STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE

PROCEDURE.

OPERATING PROCEDURE FOR GAS COMPRESSION PLANT

ELLISON has Compression Plant at GELEKI GGS-3 Compression plant consists

of Compressor, Engine, Cooler and other equipment which are necessary for
compression of Low pressure Natural Gas to High Pressure Natural Gas.
ELLISON has its own operating procedure for its Gas Compression Plant.
Operating Procedure for Gas Compression Plant includes the following.

>>>STARTING OF THE GAS COMPRESSOR UNIT:

1. Check the panel board for the cause of the shutdown. Walk around
compressor package and inspect for anything unusual. Correct the
problem and reset the shutdown system.
2. CAUTION: A gas mixture under pressure can explode violently! If the
unit has been down or the gas system has been exposed to the
atmosphere, the system must be purged. This is done as follows:

A. Open the vent valves

B. Open the inlet (suction) valve
C. Open the by-pass valve.

Alternately close then open the by-pass valve to insure a complete

purge of the system. A low suction pressure will take longer to purge
the system. After the purge cycle is completed, close the vent valve
and make sure the by-pass is open.

3. If the unit has been down several hours, the frame should be pre-
lubricated either with a hand pump or an automatic pump.
4. Check the stop-run switch. It should be set to the run position.
5. Set speed controller or throttle to idle speed. Never start an engine at
full speed, even after pre-lubing. This eliminates over speeding and
unnecessary wear.
6. Set all low pressure points on the suction, inter stage and discharge
pressure gauges, below the suction pressure to prevent a low pressure
shutdown if not on a timer circuit. (NOTE: Be sure to return these to
the recommended setting after the unit is loaded.)
 STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE
PROCEDURE.

7. Reset the fuel valve. There are several types of fuel valves. Two more
common to the industry are:

A. 1” M-25-80 CD used on smaller units up to 100HP.

B. 2” M-5—81 CD used on units above 100HP.

Gently push the lever in the direction of the gas flow until we feel the
valve catch. Do not force any of these devices. If operator do not feel
the valve catch, it might be set already. If not, do not force it, this will
only result in damage to the fuel valve. Check the fuel system to be
sure there is fuel pressure to the valve then reset the valve.
8. Rotate the start-run timer to three minutes. This will by-pass all of the
Class B shutdown points. All Class A shutdown must be satisfied to
clear the panel prior to starting the unit.
9. Push the engine start button to start the prelude pump. After the
prelude is satisfied, the starter will engage and engine will rollover and
begin running. If the engine starts, release the engine start button. If it
does not start in a few seconds, release the button. Verify that the fuel
valve is activated, and make sure the shutdown system is reset.

Reset the timer to (3) minutes and push the start button again. If the
unit does not start by the third time, a serviceman may be necessary.
(Note: One of the vibration or overspeed switches can be tripped. A
slight bump after the unit is down will trip the vibration sensors and not
trip the shutdown indicator. These must be manually reset before the
unit will start.)
10. Immediately after the units starts, check the engine and compressor oil
pressure. Verify they are in the proper range and turn the start-run
timer run to “0”. This will activate the safety shutdown system. The unit
is now running with the by-pass valve open and recycling gas. Allow
sufficient warm up time (Approximately 130 F jacket water
temperature) before loading the compressor. While the unit is warming
up, check for water and oil leaks. Check all levels, listen for any
unusual noises, and tighten any loose supports and braces. In general
give the unit a good inspection.
11. When the jacket water temperature reaches approximately 130 F and
all is in order, the unit is ready to load. Set the speed controller on
throttle to the recommended RPM.
12. Load the unit: CAUTION! Open or make sure the discharge valve is
open, then slowly close the by-pass valve.
13. Reset all pressure points that were changed in Step 6.
 STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE
PROCEDURE.

>>>SHUTDOWN PROCEDURE OF GAS COMPRESSOR PACKAGE:

To shut down compressor package for maintenance or incase of

emergency, ELLISON will follow shutdown Procedure as given below:

1. The pressure devices for gas compressed should be adjusted to

avoid premature shutdowns or alarms but be within the operating
limits of the equipment.
2. Reduce engine speed and open the by-pass valve. This prevents
over speeding the engine and the open by-pass valve circulates the
gas rather than discharging it, allowing the discharge check valve to
seat. The unit is now operating as a closed system. Watch the
working pressure and rod loads of the cylinders and scrubbers.
3. Close the inlet suction block valve.
4. If the engine is turbocharged, reduce the speed to idle and let run
to least (2) minutes, allowing the turbocharger to cool down and
prevent oil starvation.
5. Kill the engine by tripping one of the end devices. This will
shutdown the ignition system and trip the fuel valve if it is wired into
the circuit.
6. Close the discharge block valve if we are going to work on the
engine or compressor regardless of how minor the repairs
Now with unit down, the suction and discharge valves closed, and the by-pass
valve in-the-open position. Open the vent valve to bleed off all pressure before
performing maintenance or repairs. Check all connections and valve caps for
trapped gas before removing them. This can be done by loosening the studs and
breaking the seat or seal before removing

>>>RE-START UP OF COMPRESSOR PACKAGE:

Before starting gas compressor package, Operator should familiarize

themselves with compressor package. Read and Study the Start up procedures
carefully.

Gas compressor package are complicated and very dangerous pieces of

equipment and operator should not attempt to operate the compressor package if
they are not fully trained and are not familiar with the operation of a Gas
Compressor Package,

A Gas/Air mixture under pressure can explode violently which could result
in server injury or death, along with damage to the equipment. Operator will
check all vents and drain lines before starting this unit. Only after familiarizing
with the equipment and the conditions of operations and proper starting
procedure have been read and understood, should the equipment be started and
put into operation.
 STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE
PROCEDURE.

>>>MEASUREMENT AND PRODUCTION REPORT:

ELLISON has own format for Measurement and Production Report.

ELLISON will submit 24 hours production report to ONGC site incharge
according to DPR format which approved by ONGC. Day means calendar day of
twenty-four (24) consecutive hours beginning at 0600hours with reference to
local time at the site. ELLISON will submit daily production report to ONGC shift
in charge for check and sign

>>>WORKING AND SAFETY:

After starting compressor package, ELLISON will maintain safe working

environment at compression facility for smother operation. Our supervisor and
operators will follow as per safety policy of Deep Industries Limited to maintain
safe working environment at compression plant. ELLISON conduct mock drill
every month and copy of mock drill maintain at site. ELLISON conduct HSE
meeting on monthly basis. During monthly HSE meeting, we discuss various
issues of Health, Safety and Environment. A copy of HSE meeting report
maintain at site by Plant In charge. ELLISON has display data outside the main
factory gate with regard to quantity and nature of hazardous chemical being
handled in the plant, including waster water and air emissions and solid
hazardous wastes generated within the factory premises. Oil generated during
operation has collected and stored at designated location within premises. The
stored used oil transport and dispose by registered refiners as per GPCB norms.

>>>GENERAL INSTRUCTIONS FOR MAINTAINING SAFE TEMPERATURE

LEVEL OF THE UNIT (MANUFACTURER’S RECOMMENDATIONS)

Procedure:
I. Temperature across the coolers shall be checked on hourly basis and its
reading shall be recorded in log book.

II. In the event temperature is high check following:

III. Packing Over Heating

Lubrication failure.
Improper lube oil and/or insufficient lube rate.
Worn packing rings.
Dirt in packing.
Improper ring side or end gap clearance.
Scored, tapered or out of round piston rod.
Excessive piston rod runout.
 STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE
PROCEDURE.

IV. Excessive Carbon on Valves

Excessive lube oil.
Improper lube oil.
Oil carry-over from inlet system or previous stage.
Broken or leaking valves causing high temperature.
Excessive temperature due to high pressure ratio across cylinders.

V. High Discharge Temperature

Excessive ratio across cylinder due to leaking inlet valves or rings on next
higher stage.
Fouled intercooler piping.
Leaking discharge valves or piston rings.
High inlet temperature.
Improper lube oil and or lube rate.

CAUTION
HOT GAS TEMPERATURES ESPECIALLY THE CYLINDER
DISCHARGE AREAS, 190°F (88°C) OIL AND HIGH FRICTION AREAS
CAN BE A SOURCE FOR BURNS.WEAR PROPER INSULATION WHEN
WORKING AROUND THESE AREAS. SHUT DOWN UNIT AND ALLOW
TO COOL BEFORE DOING MAINTENANCE IN THESE AREAS.

VI. Read this instruction carefully while servicing.

VII. Incase if the above symptoms are found then steps shall be taken
to shutdown the compressor unit.

Record: This document shall be maintained with the site in-charge as well as
site engineer and same copy in head office with GM operations, Safety Manager
& M.R.

>>>GENERAL INSTRUCTIONS FOR MAINTAINING LEVEL IN SUCTION

KNOCK OUT DRUM (KOD).
.
Procedure:
I. It is desirous to have a minimum liquid level in the suction KOD of efficient
liquid gas separation .
 STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE
PROCEDURE.

II. Suction KOD is provided with automotive drain system from bottom and a
guage slot to monitor the liquid level in the vessel.

III. Kindly follow these steps:

a. Check level in guage slot daily and note it.
b. If there is no level/ high level in the vessel, liquid discharge valve must be
closed and automatic drain system must be checked or serviced.

>>>GENERAL INSTRUCTIONS FOR MAINTAINING LEVEL DISCHARGE IN

KNOCK OUT DRUM (KOD).

Procedure:
I. It is desirous to have a minimum liquid level in the discharge KOD of
efficient liquid gas sepration .

II. Discharge KOD is provided with automotive drain system from bottom and
a guage slot to monitor the liquid level in the vessel.

>>>GENERAL INSTRUCTIONS FOR MONITERING THE LEVEL IN THE

CONDENSATE TANK

Procedure:
I. Condensate collected from various drain points is stored in pressurized
condensate tank. Liquid level in this tank shall not exceed to avoid
drainage of condensate through vent pipe. The below mentioned steps
shall be followed.
II. Check level every 8 hours.
III. Manually drain the condensate whenever level is high.
IV. Condensate shall be drained by periodic opening of valve.
minimum level shall be maintained to avoid gas flow in drain sytem.

>>>PROCEDURE FOR DRAINING THE CONDENSATE IN BARRELS

Procedure:
I. Whenever the condensate is discharged in barrel, following procedure
shall be followed:
II. All the lights shall be kept in off condition.
III. Open the incoming valve of the hose slowly.
IV. Do not fill the barrel up to the top. barrel should be filled in such a way that
at least 20cm of the top remains vacant.
V. Air vent pipe shall be kept open at the time of filling the barrel.
 STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE
PROCEDURE.

VI. After barrel is filled, close tightly the barrel cap and air vent cap.
VII. Do not put the barrel under direct sunlight.
VIII. Wear gas mask at the time of filling the barrel.
IX. There shall not be any naked fire in 30 meters radius at time of filling the
barrels.
Keep barrel in upward position.

>>>MAINTENANCE PROCEDURE AS DEFINED BY OEM.

COMPRESSOR SECTION:
I. Check frame oil pressure. It should be 50 to 60 psig (3.5 to 4.2 barg) when
at operating temperature. Compressor inlet oil temperature is 190°F
(88°C) maximum.
II. Check frame oil level. It should be visible in the sight glass and
approximately mid-level when running, if not, determine and correct
cause. Do not overfill. Check oil makeup tank for sufficient oil supply.
III. Check lubricator block cycle movement indicator. Refer to information
plate on top of lubricator box for correct cycle time. Very dirty or wet gas
may require a more frequent cycle time than normal.
IV. Check primary and secondary packing vents for blowing. If blowing,
determine cause and, if necessary, replace packing internal parts.
V. Check and correct any gas leaks.
VI. Check and correct any oil leaks.
VII. Check operating pressure and temperatures. If not normal,
determine cause of abnormality and correct. It is recommended that a
daily log of operating temperatures and pressure be kept for reference.
VIII. Check shutdown set points.
IX. Low oil pressure shutdown 35 psig (2.4 barg) minimum. High temperature
shutdown to be set within 25°F (14°C) of actual operating temperature.
High and low pressure shutdowns set as close as practical. Consideration
should be given to rod load capacity of machine.
X. Check lubricator box oil level.
XI. Check for unusual noises or vibrations.

Monthly (in addition to Daily Requirements)

Check and confirm safety shutdown functions.

Every 6 Months or 4,000 Hours (plus Daily/Monthly)

I. Drain and replace lubricator box oil.

II. Change oil filter or when oil filter differential pressure exceeds the filter
change value, see filter information plate on the top cover or Technical
Manual, Section for value.
 STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE
PROCEDURE.

III. Change oil. A more frequent oil change interval may be required if
operating in an extremely dirty environment or if the oil supplier
recommends it or if an oil analysis dictates it. A less frequent oil change
interval may be allowed if the oil is replenished on a regular basis due to
force feed lubricator usage.
IV. Clean sintered element in the small oil filter supplied on the force feed
lubrication system or every time main oil filters is changed.
V. Clean strainer when oil is changed.
VI. Open frame when oil is changed and visually inspect for foreign material.
Disassembly is not recommended unless a reason for it found.
VII. Check fluid level in torsional vibration damper (if applicable). Take
fluid sample for viscosity testing.
VIII. Re-tighten hold down stud-nuts to proper torque values and
perform a soft foot check. More than 0.002 inch (0.05 mm) pull down
requires re-shimming. If reshimming is required, realign if necessary to
hold hot coupling alignment within 0.005 inch (0.13 mm) TIR.
IX. Check cylinders for the proper lubrication rates.
X. Reference Technical Manual, Section 4 for a practical indication using the
paper test method.

Yearly or 8,000 Hours (plus Daily/Monthly/6 Months)

I. Check main bearing clearance, connecting rod bearing clearance, and

crankshaft thrust clearance with a pry bar and dial indicator1. Any time
bearing clearances are outside the limits listed in the Technical Manual,
Clearances Table, replace the affected bearings. Disassembly to check
clearances is not recommended. Disassembly should be performed if the
pry bar check indicates excessive clearance.
II. Check crosshead guide clearance with feelers and if outside the limits
listed in the Technical Manual, Section 1, Clearances Table, replace the
affected parts.
III. Inspect valves for broken plates and loose center bolts, replace broken
parts and tighten center bolts.
IV. Inspect cylinder bores for damage or wear. If the cylinder bore surface is
blemished or gouged, affecting efficiency or causing rapid ring wear, or is
more than 0.001 inch per inch of cylinder bore diameter (0.001 mm/mm)
out of round or tapered, the cylinder body should be replaced or the bore
restored.
V. Inspect piston ring end gap. Replace rings that are outside the maximum
limit, Inspect piston rods for damage and excessive wear. If gouged or
scratched, replace the rod. If the rod is more than 0.005 inch (0.13 mm)
under size, out of round more than 0.001 inch (0.03 mm), or tapered more
than 0.002 inch (0.05mm) replaces the rod.
VI. Rebuild cylinder packing cases.
 STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE
PROCEDURE.

VII. Inspect for frame twist or bending by checking shimming of

compressor feet.
VIII. Realign if necessary to hold coupling hot alignment within 0.005
inch (0.13 mm.
IX. Check and re-calibrate all temperature and pressure gauges.
X. Check and record compressor rod run out.
XI. Grease VVCP stem threads at grease fitting, with 2 to 3 pumps of multi-
purpose grease using a standard hand pump grease gun.
XII. Clean crankcase breather filter.
XIII. Adjust drive chains.
XIV. Pressure test distribution blocks.
XV. Check gas nozzle flange, valve cap and compressor rod packing
fastener torque.

Every 2 Years or 16,000 Hours (plus Daily/Monthly/6 Months/Yearly)

I. Check auxiliary end chain drive for sprocket teeth undercutting and chain
for excessive stretching. Rebuild oil wiper cases.

Every 4 Years or 32,000 Hours (plus Daily/Monthly/6 Months/1 & 2 Years)

I. Check crosshead pin to crosshead pin bore and connecting rod bushing
bore by removing crosshead pins.
II. Check for excessive wear in the auxiliary end drive chain tightener.
III. Check for excessive ring groove wear in pistons.

Every 6 Years or 48,000 hours (plus Daily/Monthly/6 Months/1, 2 & 4 Years)

I. Replace lubricator distribution blocks. Replace crosshead bushings.

>>>EMERGENCY AT PLANT:

Emergency situation arises all sudden and contains high potential to cause
havoc. In case of emergency, ELLISON personnel will follow Emergency escape
procedure as per Emergency Action Plan (EAP) and shall contact following
numbers

Name Contact No

Ellison Oilfield Services Private Limited

1) Pranjal Goswami 9954532525

 STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE
PROCEDURE.

Hospital - 104
Ambulance - 102
Police - 100
Fire - 101

In a located fire extinguisher area ELLISON provide 25kg Bottle of CO2, and
bottles of 10kg each of DCP.

>>>MAINTENANCE:

In case of maintenance of compressor package or non availability of gas,

ELLISON will contact ONGC shift incharge at _________________ site. In
case of Major shutdown or breakdown, ELLISON operators/shift incharge will
contact ____________________ on his mobile No. ___________________
. Ellison has maintained register for predictive and preventive maintenance of
compressor package.

>>>VISITOR PROCEDURE:

In order to ensure the safe operation and to protect any visitors from the hazard
associated with ‘ELLISON’ operations it is essential that control over visitors is
exercised. A log book of visitors shall be held by the site in charge. The visitor will
report directly to the site in charge and sign in, in the log book kept at the site
incharge’s office. The visitor will be given a visitors badge. Upon completion of
the visit, the visitor shall sign out in the register and leave the site.

The following briefing message shall be given by the person manning the
location gate or site in charge (when not manned).

Welcome to "ELLISON" Site /Installation ______________________ operation.

While you are on the location you are to follow the following rules :

1. Hard hats must be worn while on the site /Installation.

2. Safety shoes are also mandatory if you are required to perform any work
outside the offices.
3. Safety glasses are required if you are to perform any work outside the
offices.
4. Please sign in the visitors log book.
5. Review your visitor reception card and the rules as Outlined.
 STANDARD OPERATING PROCEDURE-STANDARD MAINTENACE
PROCEDURE.

>>>INCIDENT REPORTING:

All work related to incidents must be reported and reviewed by the Safety
Manager and Site In Charge. All non work relating incident in trauma and
requiring care at the medical treatment level must be reported and reviewed by
safety manager.

Each and every incident should be recorded properly by site in charge as per
Incident Analysis form.