Operator Questions

1. How to hand over pump to maintenance?

a) Isolate the pump as per the lock out and tag out procedure. Lock out and tag out
procedure means closing suction, discharge, recycle, casing drain & vent line isolation
valves and providing the ‘DO NOT OPERATE’ isolation tags for all isolation valves
(Providing tags is called tag out procedure). Also electrically need to be isolated from
local push button and breaker in substation. Electrical person will provide lock for the
motor breaker (Providing lock is called lock out procedure) so that nobody can energize
the motor mistakenly. Also DO NOT OPERATE tags to be provided for local push button
and for breaker lock.
b) Drain the pump completely, if it is chemical pump than after draining need to be flushed
with water and once we get clear water than can be hand over to maintenance for
blinding job (If it is hydrocarbon pump need to purge with N2 and bring down LEL to
0%).
c) Suction, discharge, and recycle lines to be blinded. If the pump casing drain is connected
to closed drain system than the drain line also to be blinded and also if the pump
casing’s vent line is connected to the flare system than the vent line also need to be
blinded. After blinding, for all the blinds DO NOT OPERATE isolation tag to be provided
(this is as per tag out procedure).
d) Once blinding is completed than the pump is ready to hand over to maintenance for
maintenance job (like pump mechanical seal replacing or pump impeller repair or pump
bearing replacing or removal of pump to work shop etc).
e) For pump suction strainer cleaning no need to fix the blinds only isolation, draining and
purging is enough.

2. How to start the Pump?

a) Line up the pump seals coolant, Line up the pump casing jacketing cooling
water, Check the bearing oil level, Open the pump suction valve fully,
Remove the vapor/air lock from the pump casing, If it is reciprocating
pump keep both suction & discharge valves full open, If it is a centrifugal
pump then Keep the discharge valve close or crack open, If the pump has
recycle line than keep recycle control valve full open and then start the
pump and slowly open the discharge valve by monitoring discharge
pressure. Monitor for any abnormal sound.

3. What is purging?
a) Removing of hydrocarbons or hazards gases or impurities. Before lighting
up the heater it need to purge with nitrogen or air to remove the
combustible materials. In same way before handing over any equipment for
 maintenance (equipment’s which contains hydrocarbons or hazards gases) also
need to be purged with N2 or steam.
4. What is priming?
a) Removing the vapor lock or air lock from the pump casing is called
priming. Vapor lock which is called Cavitation can occur due to the suction
liquid flashing in to the vapor or if the suction strainer blocked. Pump
cavitation symptoms are abnormal sound, Vibration, discharge pressure
drop and motor load drop. Cavitation can damage the pump.

5. Handing over of any equipment or vessel for maintenance.

a) Positive isolation: - Isolate all connected lines to the equipment (Inlet valve, Outlet
valve, drain valve, vent valve, PRV valves etc.).
b) If the vessel contains flammable or toxic gas than Depressurize the vessel to flare.
c) If there is any H/C condensate or chemical drain it to the tank.
d) Purge with Nitrogen to flare by pressure bumping (Pressuring up to 6 bar and de-
pressuring) 7 to 8 times and check for LEL & H2S concentration, If LEL is 0% and H2S is
less than 5 PPM, stop purging with nitrogen.
e) Fix blinds at all lines connected to the vessel (nearest to the vessel).
f) If the equipment contains Pyrophoric iron than required to do the steam purge for 6
to 8 Hours. This required for removal of Pyrophoric iron, During steaming open vessel
top vent to atmosphere and drain the condensate. After stopping steam purge keep
vessel vent open to avoid vacuum formation during steam condensation.
g) Open top and bottom man way and fix exhaust fan at top man way for air ventilation (to
remove purge N2 and to bring up O2 content to 21%).
h) Keep exhaust fan running for 6 to 8 hours and check for gas test. If the gas test is Ok and
O2 is about 20.8% than confined space Permit can be issued.
i) For confined Space entry all the time stand by person should be standing outside and
watching the inside people. Also keep the exhaust fans running for ventilation.

6. Confined space entry.

a) Positive isolation (Complete isolation and blinding of all connected lines near to the
vessel)
b) Complete the purging and ventilation.
c) Check for the Gas test in side the vessel. Before doing gas test stop the exhaust fan (if it
is connected and running), wait for 10 to 15 Min and do the gas test. If the exhausts fan
running it will not give the correct reading because fresh air will be circulating and it will
sweep out the hazardous gas.
d) If the gas test result is ok (LEL - 0% & H2S - 0PPM) and O2 is about 20.8% than confined
space Permit can be issued.
 e) For confined Space entry all the time safety watch (stand by person) should be standing
outside and watching the inside people and also keep exhaust fan or blower running for
ventilation.
f) Just before entering to any confined space once again gas test to be done to confirm
that no hazardous gases are present and O2 is within the allowable range (More than
19.5% and less than 23.5%)
g) Stand by person will be maintaining the record of the people working inside the
confined space ( i.e. Name of the person, Emp.No, Time In, Time Out ). All the time he
has to watch in side working persons, If he see inside any abnormality he as to call for
help to rescue the inside people. Stand by person should not enter inside the vessel to
rescue people.

7. How to start the heater?

a) If all the start permissives (interlocks) are OK than first make reset from DCS
and then from field (Normal Start permissives will be Fuel gas pressure high-
high, fuel gas pressure low-low, combustion air flow low-low, heater box
pressure high-high, heater box pressure low-low, heater temperature high-
high, steam drum level low-low, stack temperature high-high etc.).
b) Check all the start permissives (If the heater is natural draft heater, due to
the draft air will be sucked through the registers, keep the stack dampener
full open. If the heater is forced draft heater than the heater will be having
FD fan. If the heater is induced draft heater than the heater will be having ID
fan. If the heater is balanced draft heater than the heater will be having ID
fan & FD fan. Start the blower or ID fan or FD fan as per the heater design
and start purging the heater (Normally purging will be done for 5Min).
c) Once purging is completed, it will give permissive to start pilot.
d) Line up the pilot fuel gas & air and light the pilot by pushing pilot ‘ON’ button.
e) Once pilot is lighted it will give permissive to light main burner.
f) Line up the main burner fuel gas & air and light up the main burner by
pushing Main burner ‘ON’ button.
g) Increase the heater temperature slowly @ 40ºC/Hr.

8. What are the differences between centrifugal pump and reciprocating pump?

a) Centrifugal pump gives high flow and low pressure. Where ever high flow
and low pressure is required there single stage centrifugal pumps are used.
Reciprocating pump gives high pressure and low flow. Where ever high
pressure and low flow is required there reciprocating pumps are used. Multi
stage centrifugal pump gives high flow and high pressure. Where ever high
 flow and high pressure is required there multi stage centrifugal pumps are
used.
b) Centrifugal pump is started by keeping suction (and also minimum flow
recycle valve) full open and discharge close or with minimum open.
Reciprocating pump is started by keeping suction and discharge valves full
open.

9. What are the differences between centrifugal compressor and reciprocating compressor?

a) Centrifugal compressor gives high flow and low pressure. Where ever high flow and low
pressure is required there single stage centrifugal compressors are used. Reciprocating
compressor gives high pressure and low flow. Where ever high pressure and low flow is
required there reciprocating compressors are used. Multi stage centrifugal compressor
gives high flow and high pressure. Where ever high flow and high pressure is required
there multi stage centrifugal compressors are used.
b) Centrifugal and Reciprocating both compressors are started by keeping suction,
discharge and recycle valves (Anti surge valves) full open.

10. How to start the compressor?

a) Purge the compressor loop with N2 and bring down O2 content to less than 0.5%. This
purging is required only if the compressor is given for maintenance and if the air
ingresses.
b) Open the compressor casing drains and if there is any condensate, drain it
to flare.
c) Line up the separation (Buffer) gas (nitrogen). This is one of the lube oil
pump start permissive. Separation gas will prevent the lube oil entering in
to the compressor seals (See the below drawing), that’s why first we have
to line up separation gas (normally nitrogen is used as separation gas) and
then only we can start lube oil pump.
d) Start the lube oil pump and establish the lube oil circulation.
e) Fill the lube oil over head tank and ensure the flow through over flow line
(Overhead tank high-level alarm as to appear. This is one of the
compressor start permissive). This overhead tank is given in case of power
failure and compressor & lube oil pump trips, overhead tank will supply
lube oil (by gravity) to compressor bearings for 4 to 5 Minutes and cool
down the compressor bearings.
f) Line up the primary seal gas, primary vent, secondary seal gas, and
secondary vent. Compressor seals (See the below drawing) will prevent
casing gas coming out to atmosphere. Normally compressor discharge gas
 is taken as primary seal gas, during start up fuel gas is used as a startup
seal gas and after starting the compressor than compressor discharge gas
will be lined up and start fuel gas will be isolated.
g) Open the compressor suction & discharge valves and spill back (Anti surge)
valves (If it is multi stage compressor than open suction & discharge valves
and Anti surge valves for all the stages). Line up Inter coolers and after
cooler.
h) Check the compressor (Inter locks) start permissives (Suction Pres not low-
low, Lube oil pressure not low-low, Seal gas differential pressure not low-
low (PDCV), Lube oil over head tank level high, Discharge Pres not high-
high, Discharge temp not high-high, Suction KOD level not high, Discharge
KOD level not high, Bearing temp not high-high, Vibration not high-high
etc)
i) If all start the permissives are ok than start the compressor and load the
compressor slowly by closing the anti-surge valve (Spill back or recycle
valve).