent of electrical power. This supply is typically a small, certified cylinder fastened to the
safety harness and connected to the main supply line via a special regulator that activates when
the air pressure to the mask drops below normal. The auxiliary supply should have an alarm
which alerts the user that he is on backup supply and it should be sufficiently large to give the
user 5 minutes to escape from danger.

Preparation of Vessel Entry Permit

Before entering the vessel a vessel entry permit must be obtained. A vessel entry permit
ensures that all responsible parties know that work is being conducted inside of a vessel and
establishes a safe preparation procedure to follow in order to prevent mistakes which could
result in an accident. The permit is typically issued by the safety engineer or by the shift
supervisor. The permit should be based on a safety checklist to be completed before it is
issued. The permit should also require the signatures of the safety engineer, the shift
supervisor, and the person that preformed the oxygen toxic and explosive gas check on the
vessel atmosphere. Four copies of the permit should be provided. One copy goes to the safety

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engineer, one to the shift supervisor, one to the control room, and one copy should be posted
prominently on the man way through which the personnel will enter the vessel. The permit
should be renewed before each shift and all copies of the permit should be returned to the
safety engineer when the work is complete. Additional requirements or procedures may be
imposed by the refiner, but the foregoing is considered the minimum acceptable for good safety
practice.

Checkout Prior to New Unit Start-up

The risk of exposure to hydrocarbon, toxic or poisonous gases, and catalyst dust is low during a
new unit checkout; the primary danger is nitrogen. There will be pressure testing, line flushing,
hydrotesting, and possibly chemical cleaning being conducted in the unit and nitrogen may be
used during any of these activities. Some of the equipment may have been inventoried with
nitrogen to protect the internals from corrosion. An additional hazard is posed by operations in
other parts of the plant which may be beyond the control of the people entering the vessel so
that action taken at a remote location could admit nitrogen, fuel gas, steam, or other dangerous
material through a connecting process line into the vessel which is being entered. For these
reasons vessel entry procedures must still be rigorously followed during the checkout of a new
unit.

The oxygen content of the atmosphere inside of the vessel should be checked before every
entry and the vessel should be blinded. Independent blinds at each vessel nozzle are preferred.
However, in the event that many vessels are to be entered in a new unit which is separate from
the rest of the plant, the entire unit can be isolated by installing blinds at the battery limits rather
than by individually isolating every vessel nozzle.

Inspections during Turnarounds

In turnaround inspections, the possibility that vessels will contain dangerous gases is much
higher. Equipment which has been in service must be thoroughly purged before entry. The
vessel should have been steamed out unless steam presents a hazard o the internals and then
fresh air circulated through it until all traces of hydrocarbons are gone. If liquid hydrocarbon
remains or if odours persist afterwards, repeat the purging procedure until the vessel is clean.
The service history of the vessel must also be investigated before entry so that appropriate
precautions may be taken. The service may require a neutralization step or a special cleaning

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step to make the vessel safe. Internal scale can trap poisonous gases such as hydrogen
sulphide or hydrogen fluoride which may be released when the scale is disturbed. If this sort of
danger is present, fresh air masks and protective clothing may be required to be worn while
working inside of the equipment.

In a turnaround inspection, every vessel nozzle must be blinded at the vessel with absolutely no
exceptions. There will always be process material at the low and high points in the lines
connecting to the vessel because it is not possible to purge them completely clean. The blinds
must all be in place before the vessel is purge.

Another factor to be cautious of, especially if entering a vessel immediately after the unit has
been shut down, is heat stress. The internals of the vessels can still be very hot from the
steam-out procedure or from operations prior to the shutdown. If that is the case, the period of
time spent working inside of the vessel should be limited and frequent breaks should be taken
outside of the vessel.

7.6 HAZARDOUS CHEMICAL HANDLING

Hazardous properties of chemicals and their handling procedure are available in Material Safety
Datasheet. In storage area key points from MSDS of TEG may be noted down as display board so
that operator may know how to deal with abnormal situation like leak, etc.

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ANNEXURE-I

PROCESS FLOW DIAGRAM

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ANNEXURE-II

PIPING AND INSTRUMENTATION DIAGRAM

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ANNEXURE-III

MSDS OF TEG

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