MCOT 048 Instrument and Utility Air System Operation

Operating Procedure – MCOT MY SKO O 05 MCOT 048
MCOT Instrument and Utility Air System Operation 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
"UNCONTROLLED WHEN PRINTED"
30/07/2012 10:41 AM PETRONAS CARIGALI SDN BHD Page 1 of 20

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

Proprietary Information
This document contains proprietary information belonging to
PETRONAS Carigali Sdn Bhd and must not be wholly or partially reproduced
nor disclosed without prior permission from PETRONAS Carigali Sdn Bhd.
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.

GLOSSARY
USD Unit Shutdown
REFERENCE
DOC. NO TITLE
MY SKO O 07 016 MCOT OPERATING PROCEDURES MANUAL
PSP-MCOR-101 WORK METHOD MANUAL

Section 1
INTRODUCTION
Content Page
1.1 OBJECTIVE/PURPOSE .................................................................................................... 7

1.2 SCOPE .............................................................................................................................. 7
1.3 OP TYPE ........................................................................................................................... 7
1.4 PREREQUISITES ............................................................................................................. 7
1.5 LIMITATIONS .................................................................................................................... 7
1.6 ROLES / RESPONSIBILITY: ............................................................................................. 8
1.7 HSE REQUIREMENTS ..................................................................................................... 8

1 INTRODUCTION
1.1 OBJECTIVE/PURPOSE
1.1.1 This operating procedure defines the step-by-step instructions to perform the start-up
operation of the instrument and utility air system. 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 The objective of this task is to start up the instrument and utility air system in a safe manner.
1.2 SCOPE
1.2.1 The requirements in this procedure shall apply to MCOT.

1.2.2 The instrument and utility air start-up involves the following equipment
• Air compressors K-5410/20
• Wet Air Receiver V-5430
• Air Dryer V- 5500
1.1.1 The main activities for instrument and utility air system are:
• Preparation
• System start up
• System switch over
• System shutdown
1.3 OP TYPE
Type and Normal / Start Up / Shutdown / Checklist Required: Yes / No

Emergency / Special / Temporary /
attributes
Abnormal / Decommissioning
1.4 PREREQUISITES
1.4.1 Establish communication with MCOT CCR.
1.5 LIMITATIONS
1.5.1 N/A

1.6 ROLES / RESPONSIBILITY:
1.6.1 Refer to steps in the procedure.
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,
etcF before beginning this procedure.
Hazard Precaution
Pressure Bleed off pressure prior to
removing pressure gauge and
other equipment.
Loud noise Wear proper ear protection.
Hot surfaces Wear appropriate PPE.
Rotating equipment Ensure protective covers over
rotating parts such as fan is in
place.
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

N/A
ESD /
Interlocks PZALL-5501/ 2/ 3
NOTE: Only where applicable

Unit: Instrument and Utility Air Never

Safe Operating SOL
System Exceed
Limit Excursions
Limit
Equipment Inst. Consequence of Corrective
Tag # H L HH LL Deviation Actions
• Check PCV 5430 opening
Pressure Low PIAL 5400 8 barg Will activate Low Press Alarm
• Reduce flow to end users
Pressure Low PICAL 5550 6.2 barg Pre-Alarm • Increase compressor load
PZALL
Pressure Low Low 5.5 barg Trip Instrument Air System • Execute normal ESD
5551/2/3
NOTE: Only where applicable

Section 2
PROCEDURE
Content Page
2.1 PREPARATION OF LEAD INSTRUMENT AIR COMPRESSOR K-5410/20 .................. 11

2.2 START UP OF LEAD INSTRUMENT AIR COMPRESSOR K-5410/20 .......................... 11
2.3 SHUT DOWN OF LEAD INSTRUMENT AIR COMPRESSOR (K-5410/20) .................... 11
2.4 START UP OF LAG INSTRUMENT AIR COMPRESSOR (K-5410/20) .......................... 12
2.5 SWITCHING OVER OF INSTRUMENT AIR COMPRESSOR (K-5410/20) FROM LEAD
TO LAG ..............................................................................................................................13
2.6 INSTRUMENT AIR SYSTEM OPERATIONFFFFFFFFFFFFFFFFFFF.13

2 PROCEDURE
2.1 PREPARATION OF LEAD INSTRUMENT AIR COMPRESSOR (K-5410/20)
No. Action Action Party
2.1.1 Ensure the pre filter, instrument air dryer, after filter and dry air receiver are Area Operator
lined up.
2.1.2 Ensure the dew point analyser QIA-5540 is functioning. Area Operator
2.1.3 Check and confirm that single phase and 3-phase power are available and Area Operator
compressor ready to start.
2.1.4 Check the air compressor coolant level is sufficient. Area Operator
2.1.5 Check the air compressor discharge valve is in open position. Area Operator
2.1.6 Area Operator

Ensure the wet air receiver, air pre-filter, air dryer, air after filter are lined up
and power supply is available.
2.1.7 Inform Panel man 2 that Instrument Air Compressor is ready to be started Area Operator
up.
2.2 START UP OF LEAD INSTRUMENT AIR COMPRESSOR (K-5410/20)
2.2.1 Select LEAD on display panel by pressing the SET button. Change the LAG Area Operator
to LEAD by pressing / button and press SET button. Refer to
Appendix.
2.2.2 Ensure operating set point parameters as per Appendix. Area Operator
2.2.3 Check and confirm the display panel indicate ‘Ready to Start’. Area Operator
2.2.4 Press START button at the air compressor Local Control Panel to start the Area Operator
lead compressor.
2.2.5 Monitor the air compressor operating at desired pressure (i.e. load at 8.3 Area Operator
barg and unload at 9.0 barg).
2.2.6 Area Operator
Ensure motor current is between 90 amps – 120 amp, discharge
temperature below 90°C, discharge pressure within 8.3 – 9.0 barg, no
abnormal sound, no excessive vibration and no leak.
2.3 SHUT DOWN OF LEAD INSTRUMENT AIR COMPRESSOR (K-5410/20)
2.3.1 Press UNLOAD STOP button to stop the air compressor. Area Operator
NOTE:
The lag compressor will stop automatically after 10 minutes of unload. The
indicator will display ‘Auto Start’ at display panel

2.4 START UP OF LAG INSTRUMENT AIR COMPRESSOR (K-5410/20)
2.4.1 Select LAG on display panel by pressing the SET button. Change the LEAD Area Operator
to LAG by pressing / button and press SET button. Refer Appendix.
2.4.2 Ensure operating set point parameters as per Appendix. Area Operator
2.4.3 Check and confirm the display panel indicate ‘Ready to Start’. Area Operator
2.4.4 Press START button at the air compressor Local Control Panel to start the Area Operator
lag compressor.
2.4.5 Monitor the air compressor operating at desired pressure (i.e. load at 8.3 Area Operator
2.4.6 Area Operator
Ensure motor current is between 90 amps – 120 amp, discharge
temperature below 90°C, discharge pressure within 8.3 – 9.0 barg, no
abnormal sound, no excessive vibration and no leak.
2.4.7 Area Operator
The lag compressor will stop automatically after 10 minutes of unload. The
indicator will display ‘Auto Start’ at display panel.
2.5 SWITCHING OVER OF INSTRUMENT AIR COMPRESSOR (K-5410/20) FROM

LEAD TO LAG (EXAMPLE: K-5410 ON LEAD AND K-5420 ON LAG)
2.5.1 Inform Panel man 2 before the switch over. Area Operator
2.5.2 Check the air compressor coolant level is sufficient at lag compressor K- Area Operator
5420.
2.5.3 Select LEAD on display panel by pressing the SET button. Change the LAG Area Operator
to LEAD by pressing / button and press SET button for K-5420.
2.5.4 The lag compressor K-5420 will automatically start-up. Area Operator
NOTE:
Both compressors K-5410 and K-5420 are now in lead mode.
2.5.5 Monitor the air compressors operating at desired pressure (i.e. load at 8.3 Area Operator
2.5.6 Area Operator
Select LAG on display panel by pressing the SET button. Change the LEAD
to LAG by pressing / button and press SET button for K-5410.
NOTE:
K-5410 now in LAG mode.
2.5.7 Area Operator
The compressor K-5410 will stop automatically after 10 minutes of unload.
The indicator will display ‘Auto Start’ at display panel.

2.6 INSTRUMENT AIR SYSTEM OPERATION
2.6.1 Ensure that compressed air is available from the instrument air/ utility air Area Operator
system.
2.6.2 Ensure the isolation valves to the distribution header are correctly lined up. Area Operator
2.6.3 Check and confirm that pressure control valve, alarm and trip settings are Area Operator
set and functioning accordingly as follows:
Tag No. Location Set Point

PCV-5550/ 51 Instrument Air Header 9 barg
PICA-5550 (Low) Instrument Air Header 6.2 barg
PICA-5430 (Low) Instrument Air Header 6 barg
PZA-5551/2/3 (Low low) Instrument Air Header 5.5 barg
NOTE:
2 out of 3 voting system
END OF PROCEDURE

Appendix
APPENDIX A
Content Page
1 CHECKLIST ................................................................................................................ 15
1.1 TABLE 1: SET POINT PARAMETER FOR AIR COMPRESSER .................................... 15
1.2 TABLE 2: VALVE LIST ..................................................................................................... 15
2 DIAGRAMS ................................................................................................................. 17
2.1 FIGURE 1: AIR COMPRESSOR AND UTILITY AIR RECEIVER ................................... 17
2.2 FIGURE 2: INSTRUMENT AIR DRYER PACKAGE ....................................................... 18
2.3 FIGURE 3: INSTRUMENT AIR RECEIVER.................................................................... 19
2.4 FIGURE 4: COMPRESSED AIR DISTRIBUTION........................................................... 20

1 CHECKLIST
1.1 TABLE 1: SET POINT PARAMETER FOR AIR COMPRESSER
Description Operation Set points
Offline Pressure 150 psig/ 10.35 barg

Online Pressure 125 psig/ 8.6 barg
Control Mode On/ Off line
Display Time 10 secs
Auto Restart On
Auto Restart Time 10 min
Sequencer On
Remote Start/ Stop On
Delay Load Time 0 sec
Lead/ Lag Lead
Lag Offset 10 psi
1.2 TABLE 2: VALVE LIST
Tag No Description Open Close

V-279 Compressor K-5410 Valve Outlet Open
V-280 Compressor K-5420 Valve Outlet Open
V-289 (80VX541289) Valve inlet to V-5430 Open
V-281 (80VX541292) Bypass valve inlet to V-5430 Closed
V-288 (50VX541288) Standby-compressor valve inlet Closed
V-282 (80VX541293) V-5430 valve outlet Open
V-283 (80VX541294) Valve inlet to dryers Open
V-284 (50VX541295) Open
V-285 (50VX541469)
V-286 (25VX541470) Closed
V-287 (25VX542531) Closed
V-313 (50VX551415) Open
V-314 (50VX551303) Open
V-TP2-30 Open
V-304 (50VX551645) Open
V-305 Open

(50VX5513005)
V-306 (50VX551311) Open

2 DIAGRAMS
2.1 FIGURE 1: AIR COMPRESSOR AND UTILITY AIR RECEIVER

2.2 FIGURE 2: INSTRUMENT AIR DRYER PACKAGE

2.3 FIGURE 3: INSTRUMENT AIR RECEIVER

2.4 FIGURE 4: COMPRESSED AIR DISTRIBUTION

MCOT 048 Instrument and Utility Air System Operation

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Operating Procedure – MCOT MY SKO O 05 MCOT 048

"UNCONTROLLED WHEN PRINTED"

30/07/2012 10:41 AM PETRONAS CARIGALI SDN BHD Page 1 of 20

Name: Mentor Solutions & Resources Sdn Bhd

Position: Technician/ Consultant/ Contractor

Position: Head of Production

Position Onshore Installation Manager

"UNCONTROLLED WHEN PRINTED"

30/07/2012 10:41 AM PETRONAS CARIGALI SDN BHD Page 2 of 20

"UNCONTROLLED WHEN PRINTED"

30/07/2012 10:41 AM PETRONAS CARIGALI SDN BHD Page 3 of 20

Rev Description Date Approver Title Name

Rev 0 Original Document

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

"UNCONTROLLED WHEN PRINTED"

30/07/2012 10:41 AM PETRONAS CARIGALI SDN BHD Page 4 of 20

USD Unit Shutdown

"UNCONTROLLED WHEN PRINTED"

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1.1 OBJECTIVE/PURPOSE .................................................................................................... 7

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1.2.1 The requirements in this procedure shall apply to MCOT.

Type and Normal / Start Up / Shutdown / Checklist Required: Yes / No

1.4.1 Establish communication with MCOT CCR.

"UNCONTROLLED WHEN PRINTED"

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1.6 ROLES / RESPONSIBILITY:

1.6.1 Refer to steps in the procedure.

1.7 HSE REQUIREMENTS

Tools and/or Equipment Use

NOTE: Only where applicable

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Unit: Instrument and Utility Air Never

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2.1 PREPARATION OF LEAD INSTRUMENT AIR COMPRESSOR K-5410/20 .................. 11

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2.1 PREPARATION OF LEAD INSTRUMENT AIR COMPRESSOR (K-5410/20)

No. Action Action Party

2.1.6 Area Operator

2.2 START UP OF LEAD INSTRUMENT AIR COMPRESSOR (K-5410/20)

No. Action Action Party

2.3 SHUT DOWN OF LEAD INSTRUMENT AIR COMPRESSOR (K-5410/20)

No. Action Action Party

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2.4 START UP OF LAG INSTRUMENT AIR COMPRESSOR (K-5410/20)

No. Action Action Party

2.5 SWITCHING OVER OF INSTRUMENT AIR COMPRESSOR (K-5410/20) FROM

No. Action Action Party

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2.6 INSTRUMENT AIR SYSTEM OPERATION

No. Action Action Party

Tag No. Location Set Point

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1.1 TABLE 1: SET POINT PARAMETER FOR AIR COMPRESSER