You are on page 1of 41

VIETNAM OIL AND GAS CORPORATION

(PETROVIETNAM)
DUNG QUAT REFINERY

OPERATING MANUAL
VOLUME 36

JETTY TOPSIDES
(MARINE LOADING)
UNIT 081
BOOK 1/X
8474L-081-ML-001- A

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

TABLE OF CONTENTS
BASIS OF DESIGN

1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2.

DUTY OF PLANT
FEED CHARACTERISTICS
PRODUCT SPECIFICATION
MATERIAL BALANCE
BATTERY LIMIT CONDITIONS
DESIGN FEATURES
GAS AND LIQUID EFFLUENTS
DESCRIPTION OF PROCESS

2.1
2.2
2.3
2.4
3.

LOADING ARMS AND CUSTODY METERS


SLOPS AND OILY WATER COLLECTION
LOADING ARM STRIPPING
UTILITY SYSTEMS
DESCRIPTION OF UNIT CONTROL

3.1
3.2
3.3
4.

DESCRIPTION OF FLOW WITH CONTROLS


OPERATING CONDITIONS
PROCESS VARIABLES
UTILITY, CHEMICAL AND CATALYST REQUIREMENT

4.1
4.2

UTILITY CONSUMPTION
CHEMICAL CONSUMPTION

5.

PREPARATION FOR INITIAL START-UP

6.

NORMAL START-UP
6.1
6.2
6.3
6.4
6.5

SUMMARY OF FEED TO UNIT


FINAL PREPARATIONS
STREAMING PRODUCTS
NORMAL OPERATION
ALTERNATIVE OPERATION

7.

NORMAL SHUTDOWN

8.

EMERGENCY SHUTDOWN PROCEDURES


8.1
8.2
8.3
8.4
8.5
8.6

9.

GENERAL EMERGENCY SHUTDOWN


POWER FAILURE
STEAM FAILURE
INSTRUMENT AIR FAILURE
NITROGEN FAILURE
MECHANICAL FAILURE
SAFETY EQUIPMENT AND PROCEDURES

9.1
9.2
9.3
9.4
9.5
9.6
9.7
10.

PRESSURE SAFETY DEVICES


ALARM SETTINGS
TRIP SETTINGS
TRIP SYSTEM CHART
CAUSE AND EFFECT DIAGRAMS
MATERIAL HAZARD DATA SHEETS
SAFEGUARDING MEMORANDUM
INSTRUMENT DATA

April 2007
Rev.
:A
Chapter : Page
:1

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

11.
11.1
11.2
11.4

SUMMARY OF MAJOR EQUIPMENT


EQUIPMENT LIST
PUMPS
OTHER VENDOR INFORMATION

12.

ANALYSIS

13.

PROCESS CONTROL

13.1
13.2
13.3
13.4
14.
14.1
14.2
14.3
14.4

April 2007
Rev.
:A
Chapter : Page
:2

DISTRIBUTED CONTROL SYSTEM (DCS)


INSTRUMENTED PROTECTIVE SYSTEM (IPS) AND SAFEGUARDING SYSTEMS
CONTROL CENTRE
OTHER SPECIFICATIONS
DRAWINGS
PLOT PLANS
PROCESS FLOW DIAGRAM
PIPING AND INSTRUMENTATION DIAGRAMS
OTHER DRAWINGS

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

1.

BASIS OF DESIGN

1.1

DUTY OF PLANT

1.1.1

DESCRIPTION OF UNIT

April 2007
Rev.
:A
Chapter : 1
Page
:1

The Jetty is located in Dung Quat Bay, approximately 2km west of Product Tankage, which in
turn is located approximately 5 km north of the Refinery
The Jetty Topsides facility includes the loading arms, MOVs, ESD valves as well as other
facilities including custody transfer flow meters and oily water collection and disposal systems.
1.1.2

DESIGN CODES/STANDARDS
The design of Jetty Topside complies with relevant guidelines/recommendations published by
the following organizations:
International Maritime Organisation (IMO)

Oil Companies International Marine Forum (OCIMF)


International Safety Guide for Oil Tankers and Terminals (ISGOTT)
1.1.3

PRODUCTS HANDLED AT BERTHS


The Jetty Topside facilities are designed to receive products by pipelines from Product Tankage
and to load the products into ocean and coastal carriers at the respective berths.
The table below shows distribution of products regularly exported at the Ocean and Coastal
Berths.
Product
Propylene
LPG
Mogas92/95/ FRN(*)
Mogas 90
Jet A1/Kerosene
Auto Diesel
Fuel Oil

Product Tankage to
Ocean Berths
No
No
Yes
Yes
No
Yes
Bunkering only

Product Tankage to
Coastal Berths
Yes
Yes
Yes
Yes
Yes
Yes
Yes

(*) Mogas 92/95 rundown and export facilities may also be used for Full-range Naphtha (FRN)
export.
At Refinery start-up, diesel oil will be imported via the SPM (unit 82) and LPG will be imported via
the jetty. Fuel Oil will not be imported via the Jetty. Bunkering Fuel Oil is available at each berth
via hose connections, when there is no Fuel Oil loading.
1.1.4

BERTH OCCUPANCY, NUMBER OF BERTHS REQUIRED


The time that a vessel occupies a berth includes the service time taken to approach the berth, tie
up, connect loading arms, de-ballasting (for fuel oil tankers only), complete paperwork, detach
loading arms, untie and leave the berth.
The Ocean Berths are designed to handle vessels in the range 15,000 to 30,000 DWT and
Coastal Berths are designed to handle vessels in the range 1,000 to 2,000 DWT for LPG and
Propylene, and in the range 3,000 to 5,000 DWT for the other products.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 1
Page
:2

The berth occupancy is calculated based on the number of parcels per year taking into account
berth outage due to bad weather. A berth with the occupancy of 55% is considered to be
optimally loaded.
In practice if the berth occupancy is significantly higher than 55% (i.e. 60% to 70%), there is a
risk of congestion at the berth or berths, resulting in vessel being delayed and demurrage
charges being incurred. Hence in determining the number of berths required, target berth
occupancy of 55% has been used.
Outage of 8 days due to bad weather has been accounted for the coastal berths only.
In the design case 75% of the Mogas and Auto Diesel are exported via the ocean berths, and the
remaining 25 % being exported via the coastal berths.
100% of Propylene, LPG, Jet A1/Kerosene and Fuel Oil are exported via coastal berths.
A 4 hour service time has been considered for Mogas, Auto Diesel, JetA1/Kerosene, LPG and
propylene exported via Coastal Berths. For Fuel Oil exported via coastal berths the service time
is 7 hours. For Mogas and Auto Diesel exported via ocean berths the service time of 8 hours has
been considered.
The table in the following page gives berth occupancy for this Design Case. The table
demonstrates the following:
Export by ocean tankers requires two Ocean Berths. The total occupancy of the two
Ocean Berths is maximum 39.0 % and minimum 19.5 %;
Export from Coastal Berths by tankers of minimal and maximum DWT both require 4
berths, with a total maximum occupancy of 43% and a minimum of 31%.
Six product berths in total are provided:
Berths 1 and 2 are ocean berths intended to handle ocean carriers.
Berths 3, 4, 5 and 6 are coastal berths intended to handle coastal carriers.
The service time and calculated time indicated in the tables are based on assumptions only and
subject to change depending on actual operating philosophy and local port regulations.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

Product
Name

Basic Design Data

Production Rate

Specific Gravity

Design through-put
(tonnes)
Daily

April 2007
Rev.
:A
Chapter : 1
Page
:3

Tanker/Berths

Ocean

Coastal

Annual

Annual Op Hours

8,760

8,568

365

357

Propylene

0.522

462

168630

Days/Year

LPG

0.576

1,099

401135

Hours/Day

24

24

Tanker Pay Load as


Fraction of DWT

0.95

0.95

MG 92/95

0.749

3,122

1139530

MG 90

0.725

5,135

1874275

Jet A1/ Kerosene

0.775

1,223

446395

AutoDiesel

0.832

9,041

3299965

Fuel Oil

0.885

1,135

414,275

m3/DWT for LPG/Propylene


1,000 DWT

1.3

2,000 DWT

Ocean Tanker Stay Time (Hours/Tanker)


Parcel Size
(Dwt)

Loading
Rate (m3/h)

Service
Time (h)

Ocean Berth Occupancy

Calculated
time
(h)

Max

Min

Max

Min

Max

Min

Max

Min

MG
92/95

30,000

15,000

3000

1500

20.7

20.7

MG 90

30,000

15,000

3000

1500

21.1

21.1

ADO

30000

15,000

2800

1400

20.2

20.2

Ocean Berth Occupancy Rate


Berth #1 and #2

Fraction of
Production

Max

Min

Loading
Rate
(m3/h)
Max

Min

Service
Time (h)
Max

Min

Max

Min

Max

0.75

30

60.0

7.1

14.2

0.75

49

99

11.9

23.8

0.75

87

174

20.1

40.1

1 Berth

39.0

78.0

2 Berths, #1 & #2

19.5

39.0

Coastal Berths Occupancy

Calculated
Time (h)
Max

Occupancy %
Calculated

Min

Coastal TankerStay Time (hours/tanker)


Parcel Size
(Dwt)

Number Of
Ships

Fraction of
Production

Min

Number Of
Ships

Occupancy %
Calculated

Min

Min

Max

Max

Propylene

2000

1000

400

400

9.0

7.25

1.00

162

248

17.0

21.0

LPG

2000

1000

400

400

9.0

7.25

1.00

348

536

36.6

45.3

MG 92/95

5000

3000

750

750

12.5

9.1

0.25

60

100

8.7

10.6

MG 90

5000

3000

750

750

12.7

9.2

0.25

99

164

14.7

17.7

Jet A1/
Kerosene

5000

3000

700

700

12.8

9.3

1.00

94

157

14.0

16.9

AutoDiesel

5000

3000

700

700

12.2

8.9

0.25

174

289

24.6

30.0

Fuel Oil

5000

3000

700

700

14.7

11.6

1.00

87

145

Coastal Berths Occupancy Rate


Berths 3, 4, 5 and 6

14.9

19.7

1 Berth

130.5

161.3

Average of 4 Berths

32.6

40.3

Berths 5 & 6: LPG, Propylene & FO

34.2

43.0

Berths 3 & 4: MOGAS, ADO, Jet A1

31.0

37.6

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)
1.1.5

April 2007
Rev.
:A
Chapter : 1
Page
:4

LOADING ARMS
Dedicated loading arms are provided for the following products:
LPG
Propylene
MOGAS
Auto Diesel
Jet A1/Kerosene
Fuel Oil
Ballast water from fuel oil ships only will be discharged via the Fuel Oil loading arm.
The number of dedicated loading arms is as follows:
Berth # Mogas Jet A1/ Kerosene Auto Diesel LPG Propylene Fuel Oil
2
2
1
2
2
2
1
1
2
3
2
1
1
4
1
1
5
1
Note (1)
1
6
Note 1: A crossover is provided to allow Propylene to be exported from the LPG loading arm in
case berth 5 would be unavailable.
The two loading arms on berth 3 for Auto Diesel, and the two on berth 4 for Mogas will offer:
- additional flexibility : a single ship can be loaded at twice one loading arm rate;
- Loading arm availability: in case of a loading arm could be out of service.
Space is also provided on each berth for the future addition of one loading arm and/or vapour
recovery system. Space is also provided for future product header installation.

1.1.6

LOADING ARM DIAMETERS


Diameters of the product loading arms are determined accounting for the following:
Loading (pumping) rates were determined based on the following: the ocean tankers of
15,000 DWT to 30,000 DWT to be loaded with MOGAS and Auto Diesel in not more than
14 hours. Loading of coastal vessels up to 5,000 DWT will take not more than 10 hours.
Requirements of p.7.4 of "International Safety Guide for Oil Tankers and Terminals"
(ISGOTT) specify 7m/s as safe flow rate in the loading arms and vessels on-board
pipelines.
Ocean Berths 1,2
Product

MOGAS
Auto Diesel
Jet A1 /Kerosene
LPG
Propylene
Fuel Oil

Coastal Berths 3,4

Coastal Berths 5, 6

No. of loading
arms

NB

No. of loading
arms

NB

No. of loading
arms

NB

4
4
-

12
12
-

3
3
2
-

10
10
10
-

2
1
1

10 (L) / 6 (V)
10 (L) / 6 (V)
12

Hose connection flange for bunkering Fuel Oil are 4NB size.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)
1.1.7

April 2007
Rev.
:A
Chapter : 1
Page
:5

LOADING HEADERS
A single common product header serves each product supplied to ocean and coastal berth
loading arms from Product Tankage.
Six berths are grouped in three pairs of berths. In order to ensure safe and flexible loading
operation, and minimize potential of products contamination, products allocation to Berths is
provided as follows:
Three headers are routed to Ocean Berths 1 and 2 for the following products:
Mogas 92/95
Mogas 90
Auto Diesel
Four headers are routed to Coastal Berths 3 and 4 for the following products:
Mogas 92/95
Mogas 90
Auto Diesel
Jet A1/ Kerosene
Three headers are routed to Coastal Berths 5 and 6 for the following products:
Propylene
LPG
Fuel Oil.
Each product pipeline has an isolation MOV installed close to each loading arm. Downstream of
the custody meters, each product has a loading manifold that is common for a pair of berths.
Each manifold is provided with adequate number of MOVs to ensure proper segregation and
isolation between the berths.
Bunker Fuel is available at each Berth via hose connections; bunkering is intended to be done
only when there is no fuel oil loading in berth 6.
Each LPG and Propylene loading arm includes connection to dedicated vapour return lines as a
'piggyback' design (one LPG line connected to LPG spheres, one Propylene line connected to
Propylene spheres). A pressure gauge in the vapour return pipelines is provided to record the
pressure on the ship during loading. An orifice flow assembly (senior or equivalent) that is part
of the LPG and propylene custody metering skids is provided in each of the vapour return line
that will measure the vapour return flow from the ship. The custody meter flow computer
calculates the instantaneous and total mass flow rate and subtracts from the main loading flow
meter to get the actual loaded mass flow.
Each LPG and Propylene loading arm is provided with an emergency release coupling, for
remote disconnection of the loading arms from the vessel in an emergency. All other loading
arms are provided with quick-release couplings.
For clearing LPG and Propylene liquid arms, tanker vapor is re-circulated from higher pressure
tank to lower pressure tank via vapor / liquid loading arm and jump-over line. Thus, no vessels
for recovering products are required.
Each product loading arm manifold, other than LPG and Propylene, are provided with two
dedicated loading arm stripping pumps one for each berth, which pump the contents of the
loading arm and loading arm manifold into outboard section of the appropriate loading arm when
pumping from storage is completed. As there is no multiple product loading arm, draining of
manifolds and loading arms is not required in normal operations.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)
1.1.8

April 2007
Rev.
:A
Chapter : 1
Page
:6

EMERGENCY SHUTDOWN VALVES


On each LPG export pipeline, each Propylene export pipeline and on the LPG and Propylene
Vapour Return pipelines, two ESD valves are provided on-shore close to the Jetty foot, and two
ESD valves are provided at each Berth located a minimum of 70m from the Berth.
On each product pipeline (other than LPG and Propylene) one ESD valve is provided on-shore
close to the Jetty foot, and one ESD valve is provided at the Berth, located not less than 70m
from the Berth.
All ESD valves are pneumatically actuated tight shut-off ball valves.

1.1.9

CUSTODY METERS
Transfer of all products exported via the Berths is measured by custody transfer flow meter.
The following pipelines are equipped with custody transfer flowmeters.
Product
Propylene
LPG
Mogas/FRN
Mogas
Jet A1/Kerosene
Auto Diesel
Auto Diesel
Fuel Oil

Custody Flow Meter in Pipeline to:


Berth 5
Berths 5, 6
Berths 1, 2 (2)
Berths 3, 4 (2)
Berths 3, 4
Berths 1, 2 (2)
Berths 3, 4 (2)
Berth 6

The products custody transfer meters and compact provers are located as close to the point of
loading as possible. The flow meter for measuring the small vapour return flow from each vessel
loading LPG or Propylene shall be an orifice flow assembly (type senior or equivalent) with
temperature and pressure correction. Instantaneous and total mass flowrate shall be calculated.
Compact meter provers will be used for each group of product as follows:
LPG
Propylene
Mogas and ADO (Ocean loading),
Mogas and ADO (Coastal loading)
Jet A1/Kerosene (Coastal Loading)
Fuel Oil.
Each of the provers listed above is provided with a warehouse spare. Likewise, seven spare
custody meters are kept in the warehouse.
1.1.10 FLOW CONTROL
Downstream of each of the custody transfer flow meters, there is a flow control valve, which is
part of the custody metering system. This valve will be used to ramp up and ramp down the
loading rate at the start and end of each loading operation. In accordance with SIGTTO and
ISGOTT requirements, at start loading phase, the linear flow velocity shall not exceed 1 m/sec.
The flow control signal shall be supplied from the appropriate custody transfer flowmeter.
1.1.11 HEAT TRACING OF FUEL OIL
To ensure that the Fuel Oil export pipelines and associated facilities can be left static in between
parcels during outage periods, electric heat tracing of the fuel oil pipelines is provided.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 1
Page
:7

1.1.12 SURGE ALLEVIATION


The design of the export systems takes into account overpressure due to high surge pressures
arising from, for example, closure of an ESD valve (either an ESD valve on-board a vessel or an
ESD valve located in the Jetty Topsides).
A pressure surge Analysis was performed in order to provide safe facilities, by optimization of
ESD Valves Closure time, Pumps pressure and Pipes size.
1.1.13 UTILITY SYSTEMS
1.1.13.1

POTABLE WATER

Potable water is piped to the JCC and substation-10 and for distribution to safety showers and
utility stations within the Jetty area from the water supply system of Product Tankage. At each
Berth there is a hose connection to supply and meter potable water supplied to the vessel at the
Berth.
1.1.13.2

NITROGEN

Nitrogen is supplied to Jetty Topsides by pipeline from Product Tankage. A nitrogen receiver is
located onshore in the vicinity of the Jetty foot that provides buffering capacity to meet the
demand during short-term periods of high flow (e.g., when LPG loading arms are blown down).
1.1.13.3

INSTRUMENT AIR

Instrument air is supplied to Jetty Topsides by pipeline from Product Tankage. An instrument air
receiver is located onshore in the vicinity of the Jetty foot that provides buffering capacity for safe
operation of the pneumatic ESD valves.
1.2

FEED CHARACTERISTICS
Refer to Chapter-1, section 1.2 in the operating manual of Unit-052

1.3

PRODUCT SPECIFICATION
Refer to Chapter-1, section 1.3 in the operating manual of Unit-052.

1.4

MATERIAL BALANCE
Refer to the PFDs attached in chapter-14.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)
1.5

April 2007
Rev.
:A
Chapter : 1
Page
:8

BATTERY LIMIT CONDITIONS


Product

Destination

Flow Rate (m3/h)

Mogas 92/95
Mogas 92/95
Mogas 90
Mogas 90
ADO
ADO
Jet A1/Kerosene
Fuel Oil
LPG (Note 1)
LPG Vapour (Note 1)
Propylene (Note 2)
Propylene Vapour
(Note 2)

Berth 1/2
Berth 3/4
Berth 1/2
Berth 3/4
Berth 1/2
Berth 3/4
Berth 3/4
Berth 5/6
Berth 5/6
Berth 5/6
Berth 5
Berth 5

3000
750
3000
750
2800
700
700
700
400
4522kg/h
400
10823kg/h

Pressure at Ship
Connection, kg/cm2g
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
10.1
8.0
20.1
18.0

Notes:
1. For LPG, the pressure at ship inlet depends on the vapour pressure corresponding to the
actual composition and temperature. The values given are based on an LPG composition of
60 mol% C4s and 40 mol% C3s supplied to the ship at 40C
2. Propylene liquid and vapour conditions are based on a supply temperature of 40C.
1.6

DESIGN FEATURES
Emergency Release System for LPG and Propylene Loading Arms
LPG and propylene loading arms in berths 5 and 6 are provided with emergency release system
(ERS) in accordance with the OCIMF recommendations. The ERS is a hydraulically operated
system that comprises of an emergency release coupling (ERC) between two ball valves
mounted in the vertical leg of the triple swivel assembly. A mechanical interlock through the
double acting hydraulic cylinder prevents ERC operation before complete closure of both the ball
valves. A hydraulic interlock prevents accidental operation of the ERC during parking or
manoeuvring mode of the loading arm.
Piggy-back Vapor return system on LPG and Propylene service
During the loading of LPG and Propylene, vapour return arms in piggy-back style are connected
to the ship in order to transfer displaced vapours. The liquid loading arm is equipped with a
smaller diameter line mounted piggy-back for transfer of vapour. This smaller line is also
equipped with an ERS and the hydraulic system is designed to ensure that the smaller line is
uncoupled at the same time the main loading ERS is uncoupled.
Heat Tracing of LPG and Propylene vapour return lines
In order to prevent condensation of the LPG and propylene vapour in the return lines, continuous
electric heat tracing, maintained at 40C, is provided from the loading arm (vapour return arm) up
to the product tankage area battery limit. Within the product tankage area, steam tracing is
provided.
Advanced Process Control (for tanks inventory management) through OMS system
Each product loading line is provided with dedicated custody meters, dedicated operating and
spare loading arms and dedicated loading lines. Downstream of each custody meter, there are
several loading manifolds which are segregated by a number of MOVs before it is led to the
respective loading arms. Proper selection of the loading manifold, opening only the required

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 1
Page
:9

MOVs and closing the other MOVs is a prerequisite to ensure that there is no spillage or
misloading and that the correct loading is executed. Likewise, the two grades of Mogas and Auto
diesel share a common prover and line-up of the MOVs from the correct meter to the common
prover is a prerequisite to ensure a proper proving operation. The line-up of the MOVs in the jetty
area for executing a ship loading movement and meter proving is under the control of the Oil
Movement and Storage System (OMS). The OMS minimizes the risk of errors in the field such as
misloading and undetected leaks. The OMS system enhances the basic controls implemented by
the DCS by providing advanced supervisory and control functions.
Advanced Process Control (for product despatch) through Terminal Automation System
The marine loading operations are controlled by the Terminal Automation System (TAS). TAS is
web-based client-server software used to automate the operations within the terminal for marine
loading by interfacing with the refinerys MIS for despatch order management, the OMS system
for executing the despatch orders, DCS and ESD systems. The main functions of the TAS is to
control the auto start-stop of the loading pumps, control the initial, peak and final loading rates
through the custody metering systems, berth allocation for ships, compute the actual quantity
loaded for comparison with target quantity, capture and download the meter prover K-factor, and
generate the loading reports on a periodical basis. Like the OMS system, the TAS enhances the
basic controls implemented by the DCS by providing advanced supervisory and control functions.
1.7

GAS AND LIQUID EFFLUENTS

1.7.1

EFFLUENT, SLOPS AND BALLAST WATER


Effluents/slops from Jetty Topsides and from vessels at the Berths are segregated and handled
as follows. Rain water from canopy above the custody transfer flowmeter shed is classified as
clean water and will be discharged directly to the sea. Facilities are provided at Berth 6 to
off-load and meter ballast water from vessels transporting Fuel Oil. Using the vessel on-board
pumps via the Fuel Oil loading arm, ballast water will be pumped directly to the ballast water
tanks at Product Tankage for treatment.

1.7.2

SLOP OIL
At the Jetty area, oily slops are generated during maintenance in the vicinity of the loading arms
and custody transfer flow meters. These oily slops are routed via dedicated line to the oily water
drum located in each berth and pumped out into the ballast water pipeline. Each drum is
provided with a dedicated vertical submersible pump.

1.7.3

OILY SURFACE WATER (OWS)


All OWS from berth areas are routed through a separate collection header to the oily water drum
located in each berth and pumped out into the ballast water pipeline. Each drum is provided with
a dedicated vertical submersible pump.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

2.

April 2007
Rev.
:A
Chapter : 2
Page
:1

DESCRIPTION OF PROCESS
The jetty is located in Dung Quat Bay, approximately 2 km from the product tank farm. The jetty
topsides facilities include the loading arms, custody transfer flow meters, MOVs, ESD valves,
drums, etc., as well as other facilities.
The Jetty Topside facilities are designed to receive products by pipelines from the product
tankage and to load the products into vessels at the ocean and coastal berths. A single common
product supply header for each product serves to supply the ocean and coastal berths. There
are six berths, of which two (berths 1 & 2) are designed for handling ocean carriers and four
(berths 3, 4, 5 & 6) are designed for handling smaller coastal carriers.
The table below shows distribution of products for the six berths.

2.1

Product

Product tank farm to


Ocean Berths

Product tank farm to


Coastal Berths

Mogas 92/95

Yes (Berth 1 / 2)

Yes (Berth 3 / 4)

Mogas 90

Yes (Berth 1 / 2)

Yes (Berth 3 / 4)

Auto Diesel

Yes (Berth 1 / 2)

Yes (Berth 3 / 4)

Jet A1/Kerosene

No

Yes (Berth 3 / 4)

LPG

No

Yes (Berth 5 / 6)

Propylene

No

Yes (Berth 5)

Fuel Oil

Bunkering only

Yes (Berth 6)

LOADING ARMS AND CUSTODY METERS


The loading arms provided in each berth are as follows:
Berth #
1

MOGAS Auto Diesel Jet A1/ Kerosene


LA-8111

LA-8113

LA-8112

LA-8114

LA-8121

LA-8123

LA-8122

LA-8124

LA-8134
LA-8144
LA-8145

LPG

Propylene Fuel Oil

LA-8131

LA-8143

LA-8141

LA-8133
LA-8135

LA-8152

LA-8151

LA-8162

Note (1)

LA-8161

Note: 1. A crossover has been provided to allow propylene to be exported from the LPG
loading arm in berth 6 (LA-8162) in case berth 5 is unavailable.
Each LPG or propylene loading arm includes connection to dedicated vapour return lines as a
'piggyback' design (one LPG vapour line connected to LPG spheres, one propylene vapour line
connected to propylene spheres).

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 2
Page
:2

Each LPG and Propylene loading arm has an emergency release coupling, for remote
disconnection of the loading arms from the vessel in an emergency. All other loading arms have
quick-release couplings.
Measurement of all products exported via the berths is by custody transfer flow meters. The
number of custody metering skids for each berth is as follows:
Berth #

MOGAS

Auto Diesel

1
2
3
4
5
6

A-8115
A-8116
A-8117
A-8118

A-8119
A-8120
A-8121
A-8122

Jet A1/
Kerosene

A-8123

LPG

Propylene

Fuel Oil

A-8127

A-8130

LPG

Propylene

Fuel Oil

A-8125

The available custody meter prover skids are as follows:


Berth #

MOGAS

Auto Diesel

A-8150

2
3

A-8151

Jet A1/
Kerosene

A-8155

A-8153

A-8154

A-8130

All products loaded are measured in temperature compensated net volumes by the respective
custody transfer meters.
Bunkering lines is provided at each berth to load bunker fuel to ship via flexible hose, when there
is no fuel oil loading in berth-6.
All MOV line-up is done by the OMS prior to commencement of loading operations. Ship loading
pumps in the product tank farm are automatically started and stopped based on loading demand
(loading rate) by TAS.
2.2

SLOPS AND OILY WATER COLLECTION


Oily surface water is routed by gravity through an underground line into the Oily and Surface
Water Collection Drum (D-8110A/B/C/D/E/F). Drains from custody meters, bunker hoses and
TSV discharges are routed through the separate light slop oil (LSO) header to the same drums.
There is one drum in each berth, located at the end of the berths near the berthing dolphin. From
the drums, oily water is pumped out by the pump P-8110A/B/C/D/E/F into the ballast water tank
located in the product tankage area. The oily water pump is automatically started by the level
controller when a preset high level (below the LAH) is reached and automatically stopped when
the preset low level (above the LAL) is reached.

2.3

LOADING ARM STRIPPING


For all liquid products (namely, Mogas, ADO, JetA1/Kerosene and Fuel Oil), after completion of
loading operation, the remaining liquid in the loading arm and in the line up to the loading arm
isolation MOV are pumped out into the ship via outboard section of the appropriate loading arm.
An electric motor driven loading arm stripping pump is provided for this purpose in each berth

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 2
Page
:3

(P-8122 for berth-1; P-8123 for berth-2; P-8120 for berth-3; P-8121 for berth-4; P-8119 for berth5 and P-8118 is a common spare). The loading arm stripping pumps are progressing cavity type
(helical gear), and have an in-built automatic stop facility when there is no liquid to pump and
running dry. The suction and discharge connections to the loading arm are done by hoses that
are supplied with each pump. The pumps are mounted on a trolley to facilitate movement within
the berth area. All the pumps are compatible for any of the liquid products mentioned above.
2.4

UTILITY SYSTEMS
Instrument air, nitrogen and potable water are the only utilities required in the jetty and these are
supplied by pipeline from the product tank farm.
Instrument air is mainly used for the pneumatically actuated ESD valves and flow control valves
(in the custody meters and bunkering lines). An Instrument Air receiver (D-8124) that acts as a
buffer vessel is provided for instrument air receiving and storage. The capacity of the Instrument
Air receiver can supply instrument air for up to 36 minutes in the event of loss of supply from the
product tank farm. The D-8124 is located onshore close to the jetty foot.
Nitrogen is mainly used in the utility stations for purging and pressure testing of the LPG and
propylene loading arms when required. Nitrogen is also used to pressurize the hydraulic
accumulator of the LPG and propylene loading arms ERS; which is a rare requirement and
typically done once in 6 months. A nitrogen receiver (D-8123) that acts as a buffer vessel is
provided for nitrogen receiving and storage. The drum D-8123 is located onshore close to the
jetty foot.
Potable water is directly supplied to the users (utility stations, eye-washes and safety showers)
and for loading to ship. Potable water that is loaded to the ship is metered by turbine type water
meters. One meter is provided for each berth, which has two local readings one indication for
volume flown for each loading batch (which can be reset) and another for cumulative indication
of total volume loaded (which is normally not reset and can be used for any inventory
reconciliation).

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

3.

DESCRIPTION OF UNIT CONTROL

3.1

DESCRIPTION OF FLOW WITH CONTROLS

April 2007
Rev.
:A
Chapter : 3
Page
:1

Jetty Topsides Area Control and Shutdown Philosophy (8474L-081-CN-0008-001) will be


inserted.
Ship loading Operating Philosophy (8474L-081-CN-0008-002) will be inserted.
Loading Arm Control System Description (8474L-081-A3501-4026-051-001) will be inserted
Operation and Maintenance Manual of the OMS system (8474L-500-A5015-1518-007-106) will
be inserted.
Operation and Maintenance Manual of the TAS (8474L-500-A5016-1515-008-108) will be
inserted.
3.2

OPERATING CONDITIONS
Refer to the following jetty topsides process flow diagrams attached in Chapter-14.
8474L-PFD-0010-001
8474L-PFD-0010-002
8474L-PFD-0010-003
8474L-PFD-0010-004

3.3

PROCESS VARIABLES
Refer in section 3.1, Ship loading Operating Philosophy (8474L-081-CN-0008-002, under the
sections 4.2, 5.2 and 6.2.1) for details on operational process variables for ship loading.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

4.

UTILITY, CHEMICAL AND CATALYST REQUIREMENT

4.1

UTILITY CONSUMPTION

April 2007
Rev.
:A
Chapter : 4
Page
:1

The following utilities supplied to the Jetty from the product tankage area:
(i)
Instrument Air (for pneumatically actuated ESD valves, control valves and utility
stations)
(ii)
Nitrogen (for utility stations and purging prior to maintenance)
(iii)
Potable Water (for ship loading, eye-wash and safety showers and utility
stations)
(iv)
Electric Power
Refer to Estimated Utility Consumption (8474L-081-CN-0003-001) to be attached.
4.2

CHEMICAL CONSUMPTION
There is no chemical and catalyst requirement for Unit 081 for the products.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

5.

PREPARATION FOR INITIAL START-UP


Refer to Pre-commissioning Procedures Series 8474L-000-PP-9XX.

April 2007
Rev.
:A
Chapter : 5
Page
:1

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

6.

NORMAL START-UP

6.1

SUMMARY OF FEED TO UNIT

April 2007
Rev.
:A
Chapter : 6
Page
:1

PROPYLENE

LPG

JET A1/KEROSENE

FUEL OIL

AUTO DIESEL

MOGAS 90

MOGAS

Product Tankage
Unit 052

Ocean Ships
Berth 1, 2

Coastal Ships
Berth 3, 4

PROPYLENE

LPG

FUEL OIL

JET A1/KEROSENE

AUTO DIESEL

MOGAS 90

MOGAS

MOGAS 90

AUTO DIESEL

MOGAS

Jetty Topsides
Unit 081

Coastal Ships
Berth 5, 6

Refer to section 1.1.5 for number of loading arms for each product in each berth
GENERAL NOTE: This operating manual (and chapter-6 in particular) will only cover all operations
starting from loading arm connecting to ship, through loading operations and up to disconnection of the
loading arm. This operating manual will not contain any details related to basic port operations i.e.
navigation system operations, berth allotment procedures, pre-loading and post-loading survey
operations, ship-shore compatibility checks, ship-shore safety checks, berthing, mooring operations,
normal and emergency deberthing operations, and emergency spill response operations.
6.2

FINAL PREPARATIONS
This procedure describes in general terms the steps to be followed for placing the unit on
stream. The exact sequence of events depends on the flow scheme of the particular loading line.
However, the following steps must be completed before the start-up.
1.
2.
3.
4.
5.
6.
7.
8.
9.

All unnecessary blinds removed. (Blind list to be elaborated on site by the


commissioning team).
All relief valves are tested and installed.
The sewers are in service.
All instruments and control systems are ready for service.
Electrical substation SS10 & 10A energized and ready to supply power.
Jetty Control Room energized and ready for operations.
Ensure that electrical tracing for fuel oil line and Custody Transfer Meter is online.
Ensure that electrical tracing for LPG and propylene vapor return line is online.
Ensure that loading arm stripping pumps and relevant hoses are available.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)
10.
11.
6.3

Fire fighting facilities ready for service.


All safety equipment available.

STREAMING PRODUCTS
1.
2.
3.
4.
5.
6.
7.
8.

6.4

April 2007
Rev.
:A
Chapter : 6
Page
:2

Complete the activities listed in Section 6.2.


Ensure that Custody Transfer Meter is reset to zero and ready to be put in operation.
Ensure that loading area is ready; loading arm hydraulic power unit is energized and arm
is ready for operation.
The Oil Movement and Storage System (OMS) will perform the necessary lineup.
Coordinate with all relevant parties involved in the product transfer.
Upon starting the loading and while operating the system, check if there are any leaks in
the piping and instruments.
Ensure that bleed valves in the diverter MOVs of all the custody metering system is
always in closed position.
Ensure that electrical heat tracing is switched on for the fuel oil line, fuel oil custody
meter and prover and the LPG and propylene vapour return lines if not already done
as per section 6.2.

NORMAL OPERATION
The ship loading operations are normally controlled from the Jetty Control Centre (JCC) located
on-shore close to the jetty-foot. The design of the control system also allows the operations to be
controlled from the Satellite Control Centre (SCC) which is located in the product tank farm i.e
the graphic display of the DCS, OMS and TAS are provided in the JCC and the SCC. It is
recommended that the loading operations be controlled from the JCC for ease of communication
and coordination with the jetty field operator(s). The loading arm operation and controls have to
essentially be done only from the field using the loading arm control panel (or the Jetty Head
Console) provided in each berth in order to ensure that the loading arms are securely connected
to the ship and also constantly monitor the loading operations for the entire duration. Therefore
loading arm operation and controls are not provided in the DCS (or control room). However,
general fault alarms and ESD alarms from the loading arms will be available in the DCS.

6.4.1

SHIP LOADING OPERATIONS


Before loading a bulk barge/coaster it should be inspected by a responsible person to ensure
that the ship compartments and on-board pipelines are suitable and in fit condition for loading
the product. If the tanks of the vessel are not clean and dry, or if the vessel is to be topped up,
the product already on board should be carefully checked to ensure that it is on-specification and
similar to the product to be loaded. For Jet A1/ Kerosene loading, strict precautions must be
taken.
The general procedure for product loading is as follows.
1.
2.
3.
4.
5.
6.
7.
8.

The refinerys planner/scheduler issues ship loading orders to OMS/TAS.


The marine system operator and TAS operator assign the berth to the ship.
TAS operator assigns the loading arm after communication with DCS/OMS operator.
TAS operator ensures that the MOVs on berth end on product lines are in closed position.
Agree the grades to be loaded with the responsible ship's officer.
Invite the ship's officer to witness the meter reading.
Jetty Topside operator/marine system operator connects the assigned loading arms.
Ensure that loading arm is correctly connected to the ship's manifold by the ship's crew
jointly with shore personnel.
9. Jetty Topside field operator validates through Operator Interface Terminal (OIT) that the loading
arm is connected and is ready. TAS secures connection of loading arms and this information is
made available to OMS.
10. TAS operator instructs the DCS/OMS operator to start line-up for the loading movement.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 6
Page
:3

11. DCS/OMS operator selects the source tank and by acknowledging the selected loading arm,
the line up is done accordingly by OMS.
12. When the line up is correct, OMS sends a message Line up is ready to TAS.
13. If the OMS system is not available, then a manual line-up of the MOVs has to be done. Refer to
Control and Shutdown philosophy document (8474L-081-CN-0008-001, under section 4.2)
attached in chapter-3. Full details of which MOVs and manual valves are to be open and which
MOVs and manual valves are to be closed for each product loading to the respective berths is
provided in this document.
14. The line-up will not be complete if:
i) There are any active ESD signals (or any previous ESD signal that is not reset).
ii) Any path valve is not fully open and/or any isolation valve is not fully closed (realized
by open/close limit switch position of the appropriate XVs/MOVs).
iii) Open/close position of any manual valves is not validated in the OMS
15. When the line up is ready, the respective ship loading pumps are started by the start command
from TAS.
16. TAS controls the flow rate through custody metering systems according to ship loading profile.
17. Based on the totalized flow of the respective product custody meter(s), when the required or
target loading volume is reached, TAS automatically stops the respective loading pumps,
sends out close out message to OMS and passes the information on net loaded volume to
OMS. In case of ocean carrier loading, the totalized flow is the summation of two parallel
custody meters.
18. Alternately when the ship's crew advise that loading is almost complete, the operator will
have to remote stop the loading pumps (e.g. when a compartment changeover is required
in the ships by interrupting the loading)
19. Upon completion of loading operation, OMS will close-out the movement by closing all the key
valves (flow blocking element) in the path.
20. Empty the liquid product loading arms (namely, Mogas, Diesel, Jet A1/Kerosene and fuel oil)
using the loading arm stripping pump before disconnecting the loading arms from the ship
(refer to section 6.4.6)
21. Empty the LPG and propylene loading arms into the respective vapour return lines (refer to
section 6.4.7)
Sampling Requirements

6.4.2

Since each product has a dedicated pipeline it can be shown conclusively that no
contamination could have occurred within the shore pipeline system. Therefore the
shore tank sample is acceptable.
An average sample should be obtained from each shore tank used for loading.
When a particular grade is to be loaded from more than one shore tank, a composite
sample should be made by blending the samples from individual shore tanks in the
ratio of the quantities to be loaded from them.

LOADING ARM OPERATION


For loading arm operations and controls, refer to operating manuals and control system
description of the loading arm attached in Chapter-3.

6.4.3

OMS AND TAS FUNCTIONS IN SHIP LOADING OPERATIONS:


For details regarding OMS and TAS functions and its operating guidelines, refer to operation and
maintenance manuals of the OMS and TAS attached in Chapter-3.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)
6.4.4

April 2007
Rev.
:A
Chapter : 6
Page
:4

METER PROVING
For Berth 1 and 2, there is a common meter prover (A-8150) for Mogas 90, Mogas 92/95 and
Auto Diesel.
For Berth 3 and 4, there is a common meter prover (A-8151) for Mogas 90, Mogas 92/95 and
Auto Diesel. There is a dedicated meter prover for Jet A1/Kerosene (A-8155).
For Berth 5 and 6, there are dedicated meter provers for LPG (A-8153), Propylene (A-8154) and
Fuel Oil (A-8152)
There steps for meter proving are as follows:
1.
2.
3.

6.4.5

Coordinate with all relevant parties involved in the proving.


The Oil Movement and Storage System (OMS) will perform the necessary lineup of
MOVs between the meter and the prover.
After proving, TAS captures the k-factor which can then be downloaded to the appropriate
meter flow computer by authorized personnel.

FUEL OIL BUNKERING


Fuel oil bunkering is done using hose connections and can be done at all berths. Simultaneous
fuel oil loading in berth-6 and bunkering in any other berth is not envisaged in the system design.
Bunkering can be done only as a standalone operation when there is no fuel oil loading to ship in
berth-6. Bunker fuel measurement is done by using the flow meter and totalizer provided for
each berth finger.
1.
2.
3.

Coordinate with all relevant parties involved in the loading of bunker fuel.
Ensure that electrical tracing for fuel oil line is online.
Connect the 4 flexible hose from the ship to the bunkering line.
A crane or pulley may be needed for this operation (most ships have one)

4.
5.
6.

Before starting the loading bunker fuel ensure that the manual valve on the bunkering
line is open (this valve is normally kept closed).
Take the initial reading of the flow totalizer FQIC-006 (Berth 1, 2), FQIC-005 (Berth 3, 4),
FQIC-004 (Berth 5, 6).
Inform to operator in JCC that line-up is complete, so that fuel oil ship loading pump can
be started.
The maximum expected loading rate for bunker fuel in each berth is 100m3/h

7.

6.4.6

After bunkering, take the flow totalizer reading again and compute the loaded volume.
Drain the hose as much as possible before disconnection via the slops collection
network to the oily water drum in the respective berth. If necessary, use the loading arm
stripping pump to empty the bunkering hose. Close the manual valve upstream of the
bunker flow meter.

LOADING ARM STRIPPING


In order to have a dry break before disconnection of the loading arm after loading, loading arms
with Quick Connect Disconnect Coupler (QCDC) only are provided with loading arm stripping
pumps (i.e. for Mogas, Auto Diesel, Jet A1/Kerosene and Fuel Oil). This is not applicable for
loading arms with Emergency Release System (ERS), namely, LPG and Propylene arms in
berths 5 and 6. From the low point at the base of the loading arm riser the liquid is pumped into
the ship via the outboard section of the loading arm. One pump is provided in each berth (P8119, P-8120, P-8121, P-8122 and P-8123) except Berth 5. P-8118 is a common spare.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
6.4.7

April 2007
Rev.
:A
Chapter : 6
Page
:5

Push the trolley mounted pump near the loading arm to be emptied.
Connect the inlet of the pump to the 2 flange connection at the bottom of the riser via
flexible hose.
Connect the outlet of the pump to the 2 flange connection at the outboard arm via
flexible hose.
Open the 2 gate valves at the inlet and outlet of the pump.
Connect the pump power cable to the power socket and energize it to start the pump.
The pump has a facility for automatically stopping when there is no ore liquid to be
pumped out (i.e. when stripping is complete).
De-energize the pump and remove the power socket.
Close the valves at the inlet and outlet of the pump.
Disconnect the flexible hoses.
Disconnect the loading arm from the ship and bring it to parked/stowed position.
Insert the metal plate on the QCDC to keep the loading arms outlet covered.

LPG AND PROPYLENE LOADING ARM EMPTYING


LPG and propylene loading arms are not provided with stripping pumps. Subject to facilities
available in the ship tanker, for clearing LPG and Propylene liquid arms, tanker vapor is recirculated from higher pressure tank to lower pressure tank via vapor / liquid loading arm and
jump-over line. If such facilities are not available in the ship, then the following steps need to be
carried out to empty the inboard and outboard sections of the loading arm:
1. After completion of loading, the upper ERS ball valve should be closed (using the push
button provided in the loading arm control panel). This valve should remain closed at all
times when the loading arm is not connected to the ship.
2. Open the drain valve provided in the outboard section so that the small portion of liquid
downstream of the ERS valve drains out into the spill tank/trough in the ships deck.
3. Open the drain valve at the base of the loading arm riser so that the loading arm
contents can drain into the vapour return line. A jump-over line is provided for this
purpose.
4. Disconnect the loading arm from the ship and bring it to parked/stowed position.
5. Insert the metal plate on the QCDC to keep the loading arms outlet covered.
6. Close the drain valves at the riser base and the outboard section of the loading arm.

6.4.8

BALLAST WATER TRANSFER


Deballasting of ballast water from fuel oil ships only is done via LA-8161. Ballast water is
transferred using the on board pump to the ballast water tank in Product Tankage. Deballasting
is done prior to fuel oil loading.
1.
Coordinate with all relevant parties involved in the loading.
2.
Operator action is required to line-up the respective MOVs i.e. close MOV-024 and the
downstream manual valve on fuel oil loading line. Open MOV-025 and its upstream
isolation manual valve on ballast water unloading line.
3.
Operator to ensure the manual valves to the ballast water line is open and to the fuel oil
line is closed
THE EXPECTED DEBALLASTING RATE IS 700m3/h. IT IS RECOMMENDED THAT
SLOPS AND OILY WATER IS NOT TRANSFERRED FROM JETTY TOPSIDES TO
PRODUCT TANKAGE WHEN DEBALLASTING IS DONE, OR DEBALLASTING
FLOWRATE WILL HAVE TO BE REDUCED ACCORDINGLY.
4.
5.

Take the initial totalizer reading for FQI-003.


Wait for confirmation from operator in SCC that line-up is complete and inform ship
personnel to start unloading of ballast water.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 6
Page
:6

The design pressure of the ballast water line is 16.8kg/cm2g at 65C. It is recommended
to ensure the maximum discharge pressure at ships pump before deballasting operation
and if required advice ship personnel to regulate the pressure accordingly.
6.
7.
8.
9.
10.

6.4.9

After unloading of ballast water is complete, take the reading of FQI-003 again and
compute volume unloaded.
Close the manual valve on the ship and purge the line contents towards 12-BW810039-A1Q9-NI using the 2 Utility connection with potable water.
Close MOV-025 and its upstream manual valve.
Return the line-up to normal (i.e. open the manual valve and MOV-024 on the fuel oil
line).
Inform control room operator when deballasting operation is finished so that preparation
for fuel oil loading can be started.

SLOPS AND OILY WATER TRANSFER


Slops and oily water collected in D-8110A/B/C/D/E/F is transferred using the oily water pump
(P-8110A/B/C/D/E/F) and via the ballast water line to the ballast water tanks in Product Tankage
area. The pumps have an auto start-stop facility. The pumps will auto-start and auto-stop at a
preset level. A DCS alarm is activated at LAH if the pump has failed to start and operator
intervention is required to manually start the pump and/or investigate the reasons for failure. A
DCS alarm is activated at LAL if the pump has failed to stop and operator intervention is required
to manually stop the pump and/or investigate the reasons for failure. Following are the level
settings for the oily water drum:

Berth No.
1
2
3
4
5
6
6.5

Drum Tag
No.
D-8110A
D-8110B
D-8110C
D-8110D
D-8110E
D-8110F

Pump Tag
No.
P-8110A
P-8110B
P-8110C
P-8110D
P-8110E
P-8110F

Pump Auto
Start at
470 mm
470 mm
475 mm
475 mm
475 mm
475 mm

Pump Auto
Stop at
200 mm
200 mm
225 mm
225 mm
225 mm
225 mm

LAH

LAL

600 mm
600 mm
600 mm
600 mm
600 mm
600 mm

150 mm
150 mm
175 mm
175 mm
175 mm
175 mm

ALTERNATIVE OPERATION
LPG UNLOADING FROM SHIP
LPG is imported via Berth 6 for refinery startup. (Also refer to operating manual of Unit-052, in
section 6.6)
1.
2.
3.
4.
5.
6.
7.

Complete the activities listed in section 6.2 and 6.3.


Coordinate with all relevant parties involved in the LPG receipt.
Complete the line-up by connecting the loading arm to the ship, opening of manual
valves in the line adjacent to the loading arm.
Ensure that the MOVs in the LPG custody meter are closed and open the manual valve
in the custody meter by-pass line after reversing the spectacle blind to open position.
When line-up is complete in the Jetty area, wait for confirmation of line-up from the
product tank farm operator.
Upon getting the confirmation, coordinate with the ship crew to start unloading of LPG at
a low flow rate using the ships pump(s).
Since the LPG line will be empty and contain only inert gas (nitrogen), during initial filling
the flow rate has to be slow enough to avoid rapid reduction in the line temperature.
Close coordination between Jetty operator and ship side personnel is required to
achieve the low flow rate. If required, the manual valve in the unloading line adjacent to
the loading arm may be throttled to adjust the flow rate.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)
8.
9.
10.

11.
12.
13.
14.
15.
16.

April 2007
Rev.
:A
Chapter : 6
Page
:7

Observe for any sweating or ice formation in the LPG line. If it is present, reduce the
unloading rate.
Coordinate with the product tank farm operator and coordinate with the ship crew to
gradually increase the flow rate.
The product tank farm operator will inform when the level in the tank is above the LALL
and the sphere temperature is close to the flowing (or ambient) temperature, after which
normal filling rate can be resorted to. Coordinate with ship crew for increasing the flow
rate (max. unloading rate shall not exceed 400m3/h)
Upon starting the receipt of LPG and during the operation, check if
There are any leaks in the loading arm and involved piping
The pressure gauge and pressure transmitter are working correctly.
After unloading, close the manual valves on the custody meter by-pass line, close the
loading arm isolation MOVs and disconnect the loading arm.
Repeat steps 1 to 6 and 9 to 12 if a subsequent unloading is to be done.
After completion of all unloading operations, close the manual valves on the custody
meter by-pass line and reverse the spectacle blind to close position.
The OMS and TAS systems may not be available for monitoring this unloading
operation. Hence close vigilance and supervision is required throughout the unloading
operation.
For the unloading operation, there will be no vapour return from the sphere (as a check
valve is provided in the vapour return header near the sphere in the product tank farm).
Nevertheless, the vapour return arm shall still remain connected to the ship so that
loading arm operation and controls are not affected. Since all spheres are connected by
a common vapour balance header, and the ships tanks will also have a common vapour
balance line, the unavailability of vapour return from shore to ship is not expected to
have any detrimental effects on either side (ship or shore side).

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

7.

April 2007
Rev.
:A
Chapter : 7
Page
:1

NORMAL SHUTDOWN
Each time loading of any product is completed the TAS will automatically stop the respective
loading pump(s).
For all liquid products (namely, Mogas, ADO, JetA1 and Fuel Oil), prior to disconnection of the
loading arm, the contents are emptied out to the ship by using the loading arm stripping pump.
The stripping pump is trolley mounted to be able to move within the berth area and one pump is
provided for each berth. Refer to chapter-6 section 6.4.5 for details on operation of the loading
arm stripping pump.
When the loading arm is disconnected from the ship, the loading arms isolation MOV will be
closed via the ESD interlock.
After disconnection of the loading arm it is stowed in the parked position and the hydraulic power
unit is stopped by the field operator.
By nature of the design and as per OCIMF recommendations, the loading arms are designed to
permit easy in situ inspection, maintenance and replacement of vital swivel and structural
components (namely the mechanical seals and bearings) without having to dismantle major
sections of the loading arm. Normally, there is no maintenance required in the loading arm other
than periodic lubrication of the swivels and structural bearings, and by design and construction
the lubrication can be done without dismantling the arms. However, in case of any major
maintenance that requires a positive isolation of the loading arms, the same can be achieved by
dismantling the piece of pipe between the loading arm and the isolation MOV and installing a
blind flange at the isolation MOV. A drain connection is provided at the base of the loading arm
riser which can be used to drain the liquid in the section of pipe prior to dismantling.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

8.

EMERGENCY SHUTDOWN PROCEDURES

8.1

GENERAL EMERGENCY SHUTDOWN

April 2007
Rev.
:A
Chapter : 8
Page
:1

The general emergency shutdown is broadly classified into two categories:


1) Local ESD of the individual berth
2) Total ESD of the entire jetty
This principle of categorizing the ESD activation will help in not causing a simultaneous surge
load on all the jetty topsides piping.
Refer to the Cause and Effect Charts (8474L-081-DW-1514-201) attached in Chapter 9.
8.1.1

Local ESD of individual berth


The local ESD of the individual berth can be activated by any of the following causes:
i)
ESD pushbutton activation from the field (one ESD PB per berth)
ii)
Confirmed fire detection in the berth (for berths 1, 2, 3, 4)
iii)
Confirmed fire or gas detection in berth (berths 5 and 6)
iv)
Loading Arm excess angle alarm (apex or slew angle)
v)
QCDC limit switch not closed during freewheeling mode
vi)
ESD push button activation from the loading arm control panel or pendant box
vii)
Low-low pressure in hydraulic oil circuit (only for LPG and propylene loading arms
in berths 5 and 6)
Any of the above causes will result in tripping the respective ship loading pumps and closing the
jetty ESD valve and loading arm isolation MOV of the respective loading line. The loading arms
ESD signals are hardwired to the loading arm PLC, which in turn is also hardwired to the plant
ESD system. The not closed position of the loading arm isolation MOV is used as an input (or
permissive) by the ESD logic to selectively trip only the particular loading line.
The ESD pushbutton activation from the berth and/or confirmed fire/gas detection in the berths
will result in the following effects:

ESD Signal from


Berth 1 or 2

1.

2.
3.
4.
5.
6.
Berth 3 or 4

1.

2.
3.
4.

Effects
If the Mogas loading arm(s) isolation MOV is open, trip Mogas 92/95 or Mogas
90 ship loading pumps whichever is feeding berth 1 or 2 (the not closed
position of the jetty ESD valve in Mogas 92/95 or Mogas 90 line is used as a
permissive to trip the particular pump that is feeding the berth) and close the
respective ESD valve XV-083 on Mogas 92/95 or XV-080 on Mogas 90 line.
If the ADO loading arm(s) isolation MOV is open, trip ADO ship loading pumps
and close the ESD valve XV-086 on the ADO line.
Close the Mogas loading arms isolation MOVs (MOV-095 & MOV-100 if the
signal is from berth-1; MOV-109 & MOV-112 if the signal is from berth-2)
Close Diesel loading arms isolation MOVs (MOV-102 & MOV-105 if the signal
is from berth-1; MOV-115 & MOV-117 if the signal is from berth-2).
Close the bunkering flow control valve FV-006 for berth 1 / 2
Generates BERTH-1 ESD or BERTH-2 ESD alarm in the ADP of SCC and
JCC depending from which berth the ESD signal is activated.
If the Mogas loading arm(s) isolation MOV is open, trip Mogas 92/95 or Mogas
90 ship loading pump whichever is feeding berth 3 or 4 (the not closed
position of the jetty ESD valve in Mogas 92/95 or Mogas 90 line is used as a
permissive to trip the particular pump that is feeding the berth) and close the
respective ESD valve XV-046 on Mogas 92/95 or XV-043 on Mogas 90 line.
If the ADO loading arm(s) isolation MOV is open, trip ADO ship loading pump
and close the ESD valve XV-049 on the ADO line.
If the Jet A1 loading arm isolation MOV is open, trip Jet A1/Kerosene ship
loading pump and close the ESD valve XV-042 on the Jet A1/ Kerosene line.
Close the Mogas loading arms isolation MOVs (MOV-064 if the signal is from

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

5.
6.
7.
8.
Berth 5

1.
2.

Berth 6

3.
4.
5.
6.
1.
2.
3.
4.
5.
6.

April 2007
Rev.
:A
Chapter : 8
Page
:2

berth-3; MOV-076 & MOV-078 if the signal is from berth-4)


Close Diesel loading arms isolation MOVs (MOV-060 & MOV-062 if the signal
is from berth-3; MOV-073 if the signal is from berth-4).
Close Jet A1 loading arms isolation MOV (MOV-057 if the signal is from berth3 and MOV-071 if the signal is from berth-4)
Close the bunkering flow control valve FV-005 for berth 3 / 4
Generates BERTH-3 ESD or BERTH-4 ESD alarm in the ADP of SCC and
JCC depending from which berth the ESD signal is activated.
If the LPG loading arm isolation MOV is open, trip LPG ship loading pumps
and close the ESD valves XV- 026 & XV-027on the liquid line and XV- 030 &
XV-031on vapor line.
If the propylene loading arm isolation MOV is open, trip Propylene ship loading
pumps and close the ESD valves XV-032 & XV-040 on the liquid line and XV034 & XV-040 on vapor line.
Close the LPG arm isolation MOVs (MOV-038 & MOV-039)
Close Propylene loading arms isolation MOVs (MOV-036 & MOV-037).
Close the bunkering flow control valve FV-004 for berth 5 / 6
Generates BERTH-5 ESD alarm in the ADP of SCC and JCC.
If the LPG loading arm isolation MOV is open, trip LPG ship loading pumps
and close the ESD valves XV- 026 & XV-027on the liquid line and XV- 030 &
XV-031on vapor line.
If the fuel oil loading arm isolation MOV is open, trip Fuel Oil ship loading
pump and close the ESD valve XV-035 on the fuel oil line.
Close the LPG loading arms isolation MOVs (MOV-028 & MOV-029)
Close Fuel oil loading arm isolation MOVs (MOV-024 & MOV-025).
Close the bunkering flow control valve FV-004 for berth 5 / 6
Generates BERTH-6 ESD alarm in the ADP of SCC and JCC.

The table below lists the actions that will be performed when there is an ESD signal from the
loading arms.
Causes
1. Loading Arm excess angle alarm
(apex or slew angle)
2. ESD push button activation from the
loading arm control panel or pendant
box
3. QCDC Limit Switch not closed
during freewheeling mode.

4. Loading arm not connected to ship


5. Low-low pressure in hydraulic oil
circuit (only for LPG and propylene
loading arms in berths 5 and 6)

Effect
1. Trips the respective ship loading pumps that is currently feeding
the berth (Mogas 92/95, Mogas 90, ADO pumps if the signal is
from the respective loading arm in berth 1 or 2 or 3 or 4;
JetA1/Kerosene pumps if the signal is from Jet A1 loading arm in
berth 3 or 4; LPG or propylene pumps if the signal is from the
respective loading arm in berth 5 or 6 and fuel oil pumps if the
signal is from fuel oil loading arm in berth 6)
2. Closes the jetty ESD valve to the respective berths. (Jetty ESD
valve on each product line is common to a pair of berths)
3. Closes the respective loading arm isolation MOV
1. Close the respective loading arm isolation MOV.
1. Trips the respective ship loading pump (LPG or propylene) that
is currently feeding the berth.
2. Closes the jetty ESD valve to the berth 5/6
3. Closes the respective loading arm isolation MOV

The LPG and Propylene loading arms are provided with Emergency Release System (ERS).
Activation of ERS to close the loading arms valves and disconnection of loading arm from the ship
is an ESD-2 action within the loading arm PLC. Activation of ERS can be caused due to excess
angle trip alarms (2nd stage alarms for apex and slew angles) or by ESD-2 pushbutton from the
Jetty Head Console of the loading arm. This ESD-2 action will also generate loading arm ESD
signal resulting in tripping of respective loading pumps and closing jetty ESD valves (on liquid and
vapour line). For more details refer to Loading Arm Control System Description (8474L-081-A35014026-051-001) in chapter-3.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)
8.1.2

April 2007
Rev.
:A
Chapter : 8
Page
:3

Total ESD of the Jetty


Total ESD of the jetty will occur under the following conditions:
1) Power failure in the jetty (SS-10 failure)
2) Low-low pressure of the Instrument Air header.
These two causes will result in total shutdown which is to close all the onshore ESD valves on all
the product lines and vapour return lines and trip all the ship loading pumps at one stroke. All
bunkering operations will also be stopped due to the above causes.

8.2

POWER FAILURE
Power failure will results in total shutdown of all loading operation

8.3

STEAM FAILURE
There is no steam usage in the jetty area. Therefore, steam failure is not applicable.

8.4

INSTRUMENT AIR FAILURE


Low-low pressure in instrument air receiver D-8124 will result in total shutdown of all loading
operation. Three pressure transmitters are provided in the instrument air line with a 2-out-of-3
voting system to activate the ESD logic.

8.5

NITROGEN FAILURE
Nitrogen is only used for purging and in utility stations. Hence, nitrogen failure has no major
consequence that will require an emergency shutdown.

8.6

MECHANICAL FAILURE
Loading arms do not have moving parts and generally do not require much maintenance.
Moreover, all loading arms are adequately spared (except fuel oil loading arm). Custody transfer
meter for Mogas and Auto Diesel are spared. The design of the jetty also provides the flexibility
for many loading scenarios. So, mechanical failure has no major consequence.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

9.

SAFETY EQUIPMENT AND PROCEDURES

9.1

PRESSURE SAFETY DEVICES

April 2007
Rev.
:A
Chapter : 9
Page
:1

The following pressure safety devices are provided.


PSV Tag No.

Location

PSV-041
PSV-040

D-8124
D-8123

Set Pressure
kg/cm2G
10.2
11.7

Relieving to
Atmosphere
Atmosphere

Relief
scenario
Fire
Fire

Operating/
Spare
1/0
1/0

Adequate thermal relief valves are provided in all the loading headers and loading manifolds.
The discharge from the thermal relief valves in LPG and propylene service are routed to the
vapour return header. The discharge from the thermal relief valves of other services are routed
via an open funnel to the slops collection header leading to the oily water drum in the respective
berths.
Refer to TSV and PSV Datasheets generated by InTools to be attached.
9.2

ALARM SETTINGS
Refer to I/O list of Unit-081 extracted from 8474L-600-NM-1511-002 to be attached

9.3

TRIP SETTINGS
Refer to I/O list attached in section 9.2

9.4

TRIP SYSTEM CHART


Refer to I/O list attached in section 9.2
Refer to Cause and Effect Diagram attached in section 9.5

9.5

CAUSE AND EFFECT DIAGRAMS


Refer to Cause and Effect Diagram (8474L-081-DW-1514-201) to be attached

9.6

MATERIAL HAZARD DATA SHEETS


Since all products that are handled are mixtures of liquid hydrocarbon, there are no applicable
Material Safety Data Sheets for this unit.

9.7

SAFEGUARDING MEMORANDUM
The Hazard and Operability Study (HAZOP) was conducted to identify all potential risks that
could result in unsafe conditions and safeguards. The design and plot plan have been developed
based on the international and Vietnamese regulations listed in the Basic Engineering Design
Data (8474L-000-PP-204).

9.7.1

Introduction
The transfer of hazardous materials between ship and shore during loading depends on the
effective operation of a number of systems which include:
(1) mooring system;
(2) loading arms;
(3) pumping system.
Some hazards of shipshore transfer are:
(1) ship movement;

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 9
Page
:2

(2) leakage;
(3) overfilling;
(4) overpressure;
(5) pressure surge.
The mooring system is provided so that motion of the ship is minimal and ship does not break
away during transfer.
The jetty loading systems have been designed to prevent and/or mitigate the potential hazards
like leakage, pressure surge, and fire in the berths, overfilling or overpressure of tanks. The ESD
systems are designed taking into consideration the consequence of the potential hazards
mentioned above.
The ESD trip system is designed such that the loading operation can be shut-off quickly in the
event of a potential for any of the hazardous scenario. The generation of surge pressures on
closing of an ESD valve is a vital consideration in transfer systems as transfer rates may have to
be reduced to avoid excessive surge pressures generated by rapid valve closure. From surge
calculations the Effective (optimum) Valve Closure Time has been established, being the period
over which a given ESD valve reduces the flow from 90 % of its steady state to zero at the
design flow rates. For ESD valves in LPG and propylene service the closing time is 5 seconds
regardless of the size, whilst for ESD valves in other fluid service the average closing time is
optimized to minimize the potential impact of surge pressure.
The design pressure specified for the piping system has an adequate margin over the maximum
transient pressure due to surge at maximum loading rates, and the ESD valve closing time and
characteristics have been optimized to minimize the potential risk of surge pressure. Therefore it
is concluded that surge protection equipment is not required for any of the loading lines.
The closing of the ship side ESD valve due to overfilling or overpressure while the ship loading
pumps are continuing to run (against a dead-head) is also considered in the surge analysis
with a criteria of linear characteristic ESD valves, 24 seconds valve closing time for liquid product
carriers (2 sec per inch-dia for ocean carriers and 3 sec per inch-dia for coastal carriers) and 5
seconds valve closing time, regardless of its size, for liquefied gas carriers (LPG and propylene).
The International Maritime Organisation (IMO) Code requires ship manifold valves to close within
30 seconds of initiation of the shutdown. As the response/signal time is included in the quoted 30
seconds, a long response time can result in a short valve closure time. Since the ships on-board
piping and valve sizes can vary from ship to ship, the total closing time of ship side ESD valve
will also vary. Therefore, for all vessels loaded from this terminal, it is recommended to verify the
closing time of the ship side ESD valves prior to commencement of loading operation (i.e. during
a shipshore safety check or compatibility check) and ensure that the total closing time is not
lower than 24 seconds. If the closing time of the ship ESD valve is too rapid, the closing time
needs to be increased to min. 24 seconds. If the closing time cannot be adjusted, the loading
rate has to be reduced to prevent surge pressures exceeding the design pressures of the shore
and/or the ship's piping systems.
It is recommended that any transfer operation should be well planned and there need to be
sufficient personnel available on ship and on shore throughout the loading operation. There
should be good communication between ship and shore and the principal tasks of the transfer
operation should be well coordinated.
One ESD pushbutton is provided for each berth close to the exit route walkway near the operator
shelter. Fire detectors are provided in each berth for berths 1, 2, 3 and 4. Fire and gas detectors
are provided in each berth for berths 5 and 6 as these berths are intended for loading liquefied gas
products namely LPG and propylene.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)
9.7.2

April 2007
Rev.
:A
Chapter : 9
Page
:3

Emergency Shutdown Systems General Description


The marine loading terminals Emergency Shutdown (ESD) system has been developed to
minimize potential risks during the transfer of petroleum products and liquefied gases during ship
loading operations.
On each product pipeline (other than LPG and Propylene) one ESD valve is provided on-shore
close to the Jetty foot, and one ESD valve is provided at the Berth, located not less than 70m
from the Berth. On LPG and Propylene export pipeline and on the LPG and Propylene Vapour
Return pipelines, two ESD valves are provided on-shore close to the Jetty foot, and two ESD
valves are provided at each Berth located a minimum of 70m from the Berth.
All the twenty loading arms are equipped with hydraulically operated Quick-Connect-Disconnect
Coupler (QCDC). The two LPG loading arms and one propylene loading arm are equipped with
Emergency Release System (ERS), which is mandatory as per OCIMF requirements. For other
liquid product loading arms the ERS is not essential as this is a well protected harbour, where
ships can be securely moored with minimal impact of wind, tide and current, and surge from
other ship movements in the vicinity is not a problem.
For all the twenty loading arms, the opening of the QCDC is interlocked with the loading arm
isolation MOV (via ESD system) to prevent accidental spillage.
For LPG and propylene loading systems, because of the large volumes of flammable vapours
formed in case of liquid spillage and the high liquid transfer rates, all the emergency scenarios
envisaged at the ship/shore interface require an initial action to stop the transfer operation in a
quick, safe and controlled manner. Two levels/stages of ESD action are therefore envisaged for
the LPG and propylene loading systems.
In the first level of ESD (or ESD-1), the ESD valves located in the individual berths shall close
and the respective transfer (loading) pumps shall stop when there is an emergency situation in
the respective berth (namely, fire or gas detection, ESD pushbutton activation from berth 5 or 6,
ESD pushbutton activation from loading arm control panel or pendant box, loading arm excess
angle pre-alarm and low-low pressure of hydraulic oil in the ERS).
The second level of ESD (or ESD-2) will be activated only in the event of a ship drifting away too
far from the loading berth (say during a storm in the sea and/or when the wind speed exceeds
the safe limit for loading arms to remain connected). When the ship moves beyond the design
envelope of the loading arm(s), the loading arm excess angle trip alarm is activated and the
ESD-2 is initiated which results in rapid closure of the ERS valves followed by rapid and
automatic disconnection of the loading arm from the ship. The total time for ERS valve closing
and disconnection of loading arm is 8 seconds. The loading arm excess angle pre-alarm sensor
and trip-alarm sensor are built on 2-out-of-2 logic implying that ESD-1 is positively initiated
prior to ESD-2 activation. By this way, the loading pumps would have already tripped and ESD
valves also already closed prior to or at the same time when ESD-2 is initiated. The ESD-2 can
also be manually initiated by the pushbutton provided in the loading arm control panel. Due to
potential source of spurious trips that can be caused by mechanical failure and/or human error, it
is not necessary to initiate an ESD-2 action manually from the ship. Therefore, ESD-2
pushbutton is not provided in the pendant box. However, ESD-1 can be initiated manually from
the ship through the pendant box that will be put aboard a ship along with each loading arm prior
to commencement of transfer operations
Other than LPG and propylene, all the other 17 loading arms are equipped only with a QCDC (no
ERS mechanism) and therefore have only one level of ESD.
The hydraulic control system operating the loading arm ERS has a pressure retention capability
of 3 hours in the event of power failure.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 9
Page
:4

Reset of ESD
Depending on the type of ESD action, whenever initiated, either one or more or all the loading
operation(s) is stopped. After analyzing the root cause for the ESD initiation and after checking
that all the necessary corrective actions have been implemented, the reset of the ESD is done
manually by the operator. Once the reset is done, the operator can initiate the OMS to perform a
final check for line-up of product movement prior to resuming the loading operations. Since the
OMS allows the operator to restart after a shutdown while keeping it associated to the same
movement order, the inventory reconciliation can still be performed by the OMS/TAS.
9.7.3

ESD-1, First Stage Emergency Shutdown System


The ESD-1 (First Stage Emergency Shutdown System) shuts down the transfer operation in a
quick, safe and controlled manner so as to prevent or minimise the potential release of
hydrocarbon product, liquefied gas or vapour in the event of an emergency. This is achieved by
closing of the ESD-1 valves located near the berth and simultaneous tripping of the respective
loading pumps.
ESD-1 Initiation
At all berths ESD-1 can be initiated:
- MANUALLY by means of push buttons (in the respective berths or loading arm control panel
or pendant box)
- AUTOMATICALLY by means of (emergency) alarm signals received from the loading arms
and/or fire/gas detectors and act to close ESD valves at the respective berth and trip the
respective pumps in the transfer system.
The ESD-1 system is designed to allow transfer to be restarted with minimum delay after
corrective action has been taken.
ESD-1 System components
The ESD-1 system comprises of:
(i) ESD valves installed in each of the liquid and vapour lines
(ii) Pushbuttons installed at strategic locations in the berth area
(iii) A pendant box which will be put aboard a ship prior to commencement of transfer operations
(as there will be no direct ship/shore communication link)
(iv) ESD logic control system.
ESD-1 Action
The initiation of an ESD-1 will:
(i) Close the ESD valves in the respective berth. (The ship ESD valves are expected to close
within such time as is permissible in accordance with the IMO codes and consistent with
acceptable surge pressures at agreed maximum pumping rates)
(ii) Trip the respective shore transfer pumps;
(iii) Close the loading arm isolation MOV.
ESD Valves
ESD valves installed as part of the ESD system are remotely operable, fail-safe, tight shut-off,
pneumatically actuated ball valves. Ball valves are used for ESD service in view of their relatively
smooth closure characteristic in comparison with other types of valve.
Loading Arm isolation MOV's
Each loading arm is provided with motor operated valves as primary isolation at the connection
to each product loading manifold (upstream of the loading arms). These 'Loading MOV's are
fitted with limit switches to indicate when the valves are in the 'closed' and 'not closed' position,
which is a vital input (or permissive) for activating an ESD logic.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 9
Page
:5

NOTES:
1) It should be noted that opening of the loading arm isolation MOV will only be possible if the
mode selection switch is in the 'Free-wheeling' position, i.e. when the arm is connected to a
ship and the QCDC limit switch close confirmation is available. An ESD interlock is
provided to this effect.
2) When the mode selection switch of the loading arm is put in the 'Parking/manoeuvring'
position (i.e. the loading arm is not connected to the ship and/or QCDC limit switch close
position is not available) the Loading arm isolation MOV will be closed via ESD interlock.
9.7.4

ESD-2, Second Stage Emergency Shutdown System


The purpose of ESD-2 (Second Stage Emergency Shutdown) system for LPG and propylene
service is to uncouple the loading arm quickly (typically within 8 seconds; 5 seconds to close the
ERS valve and 3 seconds for uncoupling) with minimal spillage in an emergency when the ship
or loading arm/s are at risk.
The ESD-2 shutdown is initiated:
- MANUALLY by means of push button in the loading arm control panel
- AUTOMATICALLY by the activation of excess angle (apex or slew angle) trip alarm when the
ship moves beyond the design envelope of the loading arm.
The ERS is activated when there is potential for damage to the loading arms or the ship due to
ship drift under adverse weather or current conditions (like wind, tide). Accidental manual
initiation and/or uncoupling of the ERC during maneuvering of the loading arm is inhibited by
logic interlocks within the loading arm PLC.
ESD-2 System components
The ESD-2 system comprises:
(i) The Emergency Release System (ERS) for LPG and Propylene loading arms (for both liquid
and vapour return arms).
(ii) The ESD-2 logic control system in the loading arm PLC.
The ERS comprises of the following:
(i) Emergency Release Coupling (ERC) in liquid and vapour arms
(ii) Two isolation valves (i.e. the ERS valves), one upstream and one downstream of the ERC.
The ERS valves are ball valves, and by design of the hydraulic oil circuit and logic system
complete closure of the ERS valves is ensured before the loading arm is uncoupled.
ESD-2 Action
The initiation of an ESD-2 will:
(i) Automatically close both isolating valves of the ERS on LPG and propylene loading arms
(liquid and vapour)
(ii) Automatically uncouple the loading arm after the ERS isolation valves have been closed
Loading arm excess angle alarms
To safeguard the loading arm when connected to a ship that is drifting away, it has to be
uncoupled before it reaches its mechanical limit line (i.e. exceeds the design operating
envelope). The ESD actions are initiated by proximity switches detecting the apex angle and
slew angle which are preset as follows:
(i)
Pre-alarm: A proximity switch is set to initiate a pre-alarm (1st stage over reach) and
ESD-1 when the loading arm is at 2.5 metres before the design limit line of the
mechanical reach of the loading arm.
(ii)
Trip Alarm: If the loading arm is further extended beyond the pre-alarm setting to a
position that is 2.0 metres (2nd stage over reach) before the design limit line of the
mechanical reach, an ESD-2 action shall be initiated.
For loading arms without ERS, there is only one level of excess angle alarm, which is set at a
position that is 2.0 metres before the design limit line of the loading arms mechanical reach.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

April 2007
Rev.
:A
Chapter : 9
Page
:6

Safeguards to prevent accidental activation of ESD-2


Since the weight of the end section of the loading arm together with its ERS valve is substantial,
additional safeguards are required to prevent accidental uncoupling (with associated safety
hazards) occurring when the arm is parked or being maneuvered (i.e. not connected to the ship's
manifold).
The following provisions are therefore be included:
(i)
The push buttons for manual ESD-2 initiation are provided with a protective cover in the
loading arm control panel.
(ii)
The loading arm control system provides an adequate interlock to prevent accidental
activation of the ERS during maneuvering mode i.e. solenoid valves with a 2oo3 voting
system is provided such that 2 of them need to get deenergised before ERS activation
st
can occur. If during maneuvering mode, the loading arms pre-alarm (1 stage overreach
alarm) is activated, the interlocking system will inhibit further forward movement by
closing the respective solenoid valve in the hydraulic oil loop and hydraulic oil pressure
will not be available for further forward movement until the arm is retracted back to safe
position.
9.7.5

Total Emergency Shut Down of the Jetty


Total shut down of the entire jetty can be activated due to either of the following two causes:
(i) Low-low pressure of the instrument air header
(ii) Local power failure (i.e. failure in substation 10)
Either of the causes mentioned above will result in closing all the onshore ESD valves on all the
product lines and vapour return lines and trip all the ship loading pumps at one stroke. All
bunkering operations will also be stopped due to the above causes by closing of the bunkering
flow control valves via ESD interlock and automatic switch over of these valves to manual mode
via the DCS.
Though the pneumatic ESD valves have a fail-safe design (i.e. valves automatically close in the
event of air failure), closing of all jetty side ESD valves at one stroke when loading is in progress
could result in an undue surge load on the jetty piping and structures. In order to avoid this
situation, a total emergency shutdown can be activated in the event of a low-low pressure in the
instrument air header. This is achieved through a 2oo3 voted pressure transmitters in the
instrument air header, thereby avoiding any spurious trip.
In the event of a local power failure resulting in a black-out, it is necessary to prevent any unsafe
situation in the loading berths. Therefore, local power failure will also result in total emergency
shutdown of the jetty.

9.7.6

Slops and Oily Water System


For the slops and oily water drums D-8110A/B/C/D/E/F, the level transmitter is used to control
the liquid level in the pit by auto start/stop of the slop and oily water transfer pump
P-8110A/B/C/D/E/F at high/low level respectively. In the event the pump fails to start or stop at
the preset level, the pre-alarm (LAH/LAL) in the DCS will alert the operator for taking necessary
action.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

10.

INSTRUMENT DATA
Refer to Instrument Datasheets generated by InTools.

April 2007
Rev.
:A
Chapter : 10
Page
:1

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

11.

SUMMARY OF MAJOR EQUIPMENT

11.1

EQUIPMENT LIST

April 2007
Rev.
:A
Chapter : 11
Page
:1

Equipment List for Unit-081 extracted from Document Number 8474L-600-EL-001 will be
inserted.
11.2

PUMPS
Pumps Vendor Datasheets including Q-H curve will be attached.

11.3

DRUMS
Mechanical Drawings of oily water drums, IA and nitrogen receivers, including the General
Arrangement, will be attached in this chapter.

11.4

OTHER VENDOR INFORMATION


Vendor list of instruments along with vendor P&IDs will be inserted (for Custody Transfer Meter,
Prover and Loading Arm).
Loading arms functional logic diagram will be inserted.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

12.

April 2007
Rev.
:A
Chapter : 12
Page
:1

ANALYSIS
All analyses are performed in the product tank farm (in Unit-052). No specific analytical
requirements in this unit.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

13.

PROCESS CONTROL

13.1

DISTRIBUTED CONTROL SYSTEM (DCS)

April 2007
Rev.
:A
Chapter : 13
Page
:1

Refer to the following documents (to be attached):

13.2

8474L-000-JSS-1511-001: Distributed Control System Technical Specification


8474L-000-JSD-1510-001: Design and Engineering Information for Control and
Instrumentation
8474L-000-DW-1512-001: Control Systems Interconnection Diagram.

INSTRUMENTED PROTECTIVE SYSTEM (IPS) AND SAFEGUARDING SYSTEMS


Refer to the following documents (to be attached):

13.3

8474L-000-JSS-1515-001: Emergency Shutdown Systems Standard


8474L-000-JSD-1510-001: Design and Engineering Information for Control and
Instrumentation
8474L-000-DW-1512-001: Control Systems Interconnection Diagram.

CONTROL CENTRE
Refer to the following documents (to be attached):

13.4

8474L-000-JSD-1510-001: Design and Engineering Information for Control and


Instrumentation
8474L-000-DW-1512-001: Control Systems Interconnection Diagram.

OTHER SPECIFICATIONS
The following Specifications refer to Control and Monitoring Systems provided for Off-sites
facilities:

8474L-000-JSS-1515-008: Terminal Automation System


8474L-000-JSS-1518-008: Oil Movements and Storage Control System.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
JETTY TOPSIDES - MARINE LOADING (081)

14.

DRAWINGS

14.1

PLOT PLANS

14.2

8474L-081-DW-0051-001

Unit Plot Plan

8474L-081-DW-1920-001

Hazardous Area Classification

PROCESS FLOW DIAGRAM


8474L-081-PFD-0010-001
8474L-081-PFD-0010-002
8474L-081-PFD-0010-003
8474L-081-PFD-0010-004

14.3

PIPING AND INSTRUMENTATION DIAGRAMS


8474L-081-PID-0021-001
8474L-081-PID-0021-002
8474L-081-PID-0021-003
8474L-081-PID-0021-004
8474L-081-PID-0021-005
8474L-081-PID-0021-006
8474L-081-PID-0021-007
8474L-081-PID-0021-008
8474L-081-PID-0021-009
8474L-081-PID-0021-010
8474L-081-PID-0021-031
8474L-081-PID-0021-032
8474L-081-PID-0021-033
8474L-081-PID-0021-034
8474L-081-PID-0021-035
8474L-081-PID-0021-036
8474L-081-PID-0031-001
8474L-081-PID-0031-002
8474L-081-PID-0031-003
8474L-081-PID-0031-004
8474L-081-PID-0031-005

14.4

OTHER DRAWINGS
Electric Single Line Diagram
Sewer/drainage Network
Fire Fighting Water Distribution Diagram

April 2007
Rev.
:A
Chapter : 14
Page
:1