Operating Procedure MY SKO O 05 MCOT 020

Tanker Loading Operations Rev. 0 Sept 2011

Any deviation from this procedure must follow the MANAGEMENT OF CHANGE PROCEDURE
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

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FOREWORD
Authority for original issue
Document Author
Issue of this document has been formally authored by:

Name: Mentor Solutions & Resources Sdn Bhd

Position: Technician/ Consultant/ Contractor

Date:

Issue Review
Issue of this document has been formally reviewed by:

Name:
Signature

Position: Production Supervisor/ Field Engineer

Date:

Issue Approval
Issue of this document has been formally approved by:

Name:

Signature:

Position: Head of Production

Date:

Document Custodian
The following person has been assigned as the document custodian:

Name:

Signature:

Position Onshore Installation Manager

Date

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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.
Details must include revision number, description and indication of which pages and
paragraphs have been revised, date of revision approval, approvers title and signature.

Rev Description Date Approver Title Name

Rev 0 Original Document

Notes: (1) Document Holders to update Amendment Record as and when

amendments/new revisions are received.
(2) For description of amendment the Document Holder should indicate
correction, modification, update or deletion issue.
(3) Document Holder to enter their company reference number, sign and date the
record of entry.
(4) Where part amendments are issued, the relevant page(s) will be identified
with a lower case letter in the revision status line in the header.

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GLOSSARY

API Industry standard method of expressing specific gravity of crude oils.

PMSSB PETRONAS Maritime Services Sdn Bhd
NOR Notice of Readiness
ETA Estimated Time of Arrival
SBM Single Buoy Mooring
TMB Top Middle Bottom
EOV Electrically Operated Valve
BS&W Bottom, Sentiments and Water
MOV Motor Operated Valve
CQL Certificate of Quantity Loaded
SLPS Sea Loading Pumps Station
IOP Integrated Operation Planning

REFERENCE

DOC. NO TITLE
MCOT Crude Custody Transfer Procedure for sealing/ breaking of seals on crude oil metering
Manual 8/11/1993 system
MY SKO O 07016 Rev.1 April 2010 MCOT Operating Procedures Manual

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Section 1
INTRODUCTION

Page

1.1 OBJECTIVE/PURPOSE ............................................................................................................ 6

1.2 SCOPE ...................................................................................................................................... 6

1.3 OP CATEGORY ........................................................................................................................ 6

1.4 PREREQUISITES ..................................................................................................................... 6

1.5 LIMITATIONS ............................................................................................................................ 6

1.6 ROLES / RESPONSIBILITY. ..................................................................................................... 6

1.7 HSE REQUIREMENTS ............................................................................................................. 7

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1 INTRODUCTION

1.1 OBJECTIVE/PURPOSE

1.1.1 The operating procedure outlines the normal activities required to safely execute the task, as
well as action to be taken in the event of abnormal and/or emergency situations that may
arise during the execution of the task.
1.1.2 This operating procedure outlines activities required to carry out crude loading operation to
tanker.

1.2 SCOPE

1.2.1 The requirements in this procedure shall apply to:

• Loading instruction
• Loading operation

1.3 OP CATEGORY

Categories Normal / Start Up / Shutdown / Checklist Required: Yes / No

and attributes Emergency / Special / Temporary /
Abnormal / Decommissioning

1.4 PREREQUISITES

1.4.1 Loading Instruction

1.4.2 MCOT Daily Tank Status (DTS)
1.4.3 Options to run electric motors, gas engine driven crude loading pumps or combination of
pumps must be planned up front.
1.4.4 Competent ICE Grade 1 Driver.
1.4.5 Maintain radio communication between the CCR and marine captain (pilot on board) during
tanker loading operation.

1.5 LIMITATIONS

1.5.1 The tanker loading operation is not allowed during very bad weather condition.

1.6 ROLES / RESPONSIBILITY:

1.6.1 Refer to Section 2: Procedure “Action party”.

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1.7 HSE REQUIREMENTS

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

Biological Beware of poisonous creature i.e. snakes,

bees etc.
Precaution on the soft grounds

Flammable No Hot Work within vicinity

Natural hazard Beware of lightning strike and heavy rain.
Sufficient lighting during nighttime.

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

Respirator Avoid inhaling of hydrocarbon fumes during

tank gauging
Ear protector Avoid high noise especially working at SLPS
area

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

Walkie talkie on special Communicate between CCR, Loading Master

frequency and trigger ESD trip of the SLPS.
Dipping Tape & Bob Gauging of crude in the tank

Sampling Jar & Bottle To collect crude sample in the tank

Thermometer & Flushing Cage To gauge crude temperature in the tank
Water & Oil (Dipping) Paste To test water content (unwanted) inside crude
oil.

ESD / ESD check is mandatory during every loading using special walkie-talkie
Interlocks frequency done by the pilot.

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Unit: SLPS and Metering

Never
Station Safe Operating SOL
Exceed
Limit Excursions
Limit
Area: 4
Equipment Inst. Consequence of Corrective
Tag # H L HH LL Deviation Actions

SLPS pumps SLPS pumps Refer to SLPS OP Refer to SLPS OP

SOL SOL

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Section 2
PROCEDURE

Content Page

2.1 LOADING INSTRUCTION .................................................................................................. 10

2.2 LOADING OPERATION ...................................................................................................... 12

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2 PROCEDURE

2.1 LOADING INSTRUCTION

No. Action Action Party

2.1.1 Issue loading instruction to MCOT and PMSSB Marine pilot to berth Tanker
tanker. scheduler
(IOP)

2.1.2 Calculate expected lay time and any potential demurrages Marine
Captain

NOTE:
• Calculation formula of lay time:
o Full cargo (300-500kbbls), 36 hrs after NOR.
o Cargo <300kbbls:

Lay time = X/300 x 36 hrs where X is nominated cargo in kbbls
o Cargo >500kbbls:

Lay time = X/500 x 36 hrs where X is nominated cargo in kbbls
• Potential demurrage namely due to:
o Stock availability due to offshore production quantity and quality
o Change in tanker arrival time outside date range
o Pumps performance and other mechanical breakdown

2.1.3 Establish communication between tanker, Loading Master and MCOT: Panel man /
• Estimated tanker ETA Loading
Master
• Berthing schedule

NOTE:
• Berthing priority given to tanker with earlier date range and ETA within
date range. Tanker ETA outside date range will be rescheduled.
• Vessel arrives before date range, lay time commences when the
loading hoses is connected to the vessel after 0001 hr of 1st day of
date range provided NOR is tendered and accepted by terminal
Loading Master, at least 6 hrs earlier at the normal sea pilot
embarkation area, whichever is earlier.
• If vessel arrives within the agreed date range, allowed lay time
commences either when vessel is berthed or 6 hrs after NOR,
whichever is earlier.
• If vessel arrived after 2400 hr of the last day of the date range,
allowed lay time shall commence when the loading hoses are
connected to the vessel.
• Completion of allowed lay time is when loading hoses are
disconnected.

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No. Action Action Party

CAUTION:
• BERTHING TANKER TO SBM 5 DURING ADVERSE WEATHER
CONDITION IS A RISK. USE GOOD JUDGMENT TO ENSURE SAFE
PERSONNEL TRANSFER, MOORING OF TANKERS AND
CONNECTION OF HOSES.
• SBM HOSES ARE FITTED WITH ‘MARINE BREAKAWAY
COUPLING’ FOR EMERGENCY.

2.1.4 Tanker berthing at SBM 5 and commence loading hoses connection. Loading
Master

2.1.5 Commence preloading check as per Preloading checklist. Please refer to Loading
Appendix. Master /
Panel man

2.1.6 Inform tanker on cargo volume, estimated density, API and tank Panel man
temperature for tanker to pre-calculate cargo. Estimate loading rate in
3
m /hr and completion time.

2.1.7 Determine on whether Ship to stop or Shore to stop. Loading

Master

NOTE:
• If Ship to stop, Tanker will give at least 15 min notice prior to
requesting Terminal to stop and Terminal will reduce the loading rate
for topping up. Terminal will stop the pumps based on the instruction
from Tanker Master provided the following have been achieved:

Nomination is maximum parcel and this has been reached.

Max tolerance of +-5% has been reached.

Ullage availability.
• If Shore to stop, Terminal to notify Tanker Master and Terminal will
stop the pumps provided the following have been achieved:

Nomination is maximum parcel and this has been reached.

Max tolerance of +-5% has been reached.
• Tanker has to be informed on any change in loading rate, pumps and
switching of tanks.

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2.2 LOADING OPERATION

No. Action Action Party

2.2.1 Line up fiscalised dry tanks for export. Ensure the crude quality is <0.5% Area operator
BS&W. / Lab
technician

2.2.2 Calculate expected cargo volume and determine BS&W %. Panel man

2.2.3 Fill and update the following:- Panel man

• Nominated Tanks for Loading Cargo sheet
• SBM-5 Pre-Loading Checklist sheet
• Shore Tank Calculation sheet
• A7 and A8 forms (Tank Movement forms)

2.2.4 Dip and collect tank samples Top, Middle, and Bottom (TMB) from Area operator
nominated cargo tanks within 8 hours before loading to check on quality
of the crude oil.

NOTE:
• If the water content of the Bottom sample is >0.5%, drain the water
from the tank until it meets the spec of 0.5% or less.
• Tank dipping and sampling to be witnessed by Independent
Surveyor.

2.2.5 Open nominated tanks suction side valves and respective MOVs. Area
operator/
Panel man

2.2.6 Identify SLPS booster pumps and loading (export) pumps to be used. ICE Driver

2.2.7 Open the identified SLPS booster pumps and loading (export) pumps Panel man
suction and discharge valves EOVs.

2.2.8 Prepare and line up Jiskoot Sampler and ensure it is operational. Area operator

2.2.9 Prepare metering skid, start new batch on database computer and select Area operator
meter streams to be use, breaking of seal on microcomputers and
valves.

NOTE:
• Breaking of seals at metering run and Jiskoot sampler to be
witnessed by Independent surveyor.
• MCOT has five meter streams; select appropriate number of meter
streams to be used based on flow rate. One meter stream capacity
3
is 1200 m /hr.
• Reset the database computers (duty and standby) to zero.
• Compare meter volume and station volumes with last batch and
report any discrepancies recorded.

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No. Action Action Party

2.2.10 Check valves configuration, adjust metering streams flow control valve to Area operator
40% open by input to stream line computer to control flow.

CAUTION:
• ENSURE PRESET KEY CODES IN THE COMPUTER REMAIN
UNCHANGED.

2.2.11 After Loading Master inform CCR that the ship is ready to receive cargo, ICE Driver/
ICE driver will start up nominated SLPS booster pump and one loading Panel man /
(export) pump. Loading
Master

2.2.12 Inform tanker loading master that terminal is ready to load and open the Panel man
beach valve (ABV-3006). After the confirmation to load is received from
Loading Master, loading operation start by engaging loading pump at
3
minimum loading rate (800 m /hr).

2.2.13 Loading Master will perform ESD test as soon as crude enters the Panel man /
tanker. The loading (export) pumps should trip after loading master Area operator
trigger ESD test. / Loading
Master

NOTE:
• ESD test is carried out by activating radio signal from tanker to
shutdown loading (export) pumps and close the beach valve.
• Booster pumps will be in recycle mode.

2.2.14 Reset the ESD signal and SLPS trip signal. Area operator
Restart loading (export) pump and re-commence loading upon / Panel man /
confirmation with Loading Master. Tanker
loading
master

NOTE:
• Review metering report after loading start.
• Check closed-in metering streams. If flow is registered, close the
inlet valve and confirm Rotox outlet valves are fully closed by
checking bleeder valves.
• If flow is still registered, continue with loading operation and deduct
isolated stream “Gross Total” from batch end report “Batch Gross
Volume”.

2.2.15 Increase loading rate accordingly based on Loading Master instructions. Loading
Increase pumps speed and adjust meter streams flow control valves until master / Area
safe maximum loading rate (2800 m3/hr) is achieved. operator /
Panel man

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No. Action Action Party

NOTE:
Meter streams flow control valves should be opened equally using
stream line computer control system.

CAUTION:
DO NOT EXCEED FLOW RATE OF 1200 M3/HR PER METER
STREAM.

2.2.16 Carry out meter proving for each meter stream to determine the meter Area operator
factor and download the raw meter factors to the stream line computer.

NOTE:
During the proving operation, the meter run and prover loop are used in
series. Spheres make a minimum of 5 passages through the loop.

2.2.17 Update the ‘Two Hourly Stock on Board Check’ sheet during the loading Panel man
operation. Compare MCOT metering figures loaded, shore tanks figure
and tanker receipt figures every 2 hours.

2.2.18 Suspend loading operation if any anomalies detected on pipeline or SBM Loading
hoses. Master / Shift
Operation
Supervisor /
Panel man

NOTE:
• If figures discrepancy between tanker and metering is abnormal,
recheck tanker figure.
• If discrepancy maintain, check export line and SBM hoses integrity.

2.2.19 Calculate and input average metering streams temperature for sea line Panel man
temperature correction in °C, half an hour before the end of the loading
operation.

2.2.20 Gradually decrease the pumps speed so as not to exceed the nominated Panel man
cargo volume based on metering figure.

2.2.21 When the nominated cargo volume is reached, shutdown the main Panel man /
loading (export) and booster pumps. Area operator

NOTE:
• Tolerance for cargo quantity loaded is +- 5%
• Tolerance for BS&W loaded is max 0.5%

2.2.22 Inform the loading master at tanker that loading has completed. Panel man

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No. Action Action Party

2.2.23 Close tanks suctions side valve, EOVs and export discharge line ABV- Panel man /
3006. Area operator

2.2.24 Take composite sample from Jiskoot samples and carry out required Area operator
analysis. / Lab
technician

NOTE:
Crude analysis for BS&W (max 0.5%)

2.2.25 Input results of analysis to data base computer for calculation of quantity Area operator
loaded. Print out the metering report and batch end.

NOTE:
• Compare metering figure with tanker figure, if differences is above
0.5% then compare metering figure with tank dip figure.
• Tank dip figure will be used as fall back figure if differences
between metering and tanker and metering and tanks are beyond
0.5%.

2.2.26 Seal the metering streams and valves outlet Area operator

NOTE:
• Independent surveyor to witness sealing of meter

2.2.27 Inform Oil Accounting Section to prepare export crude ‘Certificate of Panel man
Quantity Loaded’ (CQL) for tanker.

NOTE:
• Certificate to be certified by Independent Surveyor before being
forwarded to tanker.

2.2.28 Record the after loading information in the SBM-5 Pre-Loading and After Panel man
Loading Checklist sheet

END OF PROCEDURE

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Appendix

APPENDIX A

Content Page

1 DIAGRAMS ............................................................................................................................. 18

1.1 PRE LOADING CHECK LISTHHHHHHHHHHHHHHHHHHHHHHHHHHH.17

1.2 FIGURE 1: SCHEMATIC FROM DRY TANKS TO TANKER................................................ 188

1.3 FIGURE 2: LOADING (DRY) TANKS.................................................................................... 199

1.4 FIGURE 3: SEA LOADING PUMP STATION (SLPS)HHHHHHHHHHHHHHHHH20

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1 DIAGRAMS

1.2 FIGURE 1: SCHEMATIC FROM DRY TANKS TO TANKER

ABV-3006

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1.3 FIGURE 2: LOADING (DRY) TANKS

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1.4 FIGURE 3: SEA LOADING PUMP STA

STATION (SLPS)

GV

METER
PROVER
SKID

GV

TO TANKER

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