LPG Storage & Transfer Procedures

Standard Operating Procedures
Integrated Offsites & Utilities Plant (IOP)
TITLE LPG Storage & Transfer System
ACTIO
SOP No. JOB DESCRIPTION
N BY
1.1 Preface:
=> In normal operation LPG sphere 41-V-001A is designated
for receiving Mixed butane R/D from CHU, feeding to NCU ,
road tanker loading and transferring materials to propane-
LPG sphere (43-V-002A/B) for propane LPG batch preparation.
=> C4-Raff sph.C (43-V-002C) is designated for receiving C4
Raff R/D from BDEU and feeding to CHU plant. In normal
operating condition the following lines will be blinded in the
sphere.
1. 12” suction of pump 43-P-002A/B/C.
2. 6” suction of pump 43-P-008A.
3. 6” min. cir. of pump 43-P-002A/B/C
4. 3” min. cir. of pump 43-P-008A.
 C4 Raff sph. A and B are used as propane LPG spheres
in which propane R/D from NCU is received. And pump
43-P-002C is used for circulation and loading purpose.
 Presently LPG vaporizer system has been
disconnected.
GENERAL :
 Use PPE’s like Helmet, safety shoes, goggles, organic
vapor mask & hand gloves. Impart functional & safety
training for operational handling of LPG.
 Care to be taken that anybody engaged and allowed to walk
or to climb or to work on heights / areas at sphere farm
should not be exposed to direct sunrays/ sun light for more
than 30 minutes.
OPERATION PHILOSOPHY OF LPG SPHERE (41-V-001A)

 One LPG sphere is provided and designed to store pure C 3
to C4 and its mix. LPG may be unloaded from Bay-1/2 and
Bay –3. The unloaded C 3/C4 and mixed LPG are stored in a
sphere provided for the same.
 LPG is used as fuel gas make up for NCU.
 LPG will be transferred to NCU by two vertical barrel type
pumps (One is stand by). At present single sphere is
provided for the LPG storage.
Doc No. Topic Prepared by Approved by Rev. No Page
SB/BKM RM 6
HPL/IMS/IOP/SOP/ LPG Storage &
8.5.1/41/LPG Transfer System
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 Mix butane produced in the CHU stored in this sphere. This
1.2 mixed butane is connected to the mixed butane transfer
pumps suction header and through which it is pumped to
loading gantry.
 Mercaptan dosing facility available in this sphere but it is
done presently at gantry.
 During normal operation the following lines will be in
isolated Condition.
 Crude propane from NCU.
UNLOADING OF LPG FROM TANKER TO LPG SPHERE

1. Select the pump for unloading and sphere for filling.
2. Take the mechanical and electrical clearances of pump from SIC
respective department.
3. Keep the sphere and the LPG pipe lines under positive SIC
nitrogen pressure (during initial start up). SIC
4. Ensure that the sphere and pipelines are free of oxygen
(max 1%) SIC
5. Note down the liquid level of sphere before and after
unloading SIC
6. Pump to be used for unloading: 41-P-010B
7. Sphere to be charged up: 41-V-001A PE
8. Unloading bay to be used: Bay-2 SIC
9. Ensure the presence of following utilities line in the sphere SIC
B/L.
 2” AI line
 2” AP line M
 2” WP line
 2”N2 line
 FW header, monitor and hydrant system.
 Deluge system is healthy
10. Ensure that the following utilities lines are there in the
unloading bay b/l.
 2” AP line
 2” N2 line M
 3” SL line
 2” WP line
 Fire water header system
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11. Ensure that the following instruments are in line.
 LT/ LI 1201/1202 on sphere A
 LSHH- 1203 (in sphere A)
 TT-1201 (in sphere A), TT-1203 (sphere inlet hdr), TG- PE & M
1201 (i/o line)
 PT-1203 (sphere inlet header), PG-1201 (on sphere A)
 FT-1203 (on sphere inlet header)
 GE-1201 to 1208 at sphere b/l
 PSHH-1401, FT-1401, GE-1401, GE-1402(for pump
A)/GE 1403(for pump B), LSLL-1401,PT-1402,PG-
1401/1402 (in gantry area)
12. Ensure that the following interlocks are checked and kept in
line:
 I-121 (actuated by LSHH –1203)
 I-122 (actuated by PSHH –1201) PE & M
 I-131 (actuated by PSL –1301) and also take its deluge
valve in line
 I-141 (actuated by LSLL –1401)
 I-142 (actuated by PSHH –1401)
13. Ensure that the following TSV’s and PSV’s are in line and
also ensure that its I/Vs are in LO position.
 TSV –1205 in 4” LPG from road tanker line.
 PSV- 1201A on the top of the sphere 41-V-001A SIC&M
 TSV-1201 in 10” sphere inlet header.
 TSV-1401 in 4” unloading pump 41-P-010A discharge
line.
 TSV –1206 (in 10” start up line from C4 –raff)
 TSV-1204 (2” LPG line to vaporizer)
 TSV-1210 (LPG transfer to NCU)
 TSV-3211 (6” min circn header to LPG sphere)
 PSV-1501/1502 (LPG vaporizer) & PSV-2701A (CFGD)
14. Isolate and blind the following:

LPG unloading line now has been converted to Onspec
propylene unloading line .During unloading of LPG following
lines to be blinded. SIC&M
 Towards propylene sphere 4’ onspec propylene
unloading line.
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 Towards propylene unloading compressor line.
Towards propylene offspec unloading line.
 6” line from Bay-3 to 41-P-010A in Bay-1.
 Pump 41-P-010A by closing suction, discharge
and vent flare line valves.
 3” crude propane from NCU line
 10” start up LPG from C4 raff spheres.
 Sampling point lines in sphere and gantry area.
 6” Vapor return line from LPG sphere to Bay-1.
 3” vapor line from Bay-1 to Bay-3
 2” nitrogen line to tanker.
 4” unloading pump discharge line to C4 Mix. sphere.
 4” LPG start up line to C4-raff spheres.
 6”vapour balance line to C4 raff sphere
 3” vapor line for butene-1 vapor return to Bay-2.
 3” liquid line from Bay-3 to 41-P-010A/B.
 3” liquid line from Bay-2 and Bay-3 to 41-P-009A/B.
15. Inertisation of the system to be completed as per

procedure . Following condition to be achieved:
 LPG system inertised with positive isolation (at 1.0
Kg/cm2)
 Flare system is under constant purging through flare end SIC& M
purging points and 3’ N2 connection near NCU.
16. Open SDV-1201 & ROV-1201on sphere inlet line.
17. Open i/v & de blind the 6” vapor return line to gantry in both SIC
sphere and unloading bay B/L. M
18. Place the tanker at the unloading bay and ensure proper
earthing connection to the tanker. PE
19. Place stopper to restrict wheel movement of the tanker.
20. Open the I/V on 4”liquid line from gantry to LPG sphere in M
the sphere B/L. M
21. During initial unloading following shall be done:
 Liquid hose shall be connected to the tanker with
isolation valve for hose and pump discharge closed. M
The vapor hose need not to be connected at this stage.
 Hose isolation valve shall be slowly opened and
pressure at pump discharge to be made equal to tanker M
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pressure.
 Slowly open the globe valve at pump discharge.
 The LPG vapor shall start flowing to LPG sphere. M
 Once the sphere pressure is 2-2.5 kg/cm 2g, closing M
pump discharge valve can stop unloading. PUMP IS
NOT TO BE OPERATED AT THIS STAGE. M
 Start removing of inerts from sphere by using the sphere
PSV bypass and reduce the sphere pressure to 1.0 M
kg/cm2g.
 Repeat the operation twice. With this nitrogen
concentration in the sphere would reduce considerably. PE & M
If possible check nitrogen concentration of sphere.
 When next tanker is lined up, increase the system
pressure equal to tanker without operating the pump i.e. PE & M
transfer with pressure difference.
 Now connect the vapor hose and open valve on vapor
balance line. M
 Take PIC-1402 in auto mode and give set point of 10 to
12 kg/cm2g. Open the tanker vapor line and allow the
vapor to valance with sphere pressure. M
 Prime the unloading pump. Check the line up of
secondary seal flushing. Start service water to seal pot. PE & M
 Open discharge I/V 10% and start pump. Maintain a min
flow of 30 m3/hr. M
 Check the total system for any leakage.
M
22. For subsequent operation following shall be done:
 Connect the hose to the tanker vapor line.
 Connect the hose to the tanker liquid line. M
 Note down the sphere level and check line up to sphere. M
 With pump suction and discharge valve closed open M
tanker liquid line. M
 Open the unloading pump suction valve and prime the
pump. Open the pump discharge valve and allow the M
material to pass the material from tanker to sphere.
 Open vapor balance line to sphere. M
 Start the pump as per pump starting SOP.
 Keep watch on pump discharge pressure, motor amps M
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vibration & abnormal sound and the flow through the
1.3 pump.
 Keep close watch on tanker level and tanker pressure. M
At low level reduce the transfer rate to facilitate complete M
liquid transfer. M
 Stop and isolate the pump from both suction and
discharge side at tanker zero level.
 Close tanker side I/Vs for both liquid and vapor line. M
 De-pressurize the liquid and vapor hose to flare and M
isolate it.
 Disconnect the vapor and liquid hose one by one. M
 Disconnect tanker earth connection. M
 Remove stopper and release the truck. M
M
UNLOADING OF LPG FROM TANKER TO C4 RAFF SPHERE:
 Select the pump for unloading and also the sphere for filling.
 Take electrical and mechanical clearance from respective M
dept. SIC&M
 Keep the sphere and LPG pipelines under the positive N 2
pressure.
SIC
1. Pump to be used for unloading: 41-P-010B
2. Sphere to be charged up: 43-V-002B. SIC
3. Unloading bay used: Bay-1 SIC
b/l .
 2” IA line.
 2” AP line.
 2” WS line.
 2” N2 line.
 Fire water loop and deluge system. M
5. Ensure that the following utility lines are there in the Loading
bay B/L. gantry area.
 2” WS line
 3” SL line
 2” AP
 2” N2
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 LI-3202/3204 (Sphere B)
 LSHH-3206 (Sphere B)
 PT-3202/PG-3202 (Sphere B)
 TG-3202 (Sphere B)
 GE-3201 to 3212 & GE –4901 to 4906 (all GE’s in
sphere B/L) PE & M
 PSHH – 1401, FT-1401, GE – 1401 LALL-1401 (in
Gantry area)
7. Ensure that the following interlocks are checked
 I-322 (actuated by LSHH – 3206)
 I-311/312/313 and take its deluge valve (actuated by
PSL-3101/3102/3103 respectively)
 I-141 (actuated by LSLL- 1401)
 I-142 (actuated by PSHH- 1401)
 I-143 and take its deluge valve in line (actuated by PSL PE & M
–1403).
also ensure that its I/V’s are in LO position
 TSV –3202 in 6” sphere inlet line in which LPG for M
startup joins.
 PSV-3202 A/B on the top of the sphere 43-V-002B..
9. Isolate and blind the following,
 6” C4 raffinate from BDEU line at sphere B/L consulting
AU (SIC).No C4 Raffinate rundown can be received M
during unloading of LPG in C4 Raffinate spheres.
 3” CHU de-inventory line.
 4” unloading pump discharge line to C4 Mix sphere.
10.Open SDV-3202 and lineup its I/V in 12” sphere inlet line
11. Open I/V & de-blind the 6” vapor return line to gantry in both
sphere and unloading bay B/L SIC&M
10. Place tanker at the unloading bay and ensure proper M
earthing connection to the tanker.
11. Open the I/V and line up the 4” liquid line from gantry to C4 M
raffinate sphere B and in the sphere B/L.
12. De-pressurize the vapor unloading arm by opening ¾” line
to flare and then after isolating the flare line connect the arm PE&M
to the tanker vapor line. M
13. De-pressurize the liquid unloading arm by opening ¾” line to
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flare and then after isolating the flare line connect the arm to M
the tanker liquid line.
14. By isolating PV-1402 and pump suction line, line up the M
level gauge with the tanker and check the level.
15. Take PIC-1402 in auto mode and give proper set point to it. M
Open the tanker vapor line and allow the vapor to balance
with sphere pressure.
16. Close pump suction and discharge valve and open tanker M
liquid line.
17. Crack open the unloading pump suction and its discharge
valve. PE&M
18. Balance the liquid line of sphere and tanker.
19. After liquid balance of sphere close the pump discharge PE
valve and start the pump according to the steps given in the M
pump start up SOP.
20. Keep close watch on pump discharge pressure, motor M
amps, and flow through the pump, vibration, abnormal
sound, leakage and TSV, PSV popping through out the M
1.4 system.
21. Keep close watch on tanker level and tanker pressure. At M
low level reduce the transfer rate to facilitate complete liquid
transfer. M
22. Stop and isolate the pump from both suction side and
discharge side at the tanker zero level, with adequate M
pressure in the tanker.
23. Isolate vapor and liquid hoses and tanker level gauge.
24. Depressurize the liquid and vapor hose to flare and isolate
it. M
25. Disconnect the vapor and liquid hose one by one.
26. Disconnect the tanker earth connection.
27. Allow the truck to move from the bay. M
M
M
TRANSFER OF LPG FROM C4 RAFFINATE SPHERE TO LPG
SPHERE:
 Select the C4 raffinate sphere and the pumps to be used for
transfer.
 Take electrical and mechanical clearance from respective M
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dept.
SIC&M
1. Pump to be used for transfer: 43-P-002A
2. Sphere to be filled up : 41-V-001A.
3. Sphere from which transfer is to take place: 43-V-002B. SIC
B/L. SIC
 2” IA line. SIC &M
 2” AP line.
 2” WS line.
 2” N line.
 Fire water loop and deluge system.
 LI-3202/3204 (Sphere B) SIC&M
 PT-3202/PG-3202 (Sphere B)
 GE-3201 to 3212 & GE –4901 to 4906 (all GE’s in
sphere B/L)
 LSHH- 1203 (in sphere A)
 TT-1201(in sphere A), TT-1203(sphere inlet hdr), PE
 PT-1203(sphere inlet hdr),
 FT-1203 (on sphere inlet header)
6.Ensure that the following interlocks are checked

 I-311/312/313 and take its deluge valve ( actuated by
PSL-3101/3102/3103 respectively)
 I-121 (actuated by LSLL- 1203)
 I-123/124 ( actuated by 41-P-003A /B trips)
 I-131 and take its deluge valve in line (actuated by PSL
–1301)
7.Ensure that the following TSV’s and PSV’s are in line and SIC
 TSV –3203 in 12” pump suction header
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 PSV-3202 A/B on the top of the C4 raffinate sphere 43-
P_002B
 TSV-3205 in 10” pump discharge header
 PSV-1201 A/B on the top of the LPG sphere.
 TSV – 1201 in LPG sphere inlet line.
8.Ensure that the following are isolated or blinded.
 3” CHU de-inventory line to sphere 43-V-002B. SIC&M
 3” mixed butane line from CHU to sphere 43-V-002B
 6” C4 raffinate from BDEU to sphere B by closing SDV-
3202.
 6” Sphere B suction line to 43-P-008A.
 6” Sphere B suction line to 43-P-010A&B
 4’’ min. circulation line downstream I/V’s of 43-P-008A
and 43-P-010A/B , .
 12” line from sphere 41-V-001A to pump 43-P-002A/B/C. M
 6’ min. circulation line of LPG.
 12’ line from LPG sphere to 43-P-002A/B/C suction
headers, in LPG sphere B/L.
 4’ LPG for start up line in C4 raffinate sphere B/L....
 6” C4 raffinate vapor balance line from gantry.
 3’ crude propane from NCU line in LPG spheres B/l.
 4’ LPG road tanker to LPG sphere...
 Sampling points of LPG and C4 raffinate spheres.
9.Open the C4 raff. Sphere I/O line to pump suction header of
43-P-002A/B.
1.5 10.Close FV-3201 fully by taking FIC –3201 in manual mode
and open the upstream and downstream I/V’s for FV-3201. M
5. Ensure that the 10” LPG line from C 4 raff. Sphere to LPG
sphere is being lined up through which transfer to take M
place.
6. Open the pump A(43-P-002A) suction valve. M
7. Prime the pump completely and start the pump as per the
pump start up SOP.
8. Once the system gets stabilized route the LPG-to-LPG M
sphere.
9. Take FIC-3201 in Auto mode. PE&M
10. Keep close watch on C4 raff sphere/LPG sphere level;
pump discharge pressure, motor amperage and vibration. M
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11. Once the sphere gets emptied out stop the pump
12. Normalize the transfer system by closing 10” LPG transfer
valve from 43-P-002A/B discharge header at LPG B/L M
M
START-UP PROCEDURE OF LPG UNLOADING PUMPS 41-P-
010A/B M
1. Select a pump for unloading.

2. Get the clearance for running of motor and pump from
electrical and mechanical department.
3. Check lubricant in bearing housing, universal coupling and PE&M
motor and if necessary top up. M
4. Check the seal pot liquid level(MEG) and its pressure.
5. Check the free rotation of the shaft.
6. Ensure the cooling water supply to the seal pot.
7. Ensure that the discharge I/V is in closed condition. M
8. De-blind the pump discharge and suction side vent valves. M
9. Partially open the suction valve. SIC
10. Crack open the pump discharge vent valve and fill the pump SIC
casing, barrel with the LPG. M
11. Pump casing will get chilled till the discharge pressure M
reaches tanker pressure.
12. If the discharge pressure decreases close the vent valve (by M
few turns) and slightly open the pump suction valve and M
maintain the discharge pressure.
13. Slowly vent the nitrogen and LPG vapor to flare and by that M
prime the pump thoroughly during priming as nitrogen
1.6 displaces, the pump is being filled with LPG liquid. M
14. When the whole pump and discharge line is filled with liquid, M
LPG will start to de pressurize through discharge vent valve
and frosting will take place at the D/S of the vent valve.
15. Now close the pump discharge side vent valve.
16. Open the pump suction side vent valve to remove LPG M
vapor pockets and close the vent valve.
17. Start the pump and keep close observation on motor shut M
off amperage and pump discharge shut off pressure. M
18. Then open the pump discharge valve to transfer LPG to
sphere and keep close watch on pump normal amps and M
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normal discharge pressure.
19. If the pump is not developing pressure stop the pump and M
prime it completely.
20. Close the vent valve and restart the pump.
21. Then follow the step-17 to 18. M
Close the pump suction and discharge side vent line.
22.Empty polymer drums of MEG handed over to Materials M
team,thereafter materials disposing these drum through auction M
as scrap. M
Transfer of LPG to NCU

 Take the mechanical and electrical clearances of pump from
respective department. PE
 During initial start up venting out of Nitrogen in the LPG line
up to the NCU B/L is under NCU scope.
 If NCU stopped cracking LPG temporarily allow the pump
to run in min. circulation. PE
1. Transfer takes place from the sphere: 41-V-001A.

2. Pump to be used for transferring: 41-P-003A.
b/l . M
 2” AI line
 2” AP line
 2” WP line
 2”N2 line
 FW header, monitor and hydrant system.
4. Ensure that the following instruments are in line
 LSHH- 1203 (in sphere A) SIC&M
 TT-1201 (in sphere A), TG-1201 (i/o line)
 PG-1201 (sphere A), PG-1202 (pump 41-P-003A)
 FT-1204 (4’ line to NCU)
 FT-1201/FIC-1201 (min.cir.line)
 GE-1201 to 1207 (at LPG sphere b/l)
 PSHH-1201 ( 4’ line to NCU)
5. Ensure that the following interlocks are checked and kept in
line: PE&M
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 I-121 (actuated by LSHH –1203)
 I-122 (actuated by PSHH –1201)
 I-131 (actuated by PSL –1301) and also take its
deluge valve in line
 I-123/124 (actuated by 41-P-003A/B trips)
also ensure that its I/Vs are in LO position
 PSV –1203 in 4” LPG pump discharge header. PE
 PSV- 1201A/B on the top of the sphere 41-V-001A.
7. Isolate or blind the following:

 Pump 41-P-007 A/B. ( if it is not in use)
 Suction line from the sphere 41-V-001A to mixed butane
loading pumps (43-P-003A/B/C).
 Vapor return line for future connections. M
 Sphere inlet line by closing SDV-1201.
 Min. circulation line from 43-P-002A/B/C.
 Vapor line by closing ROV-1203 and its down stream I/V
 Pump 41-P-003B discharge and vent to flare line.
 4’ road tanker line to sphere..
 3’ crude propane from NCU line. M
 10’ start up LPG from C4 raff. Spheres.. M
1.7  2’ sampling point line.
8. Ensure that opening of the ROV-1202 in min. circulation
line and ROV 1201 in I/O line to 41-V-001A and its I/V. M
9. Fully close the FV-1201 in the pump min. circulation line by PE
taking FIC –1201 in manual mode and fully open its U/s and M
D/S I/v’s PE
10. Close the pump discharge valve in the LPG to NCU line.
11. For starting the pump refer pump start-up SOP. While M
starting the pump use FV-1201 by pass valve as pump M
discharge valve and keep LPG to NCU line closed. M
12. Once pump starts, route the whole LPG to sphere through M
min. circulation line. PE&M
13. After the stabilization inform NCU that the transformation
system is ready to transfer LPG. After NCU clearance slowly PE&M
charge the NCU line.
14. According to the NCU requirement give a proper set point to
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the FIC-1201 and change it to the auto mode and close FV- M
1201 bypass valve. M
15. Crack open the I/V in LPG to NCU line and ensure that LPG
is being drawn slowly and steadily.
16. Keep a close watch on pump discharge pressure, M
amperage, sphere level, LPG flow rate and pump vibration.
SIC&M
START-UP PROCEDURE OF LPG Transfer Pumps 41-P-003A/B
1. Select a pump for transfer.

2. Get the clearance for running of motor and pump from PE&M
electrical and mechanical department.
3. Check lubricant in bearing housing, universal coupling and PE&M
1.8 motor and if necessary top up.
4. Check the seal pot liquid(MEG) level and its pressure. M
5. Check the free rotation of the shaft M
6. Ensure the cooling water supply to the seal pot. M
7. Ensure that the discharge I/V is in closed condition. M
8. Ensure that the min. circulation line FV-2401 and its I/V’s M
are open.. M
9. Partially open the suction valve.
10. Crack open the pump discharge vent valve and fill the pump SIC
casing , barrel with the LPG. SIC
11. Vent the pump thoroughly & finally close the vent valve.
12. Reopen the suction valve and fill the system with pumping M
medium.
13. Start the pump and keep close observation on motor shut M
off amperage and pump discharge shut off pressure. M
14. Then open the pump discharge valve to transfer LPG to M
sphere and keep close watch on pump normal amps and
normal discharge pressure. PE & M
15. If the pump is not developing pressure stop the pump and
prime it completely. M
16. Close the vent valve and restart the pump. M
17. Once the pressure builds up open the discharge valve M
slowly as per the requirement.
M
Transfer of LPG to LPG vaporizer
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 Select the pump to be used for transfer.
 Take the mechanical and electrical clearances for running M
the pump. PE & M
 LPG vaporizer and CFGD is to be ready to receive LPG
liquid and vapor respectively.
1. Say pump 41-P-007 A to be used for transfer. M
2. Say sphere 41_P-001A from which LPG is to drawn out. SIC
3. Ensure the presence of following utilities in the sphere B/L SIC&M
as per process requirement. M
 2” IA line
 2” AP line
 2” WS line
 2” N line
 Fire water header and deluge system.
4. Ensure that the following instruments in line.
 LT-1201/1202(sphere A)
 LSHH-1203 (sphere A)
 TT-1201, TG-1201 (sphere A)
 PG-1201 (sphere A) and PG-1204 ( pump 41-P-007A)
 GE-1201 – 1207 (all GE’s in LPG sphere B/L)
5. Ensure that the following interlocks are checked SIC&M
 I-121 (actuated by LSHH-1203)
 I-131 (actuated by PSL-1301) and also take its Deluge
valve in line. SIC
 PSV-1204 in 2” LPG pump discharge header.
 PSV-1201 A/B on the top of the sphere 41-V-003A M &SIC
 PSV-1202 in discharge line of the pump 41-P-007A
 Isolate the following
 Pump 41-P-007B by closing its suction and discharge
valves.
 12” outlet line from the sphere 41-V-001A to mixed
butane loading pumps (43-P-003A/B/C)
 Vapor return line for future connections.
 Sphere inlet line by closing SDV-1201
 Minimum circulation line from 43-P-003A/B/C
 Vapor line by closing ROV –1203 and its downstream I/v
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 LPG feed pump, which is not running.
 4” Minimum circulation line by closing ROV-1202 if 41-P-
003A/B are not running.
7. Isolate and Blind the following
 4” road tanker line to sphere
1.9  2” line of heavies from Propane Purification. SIC&M
 3” Crude propane from NCU line.
 10” Start up LPG from C4 Raffinate spheres
 3” Mixed butane from NCU line
 10” line from ship tanker
 2” Sampling point line
8. Open the suction valve of 41-P-007A
9. Ensure that the 41-P-007A-discharge valve is in open
condition. M
10. Fully open the minimum circulation line valve. M
11. Adjust the stroke length of the pump and keep it in 90% of
maximum. PE
12. Start the pump as per the pump stat up SOP. M
13. take the whole LPG back to the suction header through
minimum circulation line. M
14. Once the vaporizer is ready to take LPG, slowly close the M
minimum circulation line valve till the desired flow is
required in the vaporizer. M
1.10 15. As per the required flow adjust the stroke length of the
pump.
16. Keep a close watch on the amps, flow and discharge M
pressure of the pump.
M
START UP PROCEDURE OF LPG TO VAPORIZER PUMP
1. Select the pump for transfer.
2. Get the clearance for running of motor and pump from
electrical and mechanical department. M
3. Check lubricant in bearing housing, universal coupling and
motor and if necessary top up. M
4. Ensure that the discharge I/V is in open position. M
5. Ensure that the min. circulation valve is in 50% open
position manually. M
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6. Adjust the stroke length according to the desired flow.
7. Open the suction valve and prime the pump. M
8. Start the motor and closely watch the pump discharge M
pressure, amps and the flow. M
9. Open the min. circulation C/V and its bypass to adjust the M
pump discharge pressure, flow and amps.
10. Stabilize the vaporizer level, pressure and temperature SIC
manually. SIC
11. Now put the entire controller in Auto.
M
CHANGE OVER OF LPG TRANSFER PUMPS M
 Change over of pump should be done with proper

communication between east control room personnel and
the field operator and NCU shift-in-charge.
 Take mechanical and electrical clearances before starting
1.11 the pump.
1. Pump to be stopped: 41-P-003A
2. Pump to be started: 41-P-003B SIC&M
3. Ensure that the following instruments are taken in line. SIC
 FT/FIC/FV-1202 (min. circulation. line of pump B) SIC
4. Ensure that the following interlocks are checked PE
 I-123/124 (actuated by 41-P-003A/B trip)
5. Ensure that the following valves are in closed condition: SIC
 Suction and discharge valves of pump B
 Vent and drain valves of pump B.
6. Take FV/FI/FIC-1202 in line. SIC
7. Open suction valve of PUMP B. Prime the pump and start the
pump following pump startup SOP.
8. Close discharge valve of pump A, by few turns so that the flow SICin
the discharge header is just equal to the required flow.
9. Open discharge valve of pump B slowly. Simultaneously close
discharge valve of pump A. The combined procedure should be
PE &M
such that the flow in discharge header is equal to the required flow.
10. Keep close watch on each pump discharge pressure and amps so
that load change over could be observed. PE
11. Continue till pump B discharge is fully open and pump A discharge
is fully closed. M
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12. Stop pump A and isolate its suction, discharge and vent to flare
lines.
M
Transfer LPG from 41-V-001A to 43-V-002A/B
M
Transfer of LPG from 41-V-001A to 43-V-002A/B is done for
Propane-LPG batch preparation in these two spheres.
01.Pump to be used for transfer: 43-P-002A

02.Sphere from which transfer to be done : 41-V-001A.
03.Sphere to which transfer is to take place: 43-V-002B
04.Ensure the presence of following utilities line in the sphere M
B/L. M
 2” IA line. M
 2” AP line. M
 8” WS line.
 2” N line.
 Fire water loop and deluge system.
05.Ensure that the following instruments are in line.
 LI-3202/3204 (Sphere B)
 PT-3202/PG-3202 (Sphere B)
 GE-3201 to 3212 & GE –4901 to 4906 (all GE’s in SIC/M
sphere B/L)
 LT/ LI 1201/1202 on sphere 41-V-001A
 LSHH- 1203 (in sphere A) SIC&M
 TT-1201(in sphere A), TT-1203(sphere inlet hdr),
 PT-1203(sphere inlet hdr),
06.Ensure that the following interlocks are checked
 I-311/312/313 and take its deluge valve ( actuated by PSL-
3101/3102/3103 respectively)
1.12
 I-121 (actuated by LSLL- 1203) PE & M
 I-123/124 ( actuated by 41-P-003A /B trips)
 I-131 and take its deluge valve in line (actuated by PSL –
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1301)
07.Ensure that the following are isolated or blinded
 3” CHU de-inventory line to sphere 43-V-002B.
 6” C4 raffinate from BDEU to sphere A and B .
 6” Sphere B suction line to 43-P-008A suction header.
 6” Sphere B suction line to 43-P-010A&B suction header.
 12” suction of pump 43-P-002A and B.
 3’’ min. circulation line I/V’s in the lines from 43-P-008A
and 3’’ min. circulation line I/V’s in the lines from 43-P- PE
010A/B , of the Spheres 43-V-002A/B.
08.Open 12’ suction line from LPG sphere to 43-P-002A/B
09.Open 6” min. cir. manual I/V in 43-V-002B and close the same
valve in 43-V-002A.
10. Open min. cir. ROV-3205 in 43-V-002B and close the same M
(ROV-3202) in 43-V-002A. M
11. Close 6’’ min. cir. manual I/v of 43-P-002A/B in sphere 41-V-43-v-
001A PE &M
12. Start pump 43-P-002A as per pump starting procedure.
13. Keep close watch on level rising in 43-V-002B. and transfer M
LPG corresponding propane received in that sphere.
14.After completion of transfer open 6’’ min. cir. manual valve of M in
1.13 sphere 41-V-001A and close min. cir. manual valve in 43-V-002B M
Line up 43-V-002A for propane-LPG loading:

One pump 43-P-002C is available for gantry loading as well as M
circulation purpose of propane-LPG spheres.
Two spheres 43-V-002A&B are available for propane-LPG batch
preparation. When on sphere is on loading , other sphere is on
propane receiving mode from NCU.
Say sphere from which propane-LPG to be loaded 43-V-002A
1.Ensure the presence of following utilities line in the sphere

B/L.
12. 2” IA line.
13. 2” AP line. M
14. 8” WS line.
15. 2” N line.
16. Fire water loop and deluge system.
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2.Ensure that the following instruments are in line.

17. LI-3201/3203 (Sphere A)
18. LSHH-3205 (Sphere A)
19. PT-3201/PG-3201 (Sphere A) M
20. TG-3201 (Sphere A)
21. GE-3201 to 3212 (all GE’s in sphere B/L)
3. Open min. cir. ROV-3202 in 43-V-002A
4.Start pump 43-P-002C as per pump starting procedure.
1.14 5.Inform loading member to line up propane-LPG at gantry.
SIC&M
PROCEDURE FOR SAMPLE LIQUID COLLECTION M
GENERAL: SIC
Proper PPE ( goggles, gloves, helmet) must be used.
 Inform the shift in charge about the sampling collection.
 Select/confirm the sphere from which sample is to be
collected.
 Ensure that the sampling point drain valve is closed. M
 Ensure whether the sampling bomb is properly purged and PE & M
connected.
 Close the sampling bomb vent to flare valves. M
 De-blind the 2” sampling point line and open the globe valve M
in the upstream of the blind.
 Open the globe valve in ½” line which is connected to the M
sample bomb hose. PE&
 Open the sample bomb I/V and allow the sample bomb to fill M
with LPG. PE
 Once the sample bomb gets filled close the 2” globe valve
and sample bomb I/V. M
 Open the drain valve and drain out the liquid present in the
sampling point line.
 Crack open the vent to flare globe valve and vent out the M
hydrocarbons. M
 Close the drain valve and vent to flare valves and also the
½” line globe valve. M
 Take out the filled sample bomb and replace it with a void
one.
M
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PROCEDURE WHILE LPG PUMP TRIPS/CAVITATES M
GENERAL:
 Inform the east control room shift in charge about the
pump problem.
 Inform the NCU shift in charge about the disturbance in
LPG Supply.
WHEN PUMP TRIPS M
1. Verify whether the pump has tripped due to electrical
problem or due to interlock actuation. M
1.15 2. IF ELECTRICAL PROBLEM THEN
 Inform the sub station in 12 in charge about the problem M and
start the stand by Pump.
 Once the problem is rectified restart the pump as per the pumpM
start up SOP.
 If not the problem due to the motor . Hand over the motor toMthe
Electrical department. M
3. IF INTERLOCK GETS ACTUATED THEN
 Find out whether the interlock gets actuated due to high SIC
temperature surrounding (may be fire) the sphere or not.
(I-131).
 If yes inform the fire station immediately and take
necessary action in field as per SIC. SIC
1.16
 Act as per in case fire SOP.
 If the interlock actuation is not due to the fire then inform
the instrumentation personnel and ask them to check the SIC
interlock and it’s thoroughly. SIC
 Once it is solved start the pump as per the pump start SIC
up-SOP.
WHEN PUMP CAVITATES: M

1. Stop the pump, which cavitates and start the pump, which is
already primed.
2. Restart the pump as per the pump start-up SOP (by which
the pump gets primed.) PE
3. The pump, which cavitates is to be primed and taken in line.
1.17
4. Keep this pump ready as stand by.
PROCEDURE WHILE SUDDEN STOPPAGE OF LPG BY USER SIC

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(LPG TO NCU)
SIC&M

Ensure that minimum circulation valve FV-1201 or FV-
1202 is opening according to its given set point.
 If FV-1201/1202 fails attend it immediately and open its
by pass valve slowly. This has to be done in continuous M
communication with ECR in –charge.
 Communicate with NCU SIC whether the stoppage is for
a short period of for a long period.
 If it is for a short period then allow the pump to run M
keeping the minimum circulation line full open.
M
POWER FAILURE
M
GENERAL:
 Total power failure in the petrochemical complex is an

unlikely event during normal operation. In case of local
1.18 power failure, LPG transfer pump will trip. In such situation
following action must be taken—
1. Inform in-charge of
a) Unloading gantry area
b) NCU
About non-availability of LPG.
INSTRUMENT AIR FAILURE SIC
GENERAL: PE&M
 Sudden failure of IA is not envisaged, as instrument air

storage for about 30 minutes is available. During this period,
necessary action may be taken.
1. Co-ordinate with the in-charge of

1.19 a) Unloading gantry area
b) NCU
For stopping of LPG transfer pump.
2. Stop the pump after obtaining the clearance.
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3. Inform the consumer about the non-availability of LPG.
4. On instrument air failure,
 The entire sphere ROV’s –1201/1202/1203 will close. SIC
 SDV’ 1201 will close. SIC
 Minimum flow control valve FV-1201/1202 will go to fail SIC
open position, thus protecting the pumps. SIC
PROCEDURE IN CASE OF FIRE
GENERAL:
 In the event of fire, the sphere security system will isolate
the affected sphere and protect the adjacent sphere. In the
event of fire in the loading area, the firewater security
system of the loading gantry will come into action. The
operator shall take following action as soon as fire is
1.20 detected in the sphere area.
 Inform the fire safety department immediately. Dial 6401,

2675
 Stop the LPG TRANSFER pumps in sphere area.
 Shift-in-charge should communicate the message to
shift-in-charge of other process units, NCR & SCR SIC
HAND OVER OF LPG PUMPS FOR COLD JOB SIC

(41-P-003 A/B, 41-P-007))
SIC
1. Inform the shift in charge about the pump handing over.
2. Isolate the pump by closing its suction and discharge valves.
3. Ensure that the pump drain line to OWS is closed and blinded.
4. Open the drain valve to route the liquid to flare header.
5. Close the drain valve once the liquid is routed to flare header.
6. Open the vent valve and vent the remaining vapor flare header.M
7. Purge the pump with nitrogen thoroughly. M
8. Close the vent to flare line valve. PE&M
9. Provide the blind in the following lines (if required). M
 Pump suction flange, i.e. at the D/S of I/V. M
 Pump discharge flange, i.e. at the U/S of I/V. M
 Vent flange, i.e. at the U/S of I/V. M
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10. De-energize the motor. M
11. Prepare and issue WP for working or the pump to mechanical
M &SIC
shift-in-charge. M
12. De-couple the motor if required. M
1.21 M
HAND OVER OF LPG Pumps FOR HOT JOB (41-P-003 A/B, 41- SIC
P-007)) SIC
1. Inform the shift-in-charge about the pump handing over. SIC

2. Isolate the pump by closing its suction and discharge
valves.
3. De-energize the motor. And de-couple the motor if required.
4. Ensure that pump drain line to OWS is closed and blinded.
5. Open the drain valve to route the liquid to flare header. SIC
6. Close the drain valve once the liquid is routed to flare SIC
header.
7. Open the vent valve and vent the remaining vapor to flare SIC
header.
8. Flush the casing with nitrogen while doing ,check the LEL
range using the LEL meter.
9. Close the vent to flare line.
10. Provide blind in the following line SIC&
 Pump suction flange, i.e. at the D/S of I/V. M
 Pump discharge flange, i.e. at the U/S of I/V.
 Vent flange, i.e. at the U/S of I/V. SIC
11. Check the atmosphere with LEL meter and ensure it is zero. M
12. Barricade the atmosphere with wet asbestos cloth so that
the welding spark will not spread. M
13. Keep the fire fighting equipment ready and closely follow up M
the job. M
14. Make hot job work permit and hand over the pump for hot M
job.
SIC&M
DE-COMMISSIONING OF LPG SPHERE:
De-commissioning of storage sphere may be carried out in case M
the Sphere is to be taken under maintenance for statutory PE & M
inspection.
1. Inform SCR in-charge about the possible venting of LPG in
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flare header.
2. Inform technical analysis laboratory personnel about the SIC& M
requirement of sample analysis.
1. Say LPG sphere 41-V-001A is to be de-commissioned. SIC

2. Say LPG transfer pump 41-P-003A is in operation
3. Pump entire liquid from the sphere 41-V-001A to the SIC& M
consumers till the Pump loses suction with proper
communication with NCU SIC.
4. Stop the pump 41-P-003A when step 1 is completed. SIC
5. Close ROV-1201/1202/1203, SDV-1201 and the I/V in I/O SIC
line.
6. Isolate the sampling point at the inlet /outlet line. SIC
7. Isolate and blind the following.
 4” minimum circulation of LPG sphere. M
 8” suction header of 41-P-003A/B. SIC
 4” vapor return line from sphere 41-V-001A to vapor
return header. SIC&M
 12” suction line to mixed butane loading pump
8. Make proper nitrogen connection from hose station to
sphere 41-V-001A through sampling point connection. M
9. Ensure that all the instruments are in line. PE&M
10. De-pressurize the sphere slowly as below—
 Open PSV bypass slowly towards the flare side. De- M
pressurize the sphere completely. Close PSV bypass M
after de pressurization.
 Start pressurizing the sphere using nitrogen up to 5.0
kg/cm2 and then depressurize the sphere through PSV
bypass.
 Repeat the above steps until LEL in the sphere reaches
zero percent. , If required, LP steam purging may be SIC&M
started.
 Keep thePSV1201A/B BYPASS and its I/V’s in closed PE&M
condition..
11. Disconnect and blind nitrogen connection between hose
station & sphere . SIC&M
12. Drop bottom ROV and open top manhole. Blind common
U/S flange of PSV 1201A/B on sphere top and ensure that M
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sphere is totally isolated and blinded with LPG system.
13. Connect plant air connection from hose station to sphere
(through I/O line) and start air purging M
14. Vent air through instruments drain valve also. After air
purging the sphere may be flushed with water if continuous M
Water supply and proper drainage facility is provided
15. .After analyzing the oxygen level and LEL content inside the M
sphere by fire and safety dept., permit for man entry can be
issued. SIC&
16. During pressurization activity for hydrotesting SAFET
purpose ,servo to be isolated. Y
SIC
SIC

SB/BKM RM 6
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LPG Storage & Transfer Procedures

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LPG Storage & Transfer Procedures

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Standard Operating Procedures

Integrated Offsites & Utilities Plant (IOP)

TITLE LPG Storage & Transfer System

OPERATION PHILOSOPHY OF LPG SPHERE (41-V-001A)

TITLE LPG Storage & Transfer System

UNLOADING OF LPG FROM TANKER TO LPG SPHERE

TITLE LPG Storage & Transfer System

14. Isolate and blind the following:

TITLE LPG Storage & Transfer System

15. Inertisation of the system to be completed as per

TITLE LPG Storage & Transfer System

TITLE LPG Storage & Transfer System

TITLE LPG Storage & Transfer System

TITLE LPG Storage & Transfer System

TITLE LPG Storage & Transfer System

6.Ensure that the following interlocks are checked

TITLE LPG Storage & Transfer System

TITLE LPG Storage & Transfer System

1. Select a pump for unloading.

TITLE LPG Storage & Transfer System

Transfer of LPG to NCU

1. Transfer takes place from the sphere: 41-V-001A.

TITLE LPG Storage & Transfer System

7. Isolate or blind the following:

TITLE LPG Storage & Transfer System

1. Select a pump for transfer.

TITLE LPG Storage & Transfer System

TITLE LPG Storage & Transfer System

TITLE LPG Storage & Transfer System

 Change over of pump should be done with proper

TITLE LPG Storage & Transfer System

01.Pump to be used for transfer: 43-P-002A

TITLE LPG Storage & Transfer System

Line up 43-V-002A for propane-LPG loading:

1.Ensure the presence of following utilities line in the sphere

TITLE LPG Storage & Transfer System

2.Ensure that the following instruments are in line.

TITLE LPG Storage & Transfer System

WHEN PUMP CAVITATES: M

PROCEDURE WHILE SUDDEN STOPPAGE OF LPG BY USER SIC

TITLE LPG Storage & Transfer System

 Total power failure in the petrochemical complex is an

 Sudden failure of IA is not envisaged, as instrument air

1. Co-ordinate with the in-charge of

TITLE LPG Storage & Transfer System

PROCEDURE IN CASE OF FIRE

 Inform the fire safety department immediately. Dial 6401,

HAND OVER OF LPG PUMPS FOR COLD JOB SIC

TITLE LPG Storage & Transfer System

1. Inform the shift-in-charge about the pump handing over. SIC

TITLE LPG Storage & Transfer System

1. Say LPG sphere 41-V-001A is to be de-commissioned. SIC

TITLE LPG Storage & Transfer System

Doc No. Topic Prepared by Approved by Rev. No Page

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