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AEGIS LOGISTICS LIMITED

STANDARD OPERATING PROCEDURE


SOP/GTD/001
PRE-CHILLING & SAFETY CHECKS
Page 1 of 4

I) Ship unloading line Pre-chilling Operation for LPG mix.

Ship unloading line has to be cooled to tank product temperature, before the
ship berths.

1. Bring down tank pressure to 50 mbar by running compressor before starting


chilling.

2. Line up for chilling operation at jetty and shore side by ensuring


a) Following valves are in closed position.
1 Old jetty hose connection line up is to be blinded.
2 At old jetty I/V (10”) hose connection line is to be closed.
3 At old jetty I/V (6”) line is to be closed.
4 XVX-2001 closed.
5 XVX 2001 its D/S 12” I/V is to be closed.
6 2” I/V on bypass line is to be closed.
7 Ensure that all vent valves is to be in closed position &
blinded.
8 On tank top 12” D/S I/V of PCV P1010 is to be closed.
9 PCV P1010 closed.
10 6" I/V near E402 on chilling return line is to be closed.
11 XVX 2501 and its I/V is to be closed.
12 XVX 2503 and its I/V (near E1023) is to be closed.

b) Following valves in open position


1 FCV F-1003 and its U/S and D/S I/V is to be opened.
2 At valve station XVX 2002 and its U/S and D/S I/V is to be
opened.
3 12” I/V at old jetty is to be opened.
4 6” I/V which is interconnection of 12” and 6” lines at new jetty
should be opened.
5 6” line I/V at old jetty is to be opened.
6 XVX 2003 and its 6” U/S I/V is to be opened.
7 Tank T-101 top PCV P1004 and its U/S and D/S I/V is to be
opened.
8 PCV P1004 should be opened as per requirement.

c) Pipeline Patrolling team is in place.


AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/001
PRE-CHILLING & SAFETY CHECKS
Page 2 of 4

3. Start Intank pump which is inline, after ensuring the following (If pump is not
running for tanker loading).

a) Storage tank pressure is 50 mbar to 90 mbar.


b) Liquid level of storage tank is higher than 1525 mm.
c) Open respective I/V of intank pump discharge line on tank top.
d) Ensure that HCV 1001 is in closed position.
e) After five minutes, Put FCV 1001 on auto mode keeping set point 40
m3/hr.
f) Open FCV 1003 slowly 5% to 10% and slowly increase the chilling flow
to 90 m3/hr.

4. Continue Chilling operation until ship unloading line temperature at jetty is


within 8° C of tank product temperature.

SAFETY CHECKS
1. Take trial for D.G. operation and ensure emergency back up power supply is
available.

2. Ensure that all compressors are in operating condition (check oil level in
comp oil separator)

3. Check fire water system. Ensure that fire tender is in operating condition with
all fire fighting equipments.

4. Carry out pre shipment activities as per checklist.

5. During the chilling operation check for any leakage (by portable LEL meter as
well as visually) at new jetty, old jetty, valve station and along the pipelines.

6. While chilling operation in progress, keep watch on line pressure at jetty end
and valve station. Monitor new jetty temperature at regular interval.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/001
PRE-CHILLING & SAFETY CHECKS
Page 3 of 4

II. Ship unloading line Prechilling Operation for Propane.

Ship unloading line has to be cooled to tank product temperature, before the
ship berths.

1. Bring down tank pressure to 50 mbar by running compressor before starting


chilling.

2. Line up for chilling operation at jetty and shore side by ensuring


a) Following valves are in closed position.
1. Old jetty hose connection line up is to be blinded.
2. At old jetty I/V (10”) hose connection line is to be
closed.
3. At old jetty I/V (6”) line is to be closed.
4. XVX-2001 closed.
5. XVX 2001 its D/S 12” I/V is to be closed.
6. 2” I/V on bypass line should be closed.
7 Ensure that all vent valves is to be in closed position &
blinded.
8. On tank top 12” D/S I/V of PCV P1510 is to be closed.
9. PCV P1510 closed.
10. XVX 2002 and its I/V is to be closed.
11. XVX 2003 and its U/S I/V is to be closed.

b) Following valves in open position


1. FCV F-1503 and its U/S and D/S I/V is to be opened.
2. At valve station XVX 2501 and its U/S and D/S I/V is to be
opened.
3. 12” I/V at old jetty is to be opened.
4. 6” I/V which is interconnection of 12” and 6” lines at new jetty
is to be opened.
5. 6” line I/V at old jetty is to be opened.
6. XVX 2503 and its 6” U/S I/V is to be opened.
7. Tank T-102 top PCV P1507 and its U/S and D/S I/V is to be
opened.
8. PCV P1507 is to be opened as per requirement.

c) Pipeline Patrolling team is in place.


AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/001
PRE-CHILLING & SAFETY CHECKS
Page 4 of 4

3. Start Intank pump which is inline, after ensuring the following (If pump is not
running for PLT).
a) Storage tank pressure is 50 mbar to 90 mbar.
b) Liquid level of storage tank is higher than 1525 mm.
c) Open respective I/V of intank pump discharge line on tank top.
d) Ensure that HCV 1501 is in closed position.
e) After five minutes, Put FCV 1501 on auto mode keeping set point 40
m3/hr.
f) Open FCV 1503 slowly 5% to 10% and slowly increase the chilling flow
to 90 m3/hr.

4. Continue Chilling operation until ship unloading line temperature at jetty is


within 8° C of tank product temperature.

SAFETY CHECKS
1. Take trial for D.G. operation and ensure emergency back up power supply is
available.

2. Ensure that all compressors are in operating condition (check oil level in
comp oil separator)

3. Check fire water system. Ensure that fire tender is in operating condition with
all fire fighting equipment.

4. Carry out pre shipment activities as per checklist.

5. During the chilling operation check for any leakage (by portable LEL meter as
well as visually) at new jetty, old jetty, valve station and along the pipelines.

6. While chilling operation in progress, keep watch on line pressure at jetty end
and valve station. Monitor new jetty temperature at regular interval.

Reference :
1. P&ID – Storage Tank LPG 101
2. P&ID – Storage Tank Propane 102
3. P&ID – Ship unloading arm

Prepared by : Approved by : Revision No.


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/002
SHIP UNLOADING ARM CONNECTION
Page 1 of 1

CHECKS FOR CONNECTION OF UNLOADING ARM TO SHIP MANIFOLD

1. Check ship manifold flange rating and size, if size is not compatible, check
requirement of gasket and reducer.

2. Check that manifold should remain within operating envelope range. (check
as per envelope drawing)

3. Check that vessel is moored properly.

4. Ensure that the Loading arm is de-pressurized.

5. Connect the loading arm to ship manifold.

6. Purge the loading arm with Nitrogen and take leak test.

7. After ensuring leak test is OK, depressurize and line up for ship unloading.

Reference :
1. Drawing of H201 (Loading arm)

Prepared by : Approved by : Revision No.


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/003
PROPANE / LPG SHIP UNLOADING
Page 1 of 6
I. SHIP UNLOADING OPERATION
( Prior to ship unloading operations, ship shore safety check list to be filled by
Loading Master)

1. Before ship unloading operation ship unloading line has to cool down to a
temperature within 8o C of the tank product temperature.

2. Ensure that all compressors are on AUTO MODE.

3. Before ship unloading tank pressure should maintain at 50 m bar.

4. To ensure product quality – product sampling and analysis of the existing


material is required. To ensure product quality of cargo – sampling and
analysis is required.

5. Check that ball valve on discharge side of PSV 2001 is in LOCKED OPEN
POSITION.

6. Line UP for ship unloading in JETTY and SHORE SIDE.

7. Ensure quick closing valve operations is smooth.

8. Purge loading arm – check oxygen %. Purge up to oxygen content 2%

9. Check following valve condition


a. Quick closing valve XVX 2001 open

10. Put respective intank pump on minium bypass mode & if there is no tanker
loading or PLT, stop respective intank pump close chilling supply control
valve and its isolation valve at tank top and open PCV 1010/ 1510 isolation
valve. Then open PCV 1010/ 1510 to the required extent.

11. Note level after chilling stop.

12. Inform terminal status to jetty side shift incharge.

13. Before starting ship pump bring down tank pressure at 50 m bar by
reliqufication system lineup compressor to tank.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/003
PROPANE / LPG SHIP UNLOADING
Page 2 of 6

14. Start D.G. for utilities and one LPG compressor on D.G. load only in case of
power problem.

15. Line up ship unloading line (12”) for ship unloading operation in terminal.

16. Before ship pump start ensure following valve position

a) Valve in the outboard arm of the loading arm open.

b) 6” i/v of CRL kept closed.

c) XVX 2001 & its i/v kept open.

17. OPERATION AFTER SHIP PUMP START

a. Check temperature (TI2001) that ship unloading line is cooled to required


temperature.

b. Check that unloading arm is free from vibration.

c. Check unloading arm for any leak with portable LEL meter.

d. Check & log the pressure & temperature of ship manifold & shore (jetty
manifold).

e. Log hourly readings of all parameters of tank, compressors, unloading line


(at Jetty and Valve station)

f. Control flow rate to maintain tank pressure.

g. Ensure that tank pressure does not exceed 120 m bar

h. Monitor product temperature profile in the tank, start intank pump, if TDA
exceeds 1o C on circulation mode.

i. Maintain jetty end line pressure (P-2001) below 7.5 Bar.

j. 6” i/v of CRL to be opened after getting confirmation from terminal.


AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/003
PROPANE / LPG SHIP UNLOADING
Page 3 of 6

II. OPERATION AFTER SHIP DISCHARGE COMPLETED

1. After pumping is over, note shore tank level / temperature / pressure.

2. Before hot gas blowing inform terminal incharge about starting of blowing.

3. While gas blowing monitor shore tank pressure.

4. After blowing complete, note level, temperature, pressure of tank.

5. Close 12” isolation valve and XV X 2001.

6. Isolate ship manifold.

7. Depressurize loading arm and purge with nitrogen.

8. Disconnect loading arm.

9. Empty the unloading lines as follows :

a. Start compressor C-1021 / C-1022 whichever is connected to tank.

b. Start hot gas blowing as follows:

i) Condenser E 1021 or E 1027 (whichever is in line with tanks) Vent


valve should be open.

ii) Chilling return Cooler E 1023 shell side outlet vent valve should be
open.

iii) 6” Isolation valve towards valve station on chilling return subcooler


E 1023 should be open.

iv) XVX 2503 should be open.

v) Ensure XVX2002 / XVX 2501 is open.

vi) Ensure PCV P1010 / PCV P1510 is open and controlled as per
tank pressure.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/003
PROPANE / LPG SHIP UNLOADING
Page 4 of 6

vii) Ensure XVX 2003 is closed.

viii) Ensure PCV P1004 / PCV P1507 is closed.

ix) Ensure chilling return sub cooler E1023, shell side outlet isolation
valve towards T102 is closed.

c. Continue hot gas blowing till no rise in tank level is observed or


i. change in valve station temperature or considerable rise in
tank pressure.

d. Stop hot gas blowing once above condition in points no. ‘c’ are fulfilled.

e. Close the following valves in order.

i) Condenser E 1021 or E 1027 (whichever is in line with the tank) Vent


valve

ii) Chilling return cooler E 1023 shell side outlet vent valve.

iii) XVX 2503

10. After completion of hot gas blowing, depressurize 12” ship unloading line and
6” chilling return line in respective tank.

A. PROCEDURE FOR CHANGE OVER OF PROPANE TO LPG.


After completion of Propane Unloading

1. Ask ship to start blowing hot gas in the loading arm.


2. Depressurise the loading arm, close forearm isolation valve of loading arm
and change the loading arm to LPG manifold if required.
3. After ensuring proper line up, start pumping LPG at slow rate to the unloading
rate to max 100 MT / hr.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/003
PROPANE / LPG SHIP UNLOADING
Page 5 of 6
4. Observe the Propane tank pressure and valve station temperature, where the
temperature shows an upward trend (above -42 o C) & Propane pipeline
quantity is received.
5. Perform online change over from Propane to LPG tank as follows:
a. Keep isolation valve PCV1010 at tank top open and XV2002 isolation
valve at valve station open (prior or at start of LPG cargo)
b. Open XV2002 (LPG) at valve station & open PCV1010 at tank top, after
receipt of line quantity & by observing pressure trend of propane tank.
c. Obtain confirmation from Field Officer, the valves are open at LPG tank.
d. Close XV2501 Propane at valve station & PCV1510 at tank top.
e. Observe the level in LPG tank.
f. Keep monitoring the pressure of both Propane & LPG tank & take action
accordingly. (Line up of compressor to be changed as per requirement).
g. Once the conditions are stable, raise the LPG unloading rate to maximum
(i.e. from 100 MT/hr to 450 MT/hr) gradually.

B. PROCEDURE FOR CHANGE OVER OF LPG TO PROPANE.


After completion of LPG Unloading
1. Ask ship to start blowing hot gas in the loading arm.
2. Depressurise the loading arm, close forearm isolation valve of loading arm
and change the loading arm to Propane manifold if required.
3. After ensuring proper line up, start pumping Propane at slow rate to the
unloading rate to max 100 MT / hr.
4. Observe the LPG tank pressure and valve station temperature, where the
temperature shows an upward trend (above -25 o C) & LPG pipeline quantity
is received.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/003
PROPANE / LPG SHIP UNLOADING
Page 6 of 6
5. Perform online change over from LPG to Propane tank as follows:
a. Keep isolation valve PCV1510 at tank top open and XV2501 isolation
valve at valve station open (prior or at start of Propane cargo)
b. Open XV2501 (Propane) at valve station & open PCV1510 at tank top,
after receipt of line quantity & by observing pressure trend of propane
tank.
c. Obtain confirmation from Field Officer, the valves are open at Propane
tank.
d. Close XV2002 LPG at valve station & PCV1010 at tank top.
e. Observe the level in Propane tank.
f. Keep monitoring the pressure of both Propane & LPG tank & take action
accordingly. (Line up of compressor to be changed as per requirement).
g. Once the conditions are stable, raise the Propane unloading rate to
maximum (i.e. from 100 MT/hr to 450 MT/hr) gradually.

Reference :
1. P&ID – Storage Tank LPG 101
2. P&ID – Storage Tank Propane 102
3. P&ID – Ship unloading arm

Prepared by : Approved by : Revision No.


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/004
PROPANE TANKER LOADING
Page 1 of 5
Truck loading operator shall fill the checklist every time for Truck Loading Operation
(for each Truck)

I. Control Room Officer to ensure the cooling water system line up for
Heaters from Operation Officer / Plant Operator, as per following
1. Ensure the cooling water inlet & outlet isolation valves to Propane heater
E1024 / E1024B are in open condition.
2. Ensure that isolation valve on cooling water return header from heater circuit
to cooling tower is open.
3. Ensure that all cells are in line on cooling tower deck.
4. Ensure that drain valves & vent valves in heater cooling water circuit are in
closed condition.
5. Start cooling water pump P801 A/B/C or P803 A/B & establish cooling water
flow by deaeration through vents in heater circuit as required.
6. Run the cooling tower fans as per cooling water temperature.

II Control Room Officer to ensure the Heater and Air Fin Heater system
line up from Operation Officer / Plant Operator as per following:
1. Ensure propane heaters E 1024/E & 1024B are in line.
2. Ensure Air Fin Heater E 404 & E 407 are in line.
3. Ensure that instruments are fixed and are in line.
4. Ensure that PSV at u/s and d/s of HCV – 4501 are in line.
5. Ensure that 3” bypass ball valve of Air Fin Heater is in closed condition.
6. Ensure that HCV-4501 is storke-checked and operated normally.
7. Start the Air Fin Heater fan (if heater outlet temperature falls to less than 10 o
C) and observe for any abnormal sound.
8. Ensure that HCV-4501 hand control valve is in closed condition.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/004
PROPANE TANKER LOADING
Page 2 of 5
9. Open the isolation valve on u/s and d/s of HCV-4501.

III. OPERATING PROCEDURE BEFORE START OF TRUCK FILLING (FOR


TRUCK LOADING OPERATOR)
1. On arrival of truck at the loading bay, truck loading operator shall receive the
weighbridge slip from the truck driver, examine whether the same is O.K.
2. Ask truck driver to apply handbrake and check. Ensure the truck is in first
gear position.
3. Take truck ignition key from the driver.
4. Place wheel brake trolley on the front wheel.
5. Connect earthing cable and check for earthing healthiness.
6. Crack open the vapour valve of tanker & check the O 2 content in the tanker
with the help of portable O2 meter. (If O2 % is more than 1% report to SIC).
7. Check the tanker male coupling thread condition with GO/NOGO gauge. If
found any deviation report to shift incharge.
8. Connect loading arm to the liquid line of the truck.
a) If instructed by the shift-in-charge / control room officer connect
vapour loading arm to the vapour line of the truck.
b) Depressurise the truck through vapour loading line as instructed by
shift-in-charge / control room officer. (If truck pressure is on higher
side)
9. Crack open liquid valve of truck and check for leak.
10. Preset the right quantity to be filled in the tank lorry in the batch controller, as
indicated in weighbridge slip.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/004
PROPANE TANKER LOADING
Page 3 of 5
IV. OPERATING PROCEDURE FOR START OF PROPANE TRUCK FILLING
(FOR CONTROL ROOM OFFICER)
1. Start Intank Pump after ensuring the following (If pump is not running for
PLT).
 Storage tank pressure is 50 m bar to 90 m bar.
 Liquid level in storage tank is higher than1525mm.
 Open respective isolation valve of Intank pump discharge line on tank
top.
 Intank Pump send out valve H 1501 / H 1502 is in closed position.
(When booster pumps are not running).
 Chilling supply valve FCV 1503 is closed.
 Intank Pump bypass valve FCV F 1501 / FCV 1502 is in full open
position.
2. After 5 minutes put FCV F 1501 / F1502 on auto mode, keeping set point 40
m3 / hr.
3. Inform Field Operator to take following actions :
 Open u/s isolation valve of HCV H4501 on line 4501-PL-100/25. (The
valve to be opened very carefully, by watching the suction pressure of
P1022 A/B which should not fall less than 12.0 bar if booster pumps
are running.)
 Sub-cooler E 1022 / E1023 / E1028 to be taken in line (as per
requirement).
 To open isolation valves on respective bays.
4. Obtain confirmation and ensure that Field Operator have taken all steps
under point no. (3) above.
5. The filling should start within five minutes after setting the batch controller.
Otherwise reset is to be done.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/004
PROPANE TANKER LOADING
Page 4 of 5
6. Ensure from Field Officer / Operator that the quantity to be filled is correctly
presetted in the respective batch controller and batch controller batch is
started.
7. Observe In-tank pump P 1021A/B total flow F1501/1502. If booster Pump/s
(P1022A/B) is / are running, the suction pressure should be monitored and
maintained above 12.0 bar.
8. a) Start opening of HCV H1501/HCV1502 and HCV H4501 (open in steps of
5%) simultaneously and monitor header pressure, current of pump &
vibrations of pump.
b) Start opening of HCV H4501 and monitor booster pumps suction pressure,
if booster pump/s is/are running.
9. Maintain tanker loading header pressure 10 – 13 bar.
10. Monitor tank pressure, level and temperature. Tanker loading operation will
get stopped automatically by the batch controller once the presetted quantity
is completed.
11. As a safety precaution, when the tanker level reaches 85% by the rotogauge
the operator should stop the loading from field & inform control room, if tanker
loading operation does not get stopped by batch controller.
12. Observe that respective loading bay XVs are closed after getting confirmation
from Truck Loading Operator that loading operation is completed.
13. Close HCV H1501 / HCV H1502 gradually after completion of tanker loading
operation if booster pumps are not running and then close HCV 4501
gradually. Monitor and maintain tanker loading header pressure 8 to 10 bar.
14. If booster pumps are running, close HCV 4501 gradually after completion of
tanker loading operation. Monitor and maintain tanker loading header
pressure 8 to 10 bar.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/004
PROPANE TANKER LOADING
Page 5 of 5
V. OPERATING PROCEDURE ON START OF TRUCK FILLING (FOR TRUCK
LOADING OPERATOR)
1. After information from Control Room, start the batch controller of the truck
filling in respective bays.
2. Check level and pressure of truck / tanker in regular intervals.
3. At rotogauge level of 80% inform Control Room, that 80% level has been
reached.
4. Monitor carefully rotogauge level between 80 to 85% As a safety precaution,
when the tanker level reaches 85% by the rotogauge the operator should stop
the loading from field & inform control room, if tanker loading operation does
not get stopped by batch controller.
5. Inform Control Room Officer and close all valves on loading arm and tanker
side. Record the final tanker level, pressure & temperature.
6. De-pressurise spool piece between loading arms valve and tanker loading
valve to vent stack. Check the Pressure gauge on de-pressurization line. If
the pressure is more than 0.5 bar, check the isolation valve for passing. If the
valve passing is observed, don’t disconnect the loading arm. Inform Shift
Incharge and after confirmation decant the tanker and then disconnect the
loading arm and send back the tanker.
7. Disconnect liquid and vapour loading arm (if connected) and put back on rest.
8. Remove earthing cable.
9. Remove wheel blocks.
10. Handover ignition key to the truck driver.
11. Stop the Air-Fin Heater fan after completion of propane tanker loading.
References :
1. P&ID for send out system.
2. P&ID for Truck loading system

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/005
LPG TANKER LOADING
Page 1 of 5

Truck loading operator shall fill the checklist every time for Truck Loading Operation
(for each Truck)

I) Control Room Officer to ensure the cooling water system line up for
Heaters from Operation Officer / Plant Operator, as per following

1. Ensure the cooling water inlet & outlet isolation valves to LPG heaters E402
and / or E1024A are in open condition.
2. Ensure that isolation valve on cooling water return header from heater circuit
to cooling tower is open.
3. Ensure that all cells are in line on cooling tower deck.
4. Ensure that drain valves & vent valves in heater cooling water circuit are in
closed & blinded condition.
5. Start cooling water pump P801 A/B/C or P803 A/B & establish cooling water
flow by deariation through vents in heater circuit as required.
6. Run the cooling tower fans as per cooling water temperature.

II) Control Room Officer to ensure the heater and air fin heater system line
up from Operation Officer / Plant Operator, as per following

1. Ensure LPG heaters E401/E402 and / or E1024A are in line.


2. Ensure the air fin heater E405 and E406 are in line.
3. Ensure that instruments are fixed and are in line.
4. Ensure that 3” bypass ball valve of Air Fin Heaters are in closed condition.
5. Start the Air Fin Heater fans (if heater outlet temperature falls to less than
10o C) and observe for any abnormal sound.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/005
LPG TANKER LOADING
Page 2 of 5

III. OPERATING PROCEDURE BEFORE START OF TRUCK FILLING (FOR


TRUCK LOADING OPERATOR)
1. On arrival of truck at the loading bay, truck loading operator shall receive the
weighbridge slip from the truck driver, examine whether the same is O.K.
2. Ask truck driver to apply handbrake and check. Ensure the truck is in first
gear position.
3. Take truck ignition key from the driver.
4. Place wheel brake trolley on the front wheel.
5. Connect earthing cable and check for earthing healthiness.
6. Crack open the vapour valve of tanker & check the O 2 content in the tanker
with the help of portable O2 meter. (If O2 % is more than 1% report to SIC).
7. Check the tanker male coupling thread condition with GO / NOGO gauge. If
found any deviation, report to Shift In-charge.
8. Connect loading arm to the liquid line of the truck.
a. If instructed by the shift-in-charge / control room officer connect
vapour loading arm to the vapour line of the truck.
b. Depressurise the truck through vapour loading line as instructed by
shift-in-charge / control room officer. (If truck pressure is on higher
side.)
9. Crack open liquid valve of truck and check for leak.
10. Preset the right quantity as indicated in weighbridge slip, to be filled in the
batch controller.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/005
LPG TANKER LOADING
Page 3 of 5

IV. OPERATING PROCEDURE FOR START OF LPG TRUCK FILLING (FOR


CONTROL ROOM OFFICER )
1. Start Intank Pump which is inline, after ensuring the following
 Storage tank pressure is 50 m bar to 90 m bar.
 Intank Pump send out valve H 1001 is in closed position.
 Chilling supply valve FCV 1003 is closed.
 Intank Pump bypass valve FCV F 1001 is in open position.
 Liquid level in storage tank is higher than 1525 mm.
 Open respective I/V of intank pump discharge line on tank top.
2. After 5 minutes put FCV F 1001 on auto mode keeping set point 40 m 3 / hr.
3. Inform Field Operator to take following actions :
 Open u/s isolation valve PCV P 5022.
 Open both isolation valve at the d/s of PCV P5022.
 Sub-cooler E1022A to be taken in line (as per requirement).
 Inform Truck Loading Operator/Officer to open isolation valve on
respective bays.
4. Obtain confirmation and ensure that Field Operator/Officer has taken all steps
under point no. (3) above.
5. The filling should start within five minutes after setting the batch controller.
Otherwise reset is to be done.
6. Ensure from Field Officer / Operator that the quantity to be filled is correctly
presetted in the respective batch controller and batch controller is started.
7. To open isolation valve on respective bays.
8. Start opening of HCV H 1001 and PCV P5022 (open in steps of 5%)
simultaneously and monitor header pressure.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/005
LPG TANKER LOADING
Page 4 of 5

9. Maintain header pressure 7 – 8 bar.


10. Monitor tank pressure, level, temperature and pump parameters (Current /
Vibrations).
11. Tanker loading operation will get stopped automatically by the batch controller
once the presetted quantity is completed.
12. As a safety precaution, when the tanker level reaches 85% by the rotogauge
the operator should stop the loading from field & inform control room, if tanker
loading operation does not get stopped by batch controller.
13. Observe that respective loading bay XVs are closed after getting confirmation
from Truck Loading Operator that loading operation is completed.
14. Close HCV H1001 gradually after completion of tanker loading operation.
Monitor and maintain LPG Tanker loading header pressure at around 6 to 7
bar.

V. OPERATING PROCEDURE ON START OF TRUCK FILLING (FOR TRUCK


LOADING OPERATOR)
1. After confirmation from Control Room, start the batch controller of the truck
filling in respective bays.
2. Check level and pressure of truck / tanker in regular intervals.
3. At rotogauge level of 80% inform Control Room, that 80% level has been
reached.
4. Monitor carefully rotogauge level between 80 to 85% and if the loading does
not stop automatically at 85%, as a safety precaution, when the tanker level
reaches 85% by the rotogauge the operator should stop the loading from field
& inform control room, if tanker loading operation does not get stopped by
batch controller.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/005
LPG TANKER LOADING
Page 5 of 5

5. Inform Control Room Officer and close all valves on loading arm and tanker
side. Record the final tanker level, pressure & temperature.
6. De-pressurise spool piece between loading arm valve and tanker loading
valve to vent stack. Check the Pressure gauge on de-pressurization line. If
the pressure is more than 0.5 bar, check the isolation valves for passing. If
the valve passing is observed, don’t disconnect the loading arm, inform S/I
and after confirmation decant the tanker and then disconnect the loading arm
and send back the tanker.
7. Disconnect liquid and vapour loading arm (if connected) and put back on rest.
8. Disconnect earthing cable.
9. Remove wheel blocks.
10. Handover ignition key to the truck driver.
11. Stop the Air-Fin Heater fan after completion of LPG tanker loading.

References :
1. P&ID for send out system.
2. P&ID for Truck loading system

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/006
LPG COMPRESSOR OPERATION
Page 1 of 4

I. Control Room Officer to be ensured the cooling water system line up for
condensers from Operation Officer / Plant Operator as follows:

1. Ensure the cooling water inlet & outlet isolation valves to all condensers are in open
condition.
2. Ensure that all cells are in line on cooling tower deck.
3. Ensure that drain valves & vent valves in heater & condenser cooling water circuit
are in closed condition & blinded.
4. Start cooling water pump P801 A/B/C & established cooling water flow in heater &
condenser circuit as required.
5. Deareate individual condenser and condenser cooling water by opening the
respective vent valves and cooling water flow to be established.
6. Vent valve to be closed and blinded once the cooling water flow is established.
7. Ensure the cooling water line up of compressor oil cooler.
8. Run the cooling water fan as per requirement.

II. GENERAL CHECKS FOR COMPRESSOR OPERATION


1. First check oil level in fine oil separator.

2. Check differential pressure across the oil filter.

3. Check electric switches condition whether it is energized or de-energize.

4. Check line up for cooling water to compressor oil cooler and LPG condenser.

5. Ensure that of condensate return line XV and its isolation valve to storage tank is
open.

6. Ensure that oil filters are on line.

7. Compressor suction line up to be checked and ensured with the respective tank.

8. Check and line up condenser LCVs d/s isolation valve as per compressor suction
line up.

9. Compressors to be lined up with Condenser as per operational requirement.

10. Check LEL after compressor start.


AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/006
LPG COMPRESSOR OPERATION
Page 2 of 4

11. Keep record on compressor oil level .discharge pressure, temperature.


Oil pump discharge pressure .temperature and level indicator of condenser.

12. While running the compressor ensure that following settings should be strictly
followed for avoiding any compressor damage.

a. Storage tank pressure - 50 to 90 mbar.

b. Compressor high suction pressure - 2 bar.

c. Compressor low suction pressure - 10 mbar

d. Low differential pressure between compressor oil supply and disharge


line – 1.00 bar

e. Compressor high discharge pressure - 18 bar

f. High oil filter differential pressure - 0.75 bar

g. High discharge temperature - 90 deg centigrade.

h. High oil supply temperature - 60 deg centigrade.

i. Low oil level - 10 cm.

j. High condensate liquid level - 850 mm for E331 and E332 condenser and

650 mm for E1021 and E1027 condenser.

k. High compressor motor current


- Smaller compressor 360 A
- Bigger compressor 150 A

III. OPERATING PROCEDURE FOR LPG COMPRESSOR (Auto Operation)

1. The automatic mode of compressor system is selected from control panel.


in the control room.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/006
LPG COMPRESSOR OPERATION
Page 3 of 4

2. Ensure that compressor is in auto mode.

3. Select smaller compressors is in auto basic mode.

4. Bigger compressors are in auto peak mode.

5. Ensure cooling water line up and condensate return to tank.

6. Ensure that storage tank pressure is higher than 25 m bar.

7. Ensure that capacity control of the compressor is 10% when compressor is not in
operation.

8. In automatic operation compressor start automatically by the storage tank pressure.

9. Check compressor capacity as per tank pressure while compressor is running.

10. Following set points for operating compressor should be followed strictly.

Start -90m bar


Basic mode
Stop - 50 m bar

Start -120 m bar


Peak shaving mode
Stop - 95 m bar

IV. OPERATING PROCEDURE FOR LPG COMPRESSOR (Manual Operation)

1. Before starting the compressor ensure that capacity control of the compressor
is 10% & storage tank pressure is higher than pressure 25 mbar.

2. Starting the oil pump and compressor.


a. Start oil pump and open compressor discharge XV and operate oil circuit XV
from oil separator to compressor.
b. After clearance of PDAL alarm on control room, start compressor.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/006
LPG COMPRESSOR OPERATION
Page 4 of 4

c. Oil temperature to be monitored and maintained by controlling the respective


TCV.
d. Increase capacity slowly upto 100 and %.Monitor condenser level continuously.
(if instructed by control room officer / shift in-charge the sub-coolers E1022 /
E1028 / E1022A are to be taken in to service.)

3. Stopping the compressor and oil pump.


a. After getting from control room, compressor capacity to be decreased upto 5%.
b. Stop the compressor.
c. Stop the oil pump.
d. Check and ensure Compressor discharge XV is closed and oil circuit XV is
opened towards oil separator.
e. Close condenser LCV d/s isolation valves.

V Operating procedure for LPG compressor Super manual operation refer check
list – Super Manual operation of Compressor C320 / C1022.

VI. OPERATING PROCEDURE FOR COMPRESSOR C1023 (Manual Operation)

1. De-energize C-1022 & energize C-1023


2. Line up E-1027 for C-1023 by opening i/v for C-1023 & closing i/v for C-1022.
3. Before starting the compressor ensure that capacity control of the compressor is
10% & storage tank pressure is higher than pressure 25 mbar.
4. Starting the oil pump and compressor.
5. Select respective XVs for circulation to oil separator.
6. Start oil pump, wait for PDAL alarm across the compressor oil supply and
discharge line to be healthy.
7. After clearance to PDAL alarm from control room, start compressor.
8. Increase capacity slowing upto 100% and monitor condenser level continuously, (if
instructed by control room officer / shift in-charge the sub-cooler E1028 to be
taken in to service).

Reference :
1. P&ID for LPG Compressor system
2. P&ID for Condenser system

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/007
PIPELINE TRANSFER OPERATION
Page 1 of 5
Cooling Water System Lineup
1. E1024 / E1024B are to be lined up for Propane sent out service (RIL -

Nagothane).
2. Ensure the cooling water inlet & outlet i/v to Propane heaters
E1024/E1024B are in open condition.
3. Ensure that 14” isolation valve on cooling water return header for old CT &
6” i/v for new CT from heater circuit are open.
4. Ensure that all cells are in line on cooling tower deck.
5. Ensure that drain valves & vent valves in heater cooling water circuit are in
closed condition.
6. Start cooling water pump P801 A/B/C, P803A/B & established cooling
water flow in heater circuit as required.
7. Run the cooling tower fans as per cooling water temperature.
Startup operation
1. Start line out for pipeline send out operation after receiving request from RIL
control room.
2. Ensure shell side level of E1024 / E1024B is between 80% - 90%.
3. Check communication system between RIL and ALL.
4. Ensure the line up of Air fin Heater E407 & its bypass valve is closed (if
necessary).
5. Ensure all instruments are in line.
6. Log tank level readings before starting intank pump.
7. Start intank pump which is in line after ensuring the following :
 XV 4601 / XV 4602 are in open condition.
 Inform RIL control room and obtain reconfirmation.
 Storage Tank pressure is 50 m bar to 70 m bar.
 Liquid level in storage tank is higher than 2000 MM.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/007
PIPELINE TRANSFER OPERATION
Page 2 of 5
 Intank pump send out valve H 1501 / H 1502 are in closed position.
 Chilling supply valve F 1503 is in closed position.
 Intank pump by-pass valve FCV F 1501 / F 1502 are in open
position.

8. Run intank pump on by-pass mode with FCVF 1501 / F1502 are in manual
mode.
9. After 5 minutes put FCV F 1501 / F 1502 in auto mode.

TO START FIRST BOOSTER PUMP i.e. PUMP A


Inform Field operator to take following actions :
 Line up booster pump seal flush line to tank and nitrogen flow to seal.
 Open by-pass valve FCV 4601, 30% - 40%.
 Open Booster pump suction valve.
 Ensure FCV 4612 is closed & its isolation valve is closed.
 Ensure FCV 4602 is closed & its isolation valve is open.
 Ensure XVX 4621 manual isolation valve is open.
 Open XVX 4621 from control room.
 Ensure the line up of heater E1024 / E1024 B.

1. Open HCV H 1501 slowly and pressurize gradually the suction line of
booster pump to 18 - 20 bar g.
2. Start oil pump of booster pump.
3. Ensure all alarms are healthy from control room.
4. Start booster pump from local switch.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/007
PIPELINE TRANSFER OPERATION
Page 3 of 5
5. Open the FCV 4602 by observing the pump discharge flow & reduce FCV
4601 manually. Then put FCV 4601 on auto mode (set flow must be 21
m3 / hr).
6. Adjust the FCV 4602 manually to get the flow around 18 mt / hr to avoid
two phase flow.
7. Ensure XVX 4621 discharge pressure is around 45 bar.
8. Stop oil pump of booster pump.
9. Divert the seal flush line to suction of booster pump.
10. After normalizing the first pump inform RIL control room & get the
clearance to start the second booster pump.

TO START SECOND BOOSTER PUMP i.e. PUMP B


1. Ensure the second heater E1024 B is in line.
2. Observe the parameters of first booster pump.
3. Line up seal flush line of second booster pump.
4. Open by-pass valve FCV 4611, 30% - 40%.
5. (Ensure FCV 4601 is closed on auto mode).
6. Ensure FCV 4612 is closed & its i/v is fully open.
7. Open Booster pump suction valve gradually, keeping in view that suction
pressure of running pump is not disturbed.
8. Start the oil pump of second booster pump.
9. Ensure from control room that all alarms are healthy.
10. Start booster pump by local switch.
11. Open FCV4612 to 15% to 20% gradually.
12. Close the FCV 4611 gradually by establishing the flow around 21 m 3 / hr &
put it on auto mode.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/007
PIPELINE TRANSFER OPERATION
Page 4 of 5
13. Open the FCV 4612 still further by observing the flow current suction /
discharge pressure of both booster pumps.
14. Ensure flow of both booster pumps is around 15 mt / hr to 16 mt / hr.
15. Observe the parameters of both pumps.
16. Ensure the down stream pressure of XV 4621 is around 80 bar.
17. Stop oil pump of booster pump.
18. Inform to RIL control room after normalizing both the pumps.
19. Monitor in tank pump pressure, temperature and flow.
20. Monitor outlet temperature of both heaters.
21. Monitor suction & discharge pressure of both booster pumps, as well as
flow rate.
22. Monitor 4” send out line pressure and flow.
23. Record mass flow meter readings hourly.

TO STOP ONE OF THE BOOSTER PUMPS


1. Get the clearance of RIL control room to stop one of the pumps (suppose
Pump B).
2. Put the FCV 4602 & FCV 4612 on manual mode. (After ensuring the flow
of both booster pumps is same and steady).
3. Reduce the flow of both pumps to around 12 mt / hr by gradually reducing
the valves.
4. Close the FCV 4612 gradually to zero percent by observing the opening of
FCV 4611.
5. Check the flow of booster pump A & its current (if the flow is more / less
than 18 mt / hr then adjust or bring down the flow to 18 mt / hr).
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/007
PIPELINE TRANSFER OPERATION
Page 5 of 5
6. Stop the booster pump B & close its discharge isolation valve, suction
valve.
7. Close the isolation valve of pump B’s seal flush line.
8. Check the bypass valve FCV 4611 & close it after depressurizing the
portion between suction and discharge of pump B.
9. Inform RIL control room about the stoppage of one pump.

TO STOP BOTH THE BOOSTER PUMPS


1. Stop the one of the booster pumps as per the above procedure.
2. Inform RIL control room & get the clearance for stopping the second pump
also.
3. Stop the second booster pump (After reducing the flow to 13 mt / hr).
4. Stop the intank pump after closing the HCV H1501 / 1502.
5. Close the booster pump discharge i/v & its discharge FCV.
6. Check the bypass FCV & close it after depressurizing the portion between
suction and discharge of pump.
7. Inform to RIL Control Room.

Remark : During tanker loading and or chilling operation, booster pump suction
pressure to be monitored & maintain above 12 bar.

Reference :
1. P&ID for T102
2. P&ID for Send out system

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/008
HANDOVER OF THE FIRE HYDRANT PUMPS FOR
MAINTENANCE AND RE-COMMISSIONING AFTER
MAINTENANCE
Page 1 of 1
1. Respective Hydrant pump auto/manual start switch kept in manual
position.

2. The hydrant pump is kept isolated from the suction, discharge and
recirculation sides.

3. a. The hydrant pump, motor / starter


is kept de-energised electrically
and suitable tags provided.
b. In case of DP1 and DP 2, disconnect the battery terminal.

4. The pump side is completely depressurized through the vent and drain
plugs.

5. A work permit / AVI format is made for the maintenance job.

6. The hydrant pump is handed over to maintenance.

7. After completion of maintenance the work permit is returned.

8. The hydrant pump suction, discharge, recirculation are lined up after


venting the air trapped in the system through casing vent cock.

9. a. The hydrant pump motor / starter is kept energised. An AVI format


is issued for energisation. The tags are removed.
b. In case of DP1 and DP2, connect the battery terminal.

10. In presence of maintenance the hydrant pump’s trial run is taken if found
satisfactory the work permit completion is accepted by the issuer.

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/009
DECOMMISSIONING OF ETHYL MERCAPTAN DOSING
PUMPS/SYSTEMS FOR MAINTENANCE AND
RE-COMMISSIONING AFTER MAINTENANCE
Page 1 of 1

1. The Ethyl Mercaptan dosing pump motor stop push button is kept locked and
tagged.

2. The mercaptan pump suction/discharge isolation valves kept closed.

3. The system mercaptan liquid is collected through the drains. Any spillage of
liquid is absorbed with Ekoperlite powder and cryssal solution and
completely recovered.

4. The mercaptan vessel is completely depressurized into the sodium


hypochlorite vessel by opening the isolation valve on the PSV bypass line
to Sodium Hypochlorite vessel.

5. The mercaptan pump P 790 A/B motor starters kept de-energised and
tagged.

6. The mercaptan pump/system is handed over to maintenance after making the


work permit / AVI format.

7. After completion of the job the work permit is returned by the maintenance
team.

8. The mercaptan pump/systems suction, discharge, isolation valves are opened


and leak tested.

9. The mercaptan pump motor is kept energised and trial run is taken in
presence of maintenance. If found satisfactory the work permit job
completion is accepted.

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/010
AIR COMPRESSORS SYSTEM ISOLATION/HANDOVER TO
MAINTENANCE AND RE-COMMISSIONING AFTER
MAINTENANCE
Page 1 of 1

1. The air compressor system discharge line is isolated and depressurised


through the vent. Cooling water to cooler and compressor jackets kept
isolated and drained, through the drain valves. The instrument air to
compressor loading / unloading systems kept isolated.

2. The air compressor motor/system is de-energised and tagged.

3. A work permit is made for the maintenance.

4. The air compressor/system is handed over to maintenance.

5. After the completion of maintenance the work permit is returned. The air
compressor system discharge is lined up. Cooling water to cooler and
compressor jackets kept lined up. The instrument air to compressor
loading / unloading systems is kept lined up.

6. The compressor motor /system is kept in energised condition and tags


removed.

7. The Compressor / system trial run is taken in presence of maintenance


and if found satisfactory the work completion is accepted.

Remarks: Before hand over to maintenance, please take clearance from Liquid
Terminal Division.

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/011
DECOMMISSIONIG, HANDOVER TO MAINTENANCE &
COMMISSIONING OF LPG / PROPANE COMPRESSOR
CONDENSER SYSTEM
Page 1 of 2
1. The LPG compressor C-310 / C-320 / C-1021 / C-1022 / C1023 is kept in
stop mode in DCS.

2. The LPG compressor and oil pump motors of C-310 / C-320 / C-1021 /
-1022 / C - 1023 is kept de-energised.

3. The LPG vapour in the compressor system is transferred through


respective condenser system E-331 / E-332 / E-1021 / E-1027 with the
level control valves of L-3301, L-3311, L-3701, L-3801 into the respective
tanks LPG-101 / T-102.

4. The suction valve of compressor system is closed.

5. Compressor suction filter inlet and outlet pressure gauge tapping valves to
be closed.

6. A nitrogen hose connection is made to the suction line 1” vent valve


downstream, and the compressor / condenser system is filled with
nitrogen and is vented through the (I”) PSV bypass valve of condenser E-
331 / E-322 / E-1021 / E-1027 to cold vent stack. This is done till the %
LEL level comes to zero. This is analysed with a portable gas detector on
the spare (1”) nozzle on condenser.

7. A work permit is made.

8. The LPG / Propane compressor / condenser system is handed over to


maintenance.

9. After the completion of maintenance, the work permit is returned by


maintenance.

10. The compressor / condenser system is purged with nitrogen till % O 2 level
is below 1%. The % O2 level is checked with portable oxygen analyser.

11. The suction isolation valve of the LPG / Propane compressor is opened
and nitrogen in the system is displaced with LPG vapours to vent stack.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/011
DECOMMISSIONIG, HANDOVER TO MAINTENANCE &
COMMISSIONING OF LPG / PROPANE COMPRESSOR
CONDENSER SYSTEM
Page 2 of 2
12. Leak test / % LEL check is done to ensure no leakages in the system after
maintenance.

13. Ensure the line of manual isolation valves.

14. Ensure Compressor suction filter inlet and outlet pressure gauge tapping
valves are opened.

15. Check oil levels in oil separator and to be made up if necessary.

16. The LPG / Propane compressor and oil pump motor is kept energised.

17. The LPG / Propane compressor is put on manual mode in DCS.

18. The LPG / Propane compressor / condenser system trial run is taken in
presence of maintenance.

19. Record and monitor the parameters.

20. If found satisfactory, the work completion is accepted.

Reference:
1. P&ID for Condenser system
2. P&ID for Compressor system

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/012
SHIP UNLOADING ARM DECOMMISSIONIG, HANDOVER TO
MAINTENANCE & COMMISSIONING
Page 1 of 1
1. The ship unloading arm H-201 down stream 12” line I/V kept closed.

2. Ensure XVX 2001 ESD (Emergency shut down) system valve kept in
closed position.

3. The ship unloading arm 1” I/V is connected with nitrogen and the
unloading arm system is pressurized to 2.0 bar N 2 pressure.

4. The unloading arm is depressurized through the 1” I/V at the stand post
portion.

5. The nitrogen purging of unloading arm is continued till the % LEL


becomes nil in the unloading arm system.

6. A work permit is made for maintenance and the unloading arm is handed
7. to maintenance.

8. a. After the completion of maintenance the work permit is returned by


maintenance.
b. The unloading arm is nitrogen purged as mentioned in steps 3 & 4
and % oxygen checked with portable % O 2 analyser.

9. The unloading arm is pressurized to 2.0 bar nitrogen pressure and the
loading arm joints and leak tested, in presence of maintenance.

10. After the satisfactory checks on leaks the loading arm nitrogen pressure is
depressurized through the 1” vent valve on the stand post portion.

11. The completion of work is accepted in work permit.

Reference:
1. P&ID for Ship unloading Arm

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/013
DECOMMISSIONIG, HANDOVER TO MAINTENANCE &
COMMISSIONING AFTER MAINTENANCE OF BOOSTER PUMP
P1022 (A/B)
Page 1 of 2

1. The Booster pump P 1022 (A/B) and oil pump P 1025 (A/B) motors are
kept de-energised, isolated and tagged.

2. The Booster pumps P 1022 A/B suction and discharge lines are kept
depressurized to tank through minimum bypass line valves F 4601 /
F4611.

3. The Booster pump suction and discharge isolation valves near the pump
is closed.

4. Minimum bypass line valves F 4601 / F 4611 are kept closed and isolation
valves on the downstream side kept closed.

5. Ensure seal flush line is kept positive isolated from Propane header.

6. A nitrogen hose connection is made to the suction line 1” spare nozzle and
the booster pump system is pressurized to 2.0 bar nitrogen pressure and
depressurized through the ½” vent valve on the seal flush line till % LEL
becomes nil.

7. The work permit is made for maintenance.

8. After completion of maintenance, the work permit is returned by


maintenance.

9. The Booster pump suction and discharge systems are purged with Nitrogen
and % oxygen checked with portable oxygen analyser till % oxygen in the
loop becomes less than 1%.

10. Ensure the spade is removed from seal flush line.

11. The Booster pump suction / discharge loops are pressurized to 4.5 bar
nitrogen pressure and leak tested in presence of maintenance.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/013
DECOMMISSIONIG, HANDOVER TO MAINTENANCE &
COMMISSIONING AFTER MAINTENANCE OF BOOSTER PUMP
P1022 (A/B)
Page 2 of 2
12. The Booster pump loops nitrogen is displaced with propane vapours by
opening the suction line isolation valve and % LEL checked to ensure
leak free.

13. The Booster pumps P 1022 (A/B) and oil pumps P 1025 (A/B) motors are
kept energised.

14. Trial run of Booster pumps P 1022 (A/B) and oil pumps P 1025 (A/B)
taken in presence of maintenance.

15. The work completion is accepted.

Reference :
1. P&ID for Send out system

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/014
DECOMMISSIONING / HANDOVER TO MAINTENANCE AND
COMMISSIONING OF LPG / PROPANE TANKER LOADING ARMS
Page 1 of 1
1. The LPG / Propane truck loading line isolation valve upstream of XV
6002 / XV 6012 / XV 6022 / XV 6032 / XV 6042 kept closed.

2. The hold up is depressurized through 1” depressurization line connected


down stream of XV 6002 / XV 6012 / XV 6022 / XV 6032 / XV 6042 by
opening the isolation valve and the required XV 6002 / XV 6012 / XV 6022
/ XV 6032 / XV 6042 in the loading bay.

3. a. Nitrogen hose connection is made to connect on the 1”


depressurization line and the entire tanker loading arm is purged
with nitrogen till % LEL becomes nil.

b. Nitrogen purging is isolated and XV 6002 / XV 6012 / XV 6022 / XV


6032 / XV 6042 is closed according to requirement.

4. A work permit is made for maintenance.

5. After the completion of maintenance the work permit is returned.

6. The loading arm is purged with nitrogen with the opening of 1” I/V till %
oxygen in the loading arm becomes less than 1%. The nitrogen flow is
isolated after leak test of joints at 4.5 bar N 2 pressure.

7. The loading arm / pipeline nitrogen is displaced slowly with LPG / Propane
vapour and the joints are leak tested with portable % LEL meter (gas
detector).

8. If found satisfactory, the work completion is accepted.

9. The LPG / Propane tanker loading arm is brought back into service after
opening the isolation valve upstream of XV 6002 / XV 6012 / XV 6022 / XV
6032 / XV 6042.

Reference:
1. P&ID for Truck Loading system

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/015
LPG / PROPANE TANKS SAMPLING
Page 1 of 1

1. The intank pump P-101 A/B is run forLPG-101 tank. The intank pump
P-1021 A/B is run for T-102 tank.

2. The sampling personnel should use cotton clothes, goggles, hand gloves
during the sampling.

3. The sampling point / sample container bomb is connected to the (1”) vent
valve down stream of
a. HV 1001 / F 1001 for LPG-101 sampling
b. HV 1501 / HV 1502
OR
F 1501 / F 1502 for T-102 sampling.

4. During sampling observe wind speed / direction.

5. The 1” isolation valve is slightly opened and the sample container valves
are slightly opened and the container is purged with LPG vapour.

6. The sample container vent valve is closed and the container sample inlet
valve is fully opened, to allow the container be filled with liquid.

7. The container sampling inlet valve is closed.

8. The 1” isolation valve is closed.

9. The sampling container is disconnected.

10. The sampling hose is disconnected from the 1” vent valve connection.

11. A gate pass is made for the samples.

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/016
NITROGEN PURGING OF LINE UPTO COLD VENT STACK
Page 1 of 1

1. Open F 9001 N2 purge flow on LPG-101 tank top and keep the flow
at 3.0 Nm3/hr.

2. Open F 9011 the N2 purge flow on T-102 tank top and keep the flow
at 3.0 Nm3/hr.

3. Open F 9005 N2 purge flow on the truck loading bay-I to keep the
flow at 3.0 Nm3/hr.

4. Open F 9007, F 9008 N2 purge flows in the LPG header area and
LPG compressor area to keep the nitrogen flow at 3.0 Nm3/hr.

5. Open F 9002 N2 purge flow on the cold vent stack seal drum to keep
the nitrogen flow at 3.0 Nm3/hr.

6. Open F 9003, F 9004 N2 purge flows on mounded vessels MV-501 /


MV-502 top and keep the nitrogen flow at 3.0 Nm3/hr.

Note : Please see the attached drawing.

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Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/017
COOLING TOWER CHEMICAL TREATMENT
Page 1 of 2
A. BIOCIDE DOSING PROGRAMME

1. NON OXIDATIVE BIOCIDE (I & II)


(50 ppm of system hold up)

To start dosing please follow the procedure as given below :

 Check the date and dosing amount from the file “Monthly Cooling
Water Treatment Programme”.
 To start always see the tag/label of the container before dosing the
chemicals.
 It is to be slug dosed into C.T. basin water after sun set only (the
chemical will act better in absence of sunlight, when the
microbiological activity is less).
 After slug dose do not give any blow down (filler back wash) and
chlorination for 12 hours.

2. OXIDATIVE BIOCIDE

 Chlorination (Refer SOP/GTD/019)

B. DOSING PROCEDURE OF SCALE / CORROSSION INHIBITOR


(100 ppm on make up)

I) Anodic Inhibitor (every day basis)

For dosing amount refer monthly cooling water chemical


programme file kept at GTD control room. Preparation of batch of
25 litres in a carbouy by mixing the inhibitor in 25 ltrs of water and
kept in dripping in a flow rate of 17 ml/minute in C.T. basin water

b. Cathodic Inhibitor (every day basis)

Dosing procedure and batch preparation is like anodic inhibitor.


The effectiveness of the inhibitor is checked by the corrosion
coupon kept near condenser area in a corrosion coupon rack.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/017
COOLING TOWER CHEMICAL TREATMENT
Page 2 of 2

C. DOSING PROCEDURE OF ORGANIC DISPERSANT


(10 ppm on system hold up)

For dosing amount please refer the file “C.W. Monthly treatment
programme file” kept at GTD control room. It has been slug dosed into
C.T. basin in every day basis.

Common procedure for all the above chemical dosing “

 The dosing volume is measured in a dedicated (with label) measuring plastic


bucket. The liquid Biocide is transferred from the carbouy to the bucket
with the help of plastic hand pump.

 Personal safety care :- Always refer MSDS file of C.W. chemical kept at GTD
control room.

 Always use rubber gloves, safety goggles & safety shoes during chemical
handling (kept near C.T. basin).

 The product if come in contact with skin, or eye, the affected area should be
washed in eye fountain and shower situated near C.T. basin.

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Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/018
PASSIVATION OF HEAT EXCHANGERS
Page 1 of 1

When the tubes getting chocked (flow become less) the tubes should be cleaned
and then it should be passivated. Before doing passivation with cathodic and
anodic inhibitor, ensure that the respective heat exchanger’s cooling water tubes
should be thoroughly cleaned with nylon brush and water. Smooth surface is
required for the formation of thin protective layer which will prevent corrosion.

1. Add Passivation Chemical - I (30 ppm PO4) as slug dose to the C.T. basin
water (considering 130 m3 hold up).

2. Ensure that there should not be any blow down or filter back wash for 24
hours within the passivation period.

3. Check the initial phosphate level of the re-circulating water just 10 minutes
after the dosing of Passivation Chemical - I and final phosphate level 24
hours after the dose. The difference is the PO4 absorbed for passivation,
50% absorption is desirable.

4. Add Passivation Chemical – II (4 ppm of zinc) as slug dose in to C.T. basin


water (considering 130 m3 hold up). Ensure that Passivation Chemical - II
should be dosed one hour after the dose of Passivation Chemical - II.

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Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/019
COOLING WATER CHLORINATION
Page 1 of 3

To start chlorination of cooling water please follow the procedure as given below.

1. a. Ensure CLV-5 close.


b. Regulator fixed with chlorine cylinder should be tight and the
regulator knob should be minimum.
c. Ensure valves CLV-2, 3 & 4 open.
d. Ensure CLV-1 close and pressure gauge d/s of valve CLV-1 is on
line.

Starting of chlorination

2. a. Open CLV-1 and maintain the C.W. pressure down stream line
between 4 to 5 bar.
b. Check for the vacuum creation at ejector, chlorine PVC tube
(transparent).
c. Check the C.W flow to basin through 1” line.
d. If every thing is in order open CLV-5 slightly and check cylinder
connection with regulator for any leak with ammonium hydroxide
solution.
e. If there is no leak, adjust the regulator knob for 100 gms/hour flow.
f. Note the time and continue chlorination for 30 minutes and stop. In
the meantime check FRC (Free Residual Chlorine) level at C.W.
return line. It should be around 0.5 ppm. If FRC level is more than
0.8 ppm stop chlorination.

Stopping of chlorination

3. a. Close CLV-5 valve.


b. Bring the regulator knob to minimum
c. Close CLV-1.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/019
COOLING WATER CHLORINATION
Page 2 of 3
In case of chlorine leak from cylinder connection

4. a. Isolate chlorine cylinder by closing valve CLV-5.


b. Bring down the chlorine regulator knob to minimum.
c. Close CLV-1 valve.
d. Disconnect the chlorine regulator from the cylinder with proper tools
and check the leak gasket. If leak gasket is found damaged replace
the gasket with new one and connect the regulator and start
chlorination operation and check for leak. If there is no leak
continue the operation.

In case of C.W. PH < 7.5

5. a. Stop chlorination
b. Give C.W. blow down
c. Start make up till PH >=7.5
d. Chlorination should be done to C.W if the P H is between 7.5 to 8.0.

Ejector problem

6. a. If the ejector is not working properly, it may be due to abstruction.


b. Isolate chlorination, isolate C.W. and handover ejector for check up
(of any blockage)

7. Cooling water pump trip

Stop Chlorination by closing chlorine cylinder valve.

Precautions during chlorination

a. Chlorine cylinder should be in a protected area from rain and sun.


b. Chlorine cylinder should be positioned at height (1 to 2 meter)
c. The floor should be dry.
d. One ammonium hydroxide liquor bottle with glass rod should be available
always in this area.
e. One chlorine cylinder emergency kit with proper tools and instruction
should be available in this area.
f. Minimum two face masks with chlorine canister should be available in this
area.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/019
COOLING WATER CHLORINATION
Page 3 of 3

g. Chlorination of cooling water should be done once in morning (for about


30 minutes) before starting truck loading in plant area (both LPG &
chemical) and once in evening (after completion of truck and loading, both
LPG & chemical area)
h. Shift Incharge should be present at the spot till chlorination is completed.
i. One self contained breathing apparatus should be available in this area.
j. In case of chlorine leak, isolate the chlorine cylinder. If still there is some
leak, use emergency chlorine kit.

NEVER USE WATER ON CHLORINE LEAK, OTHERWISE IT WILL


FORM HClO AND CORRODE THE LEAKY AREA VERY FAST.

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AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/020
PH METER CALIBRATION
Page 1 of 1

1. Take 10 ml of distilled water in a 100 ml conical flask by 10 ml pipette.

2. Open a buffer capsule by twisting and pulling apart, pour the content in
to the flask.

3. After dissolving the contents make it up to 100 ml with distilled water.


This solution will have a pH of 7.0 ± 0.05 at 20o C.

4. Immerse the pH meter up to the max level in pH buffer (H1 777P) and
stir gently and wait until the display stabilizes.

5. After stabilizing the reading calibrate the pH meter by using a small


jewellery screw driver by tuning the trimmer at the back side of the pH
meter to read 7.0. Calibration is now complete.

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AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/021
CHECK FREE RESIDUAL CHLORINE (FRC)
BY USING CHLOROTEX BOTTLE
Page 1 of 1

1. Take 5 ml of water (to be checked) into the test tube (the test tube should
be marked with 5 ml water part and one ml reagent part).

2. Add rapidly 1 ml chlorotex reagent in it and mix it well and wait for 20
seconds.

3. Compare the colour of the test tube mixture with colour comparator chart
given on the chlorotex bottle and determine the FRC in ppm.

Prepared by : Approved by : Revision no :


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AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/022
ETHYL MERCAPTAN STORAGE / HANDLING /
DECOMMISSIONING
Page 1 of 3

Ethyl Mercaptan is received in 160 kgs. Drums well sealed. The drum contents
are transferred into Mercaptan storage tank by the following procedure.

Ensure that following PPE’s are available and used as required:


Safety Gum- shoes, Safety Goggles, Neoprene hand-gloves and Apron, Full face
mask with Air supply system.
Ensure that Peralite powder and Chrysal liquid are available in adequate
quantity.

1. The drum must be positioned vertically near the system.


2. Connect the barrel pump up to the air supply (4 to 5 Bar) to pneumatic
pump air inlet nozzle.
3. Position the pneumatic pump in the drum, so that suction pipe has
reached the bottom of the drum. Tighten the fittings of the pump
connecting to the drum.
4. Open Mercaptan drum vent fitting ( Open to atmosphere)
5. Connect SS hose from pneumatic pump discharge side to Mercaptan
vessel product inlet connection.
6. Close the Nitrogen inlet valve to the Mercaptan vessel.
7. Open the vent isolation valve on the Mercaptan vessel to line up to the
Sodium hypochlorite vessel and bring down the Mercaptan system
pressure near to atmospheric pressure after absorbing through the
Sodium hypochlorite solution.
8. Open the isolation valves on the Mercaptan vessel product inlet.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/022
ETHYL MERCAPTAN STORAGE / HANDLING /
DECOMMISSIONING
Page 2 of 3

9. Ensure that air pressure for barrel pump pneumatic motor is o.k. and open
inlet valve on air header. Open Mercaptan pump motor air inlet valve
slowly.
10. Observe that pump starts running and Mercaptan transfer is taking place
from Mercaptan drum to Mercaptan vessel.
11. Check for any Leakage on the joints with soap solution.
12. If there is any leakage, stop the transfer by closing the air connection
isolation valve and the Mercaptan vessel inlet isolation valve.
13. Spread the Peralite powder in case of any spillage/leakage.
14. Attend the leak & restart pumping operation.
15. Once the drum product is completely transferred to Mercaptan tank or if
maximum level (850 mm) reached in Mercaptan vessel stop pumping
operation.
16. Spray the “Chrysal “solution at the leak to absorb the spillage. Recover
the Pearlite powder/solution in a container.
17. In case there is no leakage, continue the transfer operation and watch the
level rise in the Mercaptan vessel. Also keep watch on the Mercaptan
vessel pressure.
18. Stop the transfer when the level rise in the system storage is stopped/
When the Mercaptan drum is empty.
19. Isolate the air connection and close the Mercaptan vessel inlet valve.
20. Disconnect the air connection from the pneumatic pump.
21. Remove SS hose from pneumatic pump discharge side to Mercaptan
vessel product inlet connection.
22. Close Mercaptan vessel vent isolation valve.
23. Open Nitrogen inlet valve to Mercaptan vessel.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/022
ETHYL MERCAPTAN STORAGE / HANDLING /
DECOMMISSIONING
Page 3 of 3

24. Remove Pneumatic pump from the drum and clean with hypochlorite
solution/water and preserve it safely.
25. After above operation shift the drum for decommissioning.
26. Using dilute Sodium Hypochlorite solution the empty Mercaptan drum
content should be absorbed and washed with plenty of water.
27. The empty and full Mercaptan drums should be kept separately and
marked accordingly.
28. All PPE’s after use to be decontaminated from Mercaptan smell & washed
thoroughly with soap solution & water and dried.

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Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/023
COOLING WATER SYSTEM

Page 1 of 1
I START-UP OPERATION

COOLING WATER PUMP START-UP

1. Start make up water to cooling tower basin to bring up the level to 70%
2. Open the suction line isolation valve u/s of the strainer at the suction of
pump P801A / B / C, P803 A / B & P802 as per required.
3. Remove the air from the pump systems P-801 A/B/C, P803 A/B & P802
and from the casing also.
4. Open the recirculation line isolation valve.
5. Start the pump P-801 A/B/C, P803 A/B & P802 as per requirement.
6. Observe the sound/bearing temperature, gland sealing liquid conditions.
7. Open the discharge isolation valve slowly; simultaneously reducing the
2 recirculation flow. Observe the current, vibration, noise etc.
8. Observe the pump/motor conditions viz current, vibrations, noise etc.

II LINE UP OF HEATER / CONDENSERS / BOOSTER PUMP OIL COOLER,


COMPRESSOR OIL COOLER / AIR COMPRESSOR OIL COOLER.

1. Heater E402, E1024 & E1024A, E1024B & condensers E331, E332,
E1021, E1027, Compressor oil coolers, booster pump oil coolers, air
compressor oil cooler are ready for service.
2. Open Heater E402 / E1024 / E1024A, E1024B & condensers E331 / E332
/ E1021 E1027, Compressor oil coolers, booster pump oil coolers, air
compressor oil cooler, tube side vents to release air.
3. Open heater E402, E1024, E1024A, E1024B & condensers E331 / E332 /
E1021 / E1027, cooling water inlet isolation valve slightly.
4. Ensure that E402/ E1024 / E1024A / E1024B bottom portion &
condensers E331 / E332 / E1021 / E1027, tube side are fully filled with
water by removing all the air from the system.
5. Open cooling water outlet line isolation valves of heaters.
6. Open isolation valve and control valves of condensers.
7. Close tube side vent valve and blinded.
8. Open the inlet, outlet isolation valves & control valves simultaneously.
9. Ensure drain and vent valves are closed and blinded after establishing
cooling water flow.

Reference:
1. P&ID for Cooling water system

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Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/024
DECOMMISSIONING & COMMISSIONING OF LPG
HEATERS E 401 / E 402
Page 1 of 3
A. Decommissioning of Heaters E 401/E 402

1. Stop intank pump P101A/B of tank T-101.


2. Close upper heater tube side I/L and O/L valves.
3. The Heater E 401 (upper portion) tubes hold up liquid is transferred to LPG-
101 tanks thro’ PCV 1040 and line pressure is kept just above
atmospheric pressure.
4. a. Lower Heater E-402 shell side drain (1”) I/V downstream is
connected with metallic hose to LPG-101 LCV 3301 d/s (1”)
spare point. .(HOSE CONNECTION TO BE DONE UNDER
SUPERVISION.THE AIR INSIDE THE HOSE IS TO BE
PURGED BEFORE CONNECTION.)
b. Check the hose for any leakages
c. Keep water spray nearby
5. The shell side propane liquid / gas is transferred gradually to tank T-101 via
the temporary hose connection made.
6. After transferring of liquid propane, reduce shell side pressure thro’ the same
to 4.0 bar.
7. When the shell side pressure is around 4 bar stop transfer to T-101 by closing
the lower heater shell side drain i/v and connect the Nitrogen hose to
upper heater shell side 1” spare nozzle, start Nitrogen and open upper
heater shell side (1”) I/V to vent the remaining gas/N2 mixture thro’ cold
vent stack. Pressurizing with Nitrogen and depressurizing to vent stack to
be done many times to displace hydrocarbon to almost nil level.
8. Continue the nitrogen purging till the shell side becomes gas free ensured by
LEL meter (i.e. % LEL Nil and keep shell side under +ve N2 pressure
around 0.5 bar)
9. Close the cooling water supply and return lines I/V and drain the cooling
water side after opening the cooling water side vent valve.
10. Purge upper part tube side with nitrogen by venting to cold vent stack after
making connections to vent stack and if hydrocarbon is nil, pressurize with
nitrogen upto 0.5 bar and isolate.

B. Hand over for maintenance


(Upper heat exchanger)
1. Ensure both heaters shell and tube side is isolated and blinded.
2. Ensure both tube side and shell side of the heaters are Nitrogen purged
and are gas free.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/024
DECOMMISSIONING & COMMISSIONING OF LPG
HEATERS E 401 / E 402
Page 2 of 3
3. Disconnect Nitrogen supply.
4. Check the Heater tube side and shell side contents with a portable % LEL
meter and ensure that the % LEL is Nil.
5. Ensure that the cooling water supply / return are isolated and drained and
blinded both inlet and outlet side.
6. Prepare a “Per mit to Work” and handover to maintenance.

C. Commissioning after maintenance


1. Remove blinds and ensure Nitrogen purging of upper heater and tube side
and lower heater shell side. Continue Nitrogen purging and check for any
leaks and check the tube side/shell side with a portable % Oxygen meter.
2. a. If the % oxygen is less than 1%
by vol. then pressurize the
tube side/shell side with Nitrogen upto 1.0 bar. Open cooling water
I/Vs (inlet and outlet) and ensure sufficient flow of cooling water
after displacing air.
b. Stop Nitrogen supply and isolate it.
c Start C-320 compressor thro’ E-332 and stabilize in (propane
service).
3. Connect a metallic hose from E 332 shell side top portion to lower
Heaters’ shell side spare nozzles as per the requirement.
4. Start hot gas from E 332 and displace the nitrogen thro’ vent line to vent
stack. During this operation maintain E-401/402 shell side pressure upto
1.0 bar.
5. Check all flanges/joints for any
leaks with soap solution and with portable % LEL meter.
6. Pressurize the shell side with gas from E 332 upto 10 bar.
7. Change the hose connection from E-332 vapour to E 332 condenser drain
(1”) I/V to heater (bottom) shell side drain (I”) I/V.
8. Check the hose connection for leaks.
9. Keep water spray ready for use.
10. Start propane liquid gradually thro’ the hose into the lower heater shell
side, displace the vapour thro’ the (1”) line to vent stack gradually.
11. Observe the level indication provided on the lower heater shell side.
12. Check for any low temperature formation on the hose, heater
(upper/lower) portions.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/024
DECOMMISSIONING & COMMISSIONING OF LPG
HEATERS E 401 / E 402
Page 3 of 3
13. In case any frosting is observed stop the liquid transfer thro’ hose and
check the cooling water flow thro’ heater.
14. For E 402 fill the shell side upto max. 100 cms. Isolate the propane flow
thro’ hose connection.
15. Depressurize the hose connection keeping water spray.
16. Disconnect the hose and blind the connections.
17. Displace the nitrogen in the (upper portion) tube side (before introducing
LPG % O2 ensured < 1.0%) with LPG vapour from E-331 shell side
top portion (to vent stack) thru temporary connection to vent stack. Isolate
vapour, disconnect hose and blind it.
18. Slowly open the upper portion heaters tube side inlet I/V & O/L. Now the
heater is ready for service.
19. Ensure shell side pressure while heating propane and vent some vapours
to get rid of non condensables. Observe this for 2 to 4 hrs after
commissioning. If heat transfer is OK, ensure E 402 shell side liquid level
100 cm and disconnect propane liquid hose.

D. Do’s & Don’ts


1. Do keep full cooling water flow while transferring propane liquid from / into
heater shell side.
2. Do sufficient purging of the heater (tube side) with nitrogen till %
LEL becomes Nil.
3. Do % LEL check on heater tube side (upper portion) and shell side before
handing over to maintenance.
4. Do check the oxygen content in the tube side / shell side before
commissioning.
5. Do keep a water spray during any hose connection/disconnection
operations.
6. Don’t allow the propane liquid to flash inside the heater from high
pressure to low pressure as it may form localized low temperature
regions on the heater tubes which is undesirable.
7. Don’t let the commissioning and decommissioning operations go on
unattended.
8. Ensure all utility and spare nozzles are blinded before commissioning.
9. Before introducing liquid from E-331 to heater, ensure that there is no
moisture/water traces in the Propane condensate.

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/025
DECOMMISSIONING & COMMISSIONING OF PROPANE
HEATERS E 1024 & E 1024 B
Page 1 of 3
A. Decommissioning of Heaters E 1024, E 1024 B
1. Stop the booster pump& isolate the discharge i/v, mass flow meter, XV4621 .
2. Stop the intank pump P1021A/B of T- 102
3. Close upper heater tube side I/L valve.
4. The Heater E 1024 / E 1024 B upper portion tubes HOLD UP liquid is
transferred to T-102 tanks thro’ FCV 4601 / FCV 4611 respectively and
line pressure is kept just above atmospheric pressure.
5. a. Lower Heater shell side drain (1”) I/V downstream is
connected with metallic hose to T-102 via LCV 3311 d/s (1”) spare
point. (HOSE CONNECTION TO BE DONE UNDER
SUPERVISION.THE AIR INSIDE THE HOSE IS TO BE PURGED
BEFORE CONNECTION.)
b. Check the hose for any leakages
c. Keep water spray nearby
6. The shell side propane liquid / gas is transferred gradually to tank via the
temporary hose connection made.
7. After transferring of liquid propane, reduce shell side pressure thro’ the same
to 4.0 bar.
8. When the shell side pressure is around 4 bar stop transfer to T-102, by
closing the lower heater shell side drain valve connect the Nitrogen hose
to upper shell side 1” spare nozzle, start Nitrogen and open upper heater
shell side (1”) I/V to vent the remaining gas/N2 mixture thro’ cold vent
stack. Pressurizing with Nitrogen and depressurizing to vent stack to be
done many times to displace hydrocarbon to almost nil level.
9. Continue the nitrogen purging till the shell side becomes gas free (ensured by
LEL meter) (i.e. % LEL Nil and keep shell side under +ve N2 pressure
around 0.5 bar)
10. Close the cooling water supply and return lines I/V and drain the cooling
water side after opening the cooling water side vent valve.
11. Purge upper part tube side with nitrogen by venting to cold vent stack after
making connections to vent stack and if hydrocarbon is nil, pressurize with
nitrogen upto 0.5 bar and isolate.

B. Hand over for maintenance


(UPPER EXCHANGER)
1. Ensure both heaters shell and tube side is isolated and blinded by
maintenance under supervision .
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/025
DECOMMISSIONING & COMMISSIONING OF PROPANE
HEATERS E 1024 & E 1024 B
Page 2 of 3
2. Ensure both tube side and shell side of the heater are Nitrogen purged and
are gas free.
3. Disconnect Nitrogen supply.
4. Check the Heater tube side and shell side contents with a portable % LEL
meter and ensure that the % LEL is Nil.
5. Ensure that the cooling water supply / return are isolated and drained and
blinded both inlet and outlet side.
6. Prepare a “Permit to Work” and handover to maintenance.

C. Commissioning after maintenance


1. Remove blinds and ensure Nitrogen purging of the tube side (upper Heater)
and shell side of both upper and lower heaters. Continue Nitrogen purging
and check for any leaks and check the tube side/shell side with a portable
% Oxygen meter.
2. a. If the % oxygen is less than 1% by vol. then pressurize the
tube side/shell side with Nitrogen upto 1.0 bar. Open cooling water
I/Vs (inlet and outlet) and ensure sufficient flow of cooling water.
b. Stop Nitrogen supply and isolate it
c. Start C-320 compressor thro’ E-332 and stabilize (on propane
service).
3. Connect a metallic hose from E 332 shell side top portion to lower Heaters
spare nozzles as per the requirement.
4. Start hot gas from E 332 and displace the nitrogen thro’ vent line to vent
stack. During this operation maintain E-1024 / 1024 B shell side pressure
upto 1.0 bar.
5. Check all flanges/joints for any leaks with soap solution and with portable %
LEL meter.
6. Pressurize the shell side with gas from E 332 upto 10 bar.
7. Change the hose connection from E-332 vapour to E 332 condenser drain
(1”) I/V to heater (bottom) shell side drain (I”) I/V.
8. Check the hose connection for leaks.
9. Keep water spray ready for use.
10. Start propane liquid gradually thro’ the hose into the lower heater shell side,
displace the vapour thro’ the (1”) line to vent stack gradually.
11. Observe the level indication provided on the lower heater shell side.
12. Check for any low temperature formation on the hose, heater (upper/lower)
portions.
13. In case any frosting is observed stop the liquid transfer thro’ hose and check
the cooling water flow thro’ heater.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/025
DECOMMISSIONING & COMMISSIONING OF PROPANE
HEATERS E 1024 & E 1024 B
Page 3 of 3
14. For E 1024 / E 1024B fill shell side level upto max. 80 cms.
Isolate the propane flow thro’ hose connection.
15. Depressurize the hose connection keeping water spray.
16. Disconnect the hose and blind the connections.
17. Displace the nitrogen in the (upper portion) tube side (before introducing
propane % O2 ensured < 1.0%) propane vapour from E-332 (to vent
stack). After checking O2 < 1.0 isolate vapour, disconnect hose and blind
it.
18. Slowly open the upper portion heaters tube side inlet I/V & O/L. Now the
heater is ready for service.
19. Ensure shell side pressure while heating propane and vent some vapours to
get rid of non condensables. Observe this for 2 to 4 hrs after
commissioning. If heat transfer is OK, ensure E 1024 / E1024 B shell side
liquid level 80 cm and disconnect propane liquid hose.

D. Do’s & Don’ts


1. Do keep full cooling water flow while transferring propane liquid from / into
heater shell side.
2. Do sufficient purging of the heater (tube side) with nitrogen till % LEL
becomes Nil.
3. Do % LEL check on heater tube side (upper portion) and shell side before
handing over to maintenance.
4. Do check the oxygen content in the tube side / shell side before
commissioning.
5. Do keep a water spray during any hose connection/disconnection
operations.
6. Don’t allow the propane liquid to flash inside the heater from high
pressure to low pressure as it may form localized low temperature
regions on the heater tubes which is undesirable.
7. Don’t let the commissioning and decommissioning operations go on
unattended.
8. Ensure all utility and spare nozzles are blinded before commissioning.
9. Before introducing liquid from E-332 to heater, ensure that there is no
moisture/water traces in the propane condensate.

Note : This procedure is prepared for both the heaters E-1024 and E-1024 B and
is applicable only to the heater under consideration.

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/026
AIR FIN HEATER COMMISSIONING AND DE- COMMISSIONING
Page 1 of 2

I. AIR FIN HEATER COMMISSIONING.

1. Ensure air fin heater along with motor and fan is installed properly by
Engineering dept.
2. Keep inlet and outlet isolation valve closed and air blowing to be done by
pressurizing and depressurizing to remove any foreign particles through
vent and drain parts.
3. Nitrogen purging to be done till O 2 % less than 1% and due point reaches
to – 40 o C.
4. Purge the air fin heater till vapour to remove and to till 100% LEL.
5. Connect respective header as per requirement (LPG / C3) and ensure
other header is positively isolated.
6. Take electrical clearance and energize the air fin heater fan.
7. Ensure that instruments and PSV are fixed and taken in line.
8. Open inlet and outlet isolation valve of air fin heater.
9. Close and blind 1” vent valve.
10. Check the direction of rotation of fan by kick start.
11. Start air fin heater and observe for any abnormal sound.

Air Fin Heater De-commissioning


1. Stop the air fin heater fan and keep the air fin heater motor
de-energized.
2. Close inlet and outlet isolation valve of air fin heater and ensure positive
isolation from respective header (LPG / Propane).
3. Connect a temporary SS hose from the spare vent (1”) I/V to tank. (Hose
connection to be done under supervision. the air inside the hose is to be
purged before connection.)
a. Check the hose for any leakage
b. Keep water spray nearby
c. start decanting liquid and depressurize the vapor in to the tank
d. observe the pressure indication at the air fin heater outlet. when it
becomes almost zero , isolate the inlet and outlet i/vs. of the hose &
disconnect the metallic hose under supervision
e. using temporary hose connection purge the air fin heater system
with nitrogen.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/026
AIR FIN HEATER COMMISSIONING AND DE- COMMISSIONING
Page 2 of 2

f. Check % LEL with a portable gas meter at the air fin heater and
purge the system with nitrogen till %LEL becomes zero.
g. After preparing a permit to work the air fin heater can be handed
over for maintenance

Note : The commissioning and de-commissioning is for single air fin heater.

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/027
TANKER LOADING FROM MOUNDED VESSELS
Page 1 of 2

A. LPG Tanker filling by Pump P501A

1. P501A suction, discharge line, instrument tappings leak tested & found
O.K.
2. P501A start up clearance from electrical / mechanical / instrumentation
sides obtained.
3. All (1”) vent isolation valves closed / blinds provided.
4. All instruments interlocks checked & kept ready for service.
5. Check PSV 5007 kept in line.
6. Close P501A suction bypass line (6”) isolation valve.
7. Check that the flow meter FT5021 in line with tapping I/Vs in open
condition.
8. Ensure sufficient level in MV501 as per level indication. (Level should be
more than 1000 mm)
9. Ensure 6” isolation valve of suction line is opened and then open XV 5004.
10. Open FCV 5021 manually on minimum bypass lines open its 3” u/s & d/s
isolation valve.
11. Start P501A with minimum bypass & observe its vibration, noise & flow
through FI5021, set the FCV5021 minimum flow at 50 m 3/hr on auto
mode.
12. Check that the LPG tanker is ready for filling at filling bay as per SOP–
GTD-5.
13. Start Ethyl mercaptan dosing pump P790 A/B & set the ethyl mercaptan to
LPG filling to give 12 ppm of mercaptan in tanker for odorizing purpose.
14. Stop P501A after filling LPG tanker loading. Close XV5004, ensure the
minimum bypass FCV5021 is wide open in auto mode releasing pressure
to vessel MV501.

B. Propane Tanker filling by Pump P501B

1. P501B suction, discharge line, instrument tappings leak tested & found
O.K.
2. P501B start up clearance from electrical / mechanical / instrumentation
sides obtained.
3. All (1”) vent isolation valves closed / blinds provided.
4. All instruments interlocks checked & kept ready for service.
5. Check PSV 5015 kept in line.
6. Close P501B suction bypass line (6”) isolation valve.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/027
TANKER LOADING FROM MOUNDED VESSELS
Page 2 of 2

7. Check that the flow meter FT5022 in line with tapping I/Vs in open
condition.
8. Ensure sufficient level in MV502 as per level indication. (Level should be
more than 1000 mm).
9. Ensure 6” i/v of suction line is opened and then open XV 5014.
10. Open FCV 5022 manually on minimum bypass lines, open its 3” u/s & d/s
isolation valve.
11. Start P501B with minimum bypass & observe its vibration, noise & flow
through FI5022, set the FCV5022 minimum flow at 50 m 3/hr or on auto
mode.
12. Check that the C3 tanker is ready for filling at filling bay as per SOP–GTD-
4.
13. Start Ethyl mercaptan dosing pump P790 A/B & set the ethyl mercaptan to
Propane filling to give 12 ppm of mercaptan in tanker for odorizing
purpose.
14. Stop P501B after filling Propane tanker loading. Close XV5014, ensure
the minimum bypass FCV5022 is wide open in auto mode releasing
pressure to vessel MV502.

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/028
COMMISSIOING AND DECOMMISSIOING OF HEATER E 1024A
Page 1 of 5

Design Parameters :

Fluid Flow : Shell side – cooling water


Tube side – Propane or LPG mix

Capacity : 75 Mt of Propane

Temperature : - 42 o C to + 8 o C for Propane


+ 15 o C to + 10 o C for Water

Pressure drop : Tube side : 0.425 bar


Shell side : 0.431 bar

E1024A for LPG Mix Service (tanker loading)


Case I : Keeping E1024 A along with E402 / E401

At present it is not possible due to cooling water flow constraint.

Case II : To keep E1024A for LPG service alone.


1. Positive isolate E402 tube side by closed spectic blinds at inlet of E401 &
keep open 6” GV at outlet of E401 to avoid any line pressurization.
(This is to be practiced till removal of E401 / E402 from system).

2. a) E1024A cooling water side line up. (Shell side line up)
1. Ensure 12” Butterfly valve at inlet & 10” butterfly valve at outlet of
E1024A are kept open for old cooling water system.
2. Ensure 6” Butterfly valve at outlet of E1024A towards new cooling
tower is closed.
3. Ensure that all cells are in line on cooling tower deck.
4. Ensure all isolation valves of cooling water circuit for deck
distribution are open.
5. Start cooling water pumps (if they are not running for other
equipment & or establish flow across E1024A by adjusting flow to
415 ~ 425 m3 / hr. and ensuring flow meter FT8004 readings.
6. Ensure that drain valves & vent valves in heater cooling water
circuit are closed & blinded after establishing flow.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/028
COMMISSIOING AND DECOMMISSIOING OF HEATER E 1024A
Page 2 of 5

b) E1024A Line up for LPG Mix (Tube side line up)


1. Propane product side valves to be kept closed & closed spectic
blinds to be put as per drawing No. E1024A line up for LPG Mix –
Rev 0.
2. Ensure LPG Mix line up is for E1024A & E1024 / E1024B / E401
kept isolated by properly closed spectic blinds Refer enclosed
drawing.
3. Ensure the tube side PSV i/v is in locked open condition.
4. Ensure PCV5022 is stroke checked & kept open as per
requirement.
5. Ensure air fin heaters (E405 & E406) are lined up as per
SOP/GTD/005.
6. LPG mix tanker loading to be carried out as per SOP/GTD/005.

Case III : To keep E1024A for Propane service


1. De-pressurized LPG & Propane header to zero bar into respective Tank.
2. Isolate LPG inlet and outlet headers to E1024A positively by reversing
spectacle blinds.
3. Lineup Propane inlet headers to E1024A.
4. Lineup E1024 outlet to Propane header (booster pump suction &
upstream of HCV 4501).
5. Leak test to be done.
6. Charge propane header inlet toE1024A slowly as per requirement of
tanker loading and booster pump.

Abnormalities while handling E1024A & consequences


i) Due to power failure cooling water tower pumps trip & C.W. flow
across E1024 reduces.

Consequences : Ice formation outside tube, which is dangerous as volume of


ice is more than that of water, can rupture of tubes or equipment.

Trips & Interlocks :


a) If cooling water reduces to less than 100 m 3/hr (FT8001 or FT8004
whichever of these is least), HCV1001 will de energize and product flow
(LPG Mix flow) across tube will be stopped.
b) If temperature of tube side drops to + 5 o C HCV 1001 will de-energize &
product flow across tubes will be stopped.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/028
COMMISSIOING AND DECOMMISSIOING OF HEATER E 1024A
Page 3 of 5

Actions to be taken – Responsibility : CRO / SI :


a) Close PCV 5022 to 0% & de-energize.
b) Contact electrical technician, run the DG sets establish cooling water flow
at the earliest. Check visually on E1024A shell side & tube side, ensure
Cooling water flow normalized. Then normalize tanker loading if / as per
requirement.

ii) Reduction of cooling water flow due to wrong line up or choke in


downstream of heater or scale formation.

Consequences : Due to improper heat transfer required product outlet


temperature cannot be achieved. Running hours of utilization (Cooling Tower
fan, AFHs) will increase less product flow affecting desired output.

Trips & Interlocks : If cooling water flow reduces to less than 100 m 3 / hr HCV
1001 will deenergize & product flow will stop.

Actions to be taken – Responsibility Asst Manager & Manager Opns &


Mechanical dept. :
a) Check the reliability of water flow meter, get it calibrated.
b) Tube bundle sheet of HE to be removed & cleaned.

iii) Pressure drop in tube side.

Consequences : Generally during tanker loading & after tanker loading pressure
inside tubes will be 6 ~ 9 bars. Due to tube leaks, there is chance of water
seepage inside the tubes if shell side water pressure is more than that of tube
side product pressure. Tube choking due to ice formation and product
contamination (moisture in LPG mix) endanger with respect to quality.

Actions to be taken
At immediate outlet of cooling water side of E1024A a goose neck pipe along
with gas detection system is provided. Alarm of this gas detector is indication of
tube leak. Tube leak to be ensured by checking at other vent points & by close
observing pressure drop rate. Leak tube to be plugged.
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/028
COMMISSIOING AND DECOMMISSIOING OF HEATER E 1024A
Page 4 of 5

COMMISSIONING ACTIVITIES OF NEW E1024A

Deaerate the system by throttling O/L valve at elevated point & normalize the O/L
valve after deaeration.

I) Erection of E1024A from mechanical department

II) Air blowing to be done with pressurizing & depressurizing in both shell
side & tube side.

III) A) Shell Side


a) Connection of cooling water lines from mechanical department.
b) Arrangement & passivation of equipment (shell side) with the help
of LTD’s pumps & barrels.
c) Streamlining the cooling water flow (ensuring N 2 Pressure = 3.0 bar
at tube side).

B) Tube Side
a) Erection of equipment with closed spectacle blinds as shown in
drawing.
b) Purge the tube side with N2 till O2 % reduces to less than 1.0%.
c) Pressurise the tube side with N2 till 3.0 bar.
d) Cooling water line up to be done as mentioned in Part A.
e) Vapours of propane to be purged in tube side to displace N 2.
Ensure LEL is 100%.
f) Open the spectacle blinds & put closed blinds as per requirement
(for LPG Service).
AEGIS LOGISTICS LIMITED
STANDARD OPERATING PROCEDURE
SOP/GTD/028
COMMISSIOING AND DECOMMISSIOING OF HEATER E 1024A
Page 5 of 5

g) Pressurize tube side till the maximum vapour pressure releases


(from E332) (Vapour Pressure).
iv) Put condensate from E-332 till pressure reaches shell side of E-332.

DECOMMISSIONING OF HEATER E1024A


1. Stop intank pump P101 A/B.

2. Depressurize the LPG header from T-101 top to LPG tanker loading area
from respective vent point by connecting with metallic hose to LPG T-101
(Hose connection to be done under supervision the air inside the hose to
be purged before connection.)

3. The heater E1024A to be positively isolated.

4. Connect the N2 hose to tube side i/l 1” spare nozzle. Start N 2 & open heater
o/l 1” I/V to vent, pressurizing with N 2 & depressurizing to vent stack to be
done many times to displace hydrocarbon to nil level.

5. Continue the N2 purging till tube side becomes gas free ensured by LEL meter
(% LEL Nil & kept tube side under positive N2 pressure around 1.5 bar.)

6. Close the cooling water supply & return lines I/V & drain the s/s cooling water
after opening the cooling water side vent valve.

HANDOVER FOR MAINTENANCE


1. Ensure heater shell & tube side is isolated & blinded.

2. Ensure tube side & shell side of heaters are N 2 purged & are gas free.

3. Disconnect N2 supply.

4. Ensure cooling water supply / return are isolated & drained & blinded both
i/l & o/l side.

5. Prepare a ‘Permit to Work’ & handover to maintenance.


8

Prepared by : Approved by : Revision no :


Designation : Designation : Revision Date :