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or STANDING INSTRUCTIONS process before any deviation or change may be made.
OPERATING PROCEDURE
Contents
Foreword
Distribution List
Amendment Summary
Glossary
Reference
Section 1 Introduction
Section 2 Procedure
Appendix A Checklist
Diagram
FOREWORD
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Distribution List
Copy No. Title Location
01 Central Control Room MCOT
AMENDMENT SUMMARY
This sheet must be completed in detail at each revision once this document has been
approved.
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paragraphs have been revised, date of revision approval, approvers title and signature.
GLOSSARY
REFERENCE
DOC. NO TITLE
MY SKO O 07016 Rev.1 April 2010 MCOT Operating Procedures Manual
MCOT CIMAH Safety Report PCSB
MCOT CIMAH 2009 Rev 131109
SKO Rev. 0 November 2009
Work Method Manual: V-1010 isolation for inspection and
WMM
maintenance work
Section 1
INTRODUCTION
Content Page
1.1 OBJECTIVE/PURPOSE................................................................................................ 6
1 INTRODUCTION
1.1 OBJECTIVE/PURPOSE
1.1.1 This operating procedure outlines normal activities required to execute the task and actions to
be taken in event of abnormal situations that may arise during the execution of the task.
1.1.2 The task is to prepare MCOT for receiving crude from offshore Baram field.
1.2 SCOPE
1.3 OP CATEGORY
1.4 PREREQUISITES
1.4.1 MCOT to be informed minimum 24 hrs prior to receiving offshore crude for preparing the
receiving facilities.
1.4.2 Communication is established with BA CCR.
1.5 LIMITATIONS
Hazards and The table below lists job hazards and the precautions that should be taken for
precautions safety, environmental, quality, ergonomics, Good Manufacturing Practices,
etcH before beginning this procedure.
Hazard Precaution
PPE required The following Personnel Protection Equipment (PPE) must be used to do this
activity in addition to common PPEs. List any special PPEs required,
PPE Use
N/A
Tools and The tools and equipment listed below are needed to do this job. List any
Equipment special tools required in addition to hand tools.
Tools and/or Equipment Use
ESD / ESD will close ABV-9250 Beach valve besides shutting down the Terminal.
Interlocks ABV-9230/9250
SDV-1010/20/30/40
SDV-1011/21/31/41/12/22/32/42
16” BA crude PAL-9252 2.2 Alarm will be activated. Find out the cause of the low pressure
trunkline barg Beach valve ABV-9250 trip when alarm and rectify any fault found. Open
pressure drop to 1.38 barg. BA back beach valve ABV-9250.
offshore facilities trip on high trunkline
pressure
16” BA crude PAH-9252 7.5 Alarm will be activated. Find out the cause of the high pressure
trunkline barg Beach valve ABV-9230 trip when alarm and rectify any fault found. Open
pressure increase to 9.3 barg. BA back beach valve ABV-9250.
offshore facilities trip on high trunkline
pressure. There is a potential of
trunkline leak due to high pressure
leading to a loss of containment.
16” BA crude PZALL-9251 1.38 Beach valve ABV-9250 trip. Find out the cause of the low low
trunkline barg BA offshore facilities trip on high pressure, rectify if possible and re-open
trunkline pressure. back beach valve ABV-9250. Seek
expert help if unable to rectify fault.
16” BA crude PZAHH-9251 9.3 Beach valve ABV-9250 trip. Find out the cause of the high high
trunkline barg BA offshore facilities trip on high pressure, rectify if possible and re-open
trunkline pressure. There is a potential back beach valve. ABV-9250. Seek
of trunkline leak due to high pressure expert help if unable to rectify fault.
leading to a loss of containment.
V-1010/20/30/40 PIAH- 7.5 The inlet SDV-1010/20/30/40 trip when Find out the cause of the high pressure
FWKO Vessels 1011/12/13/14 barg pressure increase to 9.3 barg. alarm and rectify any fault found. Open
back the inlet SDV-1010/20/30/40.
V-1010/20/30/40 PIAL- 0.3 The inlet SDV-1010/20/30/40 and Find out the cause of the low pressure
FWKO Vessels 1011/12/13/14 barg outlet SDV- alarm and rectify any fault found. Open
1011/21/31/41/12/22/32/42trip when the inlet SDV-1010/20/30/40 and outlet
pressure drop to 0.15 barg SDV-1011/21/31/41/12/22/32/42
V-1010/20/30/40 PZAHH- 9.3 The relief valve PSV-1010/20/30/40 Find out the cause of the high high
FWKO Vessels 1012/22/32/42 barg open at 10.34 barg to relieve the pressure alarm and rectify any fault
pressure to Surge Relief header found. Re-calibrate PSV-
1010/20/30/40.
V-1010/20/30/40 PZALL- 0.15 The liquid remain stagnant as there is Find out the cause of the low low
FWKO Vessels 1013/23/33/43 barg not enough pressure to push it out. pressure alarm and rectify any fault
found. Close the manual outlet valves
and use external pressure supply to
increase the pressure to the normal
operating pressure. Open back the
manual outlet valves
V-1010/20/30/40 LZAHH(I/F)- 75 % The water enters the wet tanks and Stop the incoming crude from offshore.
FWKO Vessels 1012/22/32/42 reduces the water draining efficiency Find out the cause of the high high
of MCOT. interface level alarm and rectify any
fault found. Resume receiving of
offshore crude.
V-1010/20/30/40 LZALL(I/F)- 50 % The vessels become empty Close the manual outlet valves. Find
FWKO Vessels 1013/23/33/43 out the cause of the low low interface
level alarm and rectify any fault found.
Open back the manual outlet valves
once level is established.
Section 2
PROCEDURE
Content Page
2 PROCEDURE
2.1.1 Ensure the ESD, PSD are healthy and instrument air is operational. Panel man 2
2.1.2 Ensure BA 16” crude receiving line valves are as per checklist in Appendix Area operator
A, item 1.1, Table 1.
2.1.3 Ensure the Surge arrestors SPR-13252/54/55 are ready for operation and Area operator
Surge Relief Vessel V-6310 is lined-up.
NOTE:
The surge arrestors is set at 7.6 barg (110 psig ) and relief to the Surge
Relief Vessel V-6310
2.1.4 Ensure that the Net Oil Metering system is lined-up for operation. Area operator
2.1.5 Ensure the FWKO vessels V-1010/1020/1030/1040 are lined-up to receive Panel man 2/
crude from the incoming line. Area operator
2.1.6 Ensure the nominated wet tank is lined-up to receive crude from FWKO. Panel man 2/
Area operator
2.1.7 Ensure that the WTP is lined-up to receive water. Panel man 2/
Area operator
2.2.3 Activate the operation start-up override key switch at the CSS panel to Panel man 2
override the low low pressure trip.
Description Tag Barg Psig
Low Low pressure trip PZALL-9251 1.38 30
Low pressure alarm PZAL-9252 2.0 29
2.2.4 Slowly open 2” VO the start-up throttling bypass isolation valve to Area operator
pressurise the downstream system.
2.2.6 Once the line pressure of the upstream and downstream of MOV-9252 Area operator
equalised, open MOV-9252.
2.2.7 Close 2” VO the by-pass start-up throttling valve opened in 2.2.4. Area operator
2.2.8 The low low pressure alarm will automatically reset at 2.2 barg (31.9 psig). Area operator
Return the operation start-up override key switch to normal position.
2.2.9 Inform BA PS once MCOT is ready to receive the crude. Panel man 2
NOTE:
Assumption: FWKO vessels are empty of liquid and are filled with air
2.3.1 Set oil/water interface level (LIC-1010/1020/1030/1040) at 50% of range in Panel man 2
DCS.
2.3.4 Manually close LCV-1010/1020/1030/1040 water outlet control valves via Panel man 2
their respective LIC manual setting.
2.3.5 Manually close PCV-1010/1020/1030/1040 inlet control valves via their Panel man 2
respective FIC manual setting.
2.3.6 Confirm that the following valves are in the following position as per Area operator
Appendix A, item 1.2, Table 2.
2.3.7 Fill up vessels with water from the nearest hydrant via a temporary Area operator
connection at the top of the vessels. Then close all vent valves which were
opened at 2.3.3.
2.3.9 Slowly pressurize V-1010 by manually open PCV-1010 via PIC-1008. Then Panel man 2
slowly pressurize V-1020/1030/1040 one by one via PIC-1008 respectively.
Monitor incoming pipeline pressure closely during above operation so as to
prevent a drastic drop.
2.3.10 When the pressure in the vessels have stabilized at the normal operating Panel man 2
pressure, set the FWKO inlet control valves PCV-1010/1020/1030/1040 on
auto control.
2.3.11 Slowly adjust the water outlet control valves LCV-1010/1020/1030/1040 to Panel man 2
bring the crude/water interface down to within the interface controllers
range and then set the control valves LCV-1010/1020/1030/1040 on auto
control.
NOTE:
• This is to minimise the effect of static electricity that may be generated
due to the presence of free water
• An explosive mixture of air and vapour is present when starting up with
an empty vessel.
NOTE:
• Baram and West Lutong are not producing.
• All FWKO V-1010/1020/1030/1040 have shutdown and are still full of
liquid
2.4.1 Ensure the following valves: FWKO V-1010/1020/1030/1040are as per Area operator
checklist in Appendix A, item 1.2, Table 2.
2.4.2 Manually close PCV-1010/20/30/40 FWKO inlet control valve and manually Panel man 2
open SDV-1010/1020/1030/1040 the inlet shutdown valves via the reset
button.
2.4.3 Manually open water outlet SDV-1012/22/32/42 & crude outlet SDV- Panel man 2
1011/21/31/41 via the reset button.
2.4.4 Slowly open the PCV-1010/20/30/40 FWKO inlet control valve manually to Panel man 2
introduce crude into the vessels.
2.4.5 When the process has stabilised, set PCV-1010/20/30/40 FWKO inlet and Panel man 2
LCV-1010/20/30/40 water outlet control valves on auto-control.
2.5.1 Ensure the following valves:FWKO V-1010 is as per checklist in Appendix Area operator
A, item 1.3, Table 3.
2.5.2 Manually close PCV-1010 FWKO inlet control valve and manually open Panel man 2
SDV-1010 the inlet shutdown valves via the reset button.
2.5.3 Manually open water outlet SDV-1012 & crude outlet SDV-1011 via the Panel man 2 /
reset button. Area operator
2.5.4 Slowly open the PCV-1010 FWKO inlet control valve manually to introduce Panel man 2
crude into the vessels.
2.5.5 When the process has stabilised, set PCV-1010 FWKO inlet and LCV-1010 Panel man 2
water outlet control valves on auto-control.
NOTE:
Normal shut down of FWKO V-1010 for maintenance e.g. inspection
2.6.1 Close FWKO V-1010 water outlet LCV-1010 manually to displace most of Panel man 2
the crude to YP21.
2.6.2 Once the crude outlet samples are mostly water (>75%), close crude inlet Panel man 2/
PCV- 1010. Area operator
2.6.3 Close SDV-1010 crude inlet valve, SDV-1011 crude outlet valve and SDV- Panel man 2
1012 water outlet valve.
2.6.4 Carry out depressurise and draining as per respective Work Method Area operator
Manual (WMM) to depressurise V-1010.
2.7.1 When an operating upset occurs, the appropriate safety shutdown devices Info
will automatically act. Refer to Appendix A, item 1.4, Table 4: FWKO
Shutdown Causes and Effect.
2.7.2 When all FWKO’s are isolated by their SDVs, the incoming crude can be Area operator
diverted to the receiving tank via a bypass line with hand valve (HV-1004). / Shift
This operation can only be performed manually when it is safe. Operation
Supervisor
2.7.3 If only 1 out of 3 FWKOs are isolated by their SDVs, the remaining 2 Area operator
FWKOs are able to cope with the incoming crude flow. However, need to / Shift
monitor the flow rate and pressure of the incoming crude flow. Line-up the Operation
standby FWKO if required. Supervisor
2.7.4 If 2 out of 3 FWKOs are isolated by their SDVs, pressure build up may Area operator
occur in the incoming trunkline. Line-up the standby FWKO if required. / Shift
Operation
Supervisor
END OF PROCEDURE
Appendix
APPENDIX A
Content Page
1 CHECKLIST ................................................................................................................ 17
2 DIAGRAMS ................................................................................................................. 21
1 CHECKLIST
High high PZAHH- Trip the inlet shutdown valve To prevent vessel being
pressure 1012/22/32/42 SDV-1010/20/30/40 overpressure
Low low pressure PZALL- Trip the inlet shutdown valve To prevent loss of hydrocarbon
1013/23/33/43 SDV-1010/20/30/40, the oil containment as the low low
outlet SDV-1011/21/31/41 pressure trip may be due to a
and water outlet SDV- leak or rupture in the FWKO or
1012/22/32/42 associated pipes.
High high LZAHH(I/F)- Trip the inlet shutdown valve To prevent severe water carry
interface 1012/22/32/42 SDV-1010/20/30/40 and oil over to the downstream
outlet SDV-1011/21/31/41 facilities.
Low low interface LZALL(I/F) – Tripe the water outlet SDV- To prevent oil underflow to the
1012/22/32/42 1013/23/33/43. Produced Water system.
These SDV will be auto reset
when the interface is back to
the normal level.
Power failure NA Will lead to air failure and all To isolate the vessels
SDVs will close
2 DIAGRAMS