MOCK DRILL REPORT

AVU & SR-LPG TREATMENT UNIT

MOCK DRILL SCENARIO: INSTRUMENT AIR FAILURE: Date & Shift:09/04/2022

Unit Operating Condition: Throughput 1750 MT/hr

 The mock drill scenario was discussed with all concerned prior to starting of the mock drill. Emergency scenario was also explained.
 Opened / Closed tags were put in the valves to indicate operation done by EAs/JEAs in the field.
 Changes done in Panels, viz. set point changes / control valve opening / closing etc were verbally communicated and recorded.
 Internal Observers monitored the activities in control room and field.
 After the mock drill a concluding session was held for discussion on the emergency and observations of all concerned were discussed.

Any Other Special Conditions: Instrument air is supplied to the unit at a pressure of about 7.0 kg/cm2 g. normally with instrument Air failure CPP will also go for an
emergency shutdown. Steam, power and other utilities will not be available. Initiate emergency shutdown action when instrument Air pressure comes down to 3.0
kg/cm2 g.
Following points to be remembered before taking any action during instrument air failure:
 In case of Instrument Air failure all C/V and XZV will go to fail safe position.
 Unit to be shut down safely with the help of available resources.
 If the instrument air failure is due to a big leak inside AVU B/L, instrument air B/L block valve to be isolated immediately so that CPP/other unit can be saved from an
emergency shutdown due to instrument air failure.
 Generally, valves on systems that eventually supply a heat source fail closed (FC) and those that contribute to heat removal fail open (FO). (FAIL SAFE POSITION)

The effects with the corresponding action to be taken are summarised as follows:
(N.B: Emergency action will be taken in the field with proper communication with panel in charge in case of Instrument Air Failure)

Sl
Description of Action point Actio Time Remark
No. n By
1 Shut down valves on both fuel gas/fuel oil including the pilot will close to cut off fuel EA/JEA
supply to burners.
Both CDU&VDU heaters will be shutdown as per the logic. ENSURE:
SIC
Isolate MANUAL IVS at FG/FO/PILOT lines, FG bypass if open,
Ensure All shutdown valves physically closed as per SHUTDOWN LOGIC

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2 PANEL
Desalter pressure controller PV-1019/1022 will get full open. OFFICER
 Furnace feed flow control valves will get full open.
 Pre-Desalter and post Desalter HIC’s will get full open.

Desalter pressure and post Desalter exchanger train pressure to be monitored.

EA/JEA
If required throttle 010-P-003 discharge to maintain the pressures.
ENSURE:
SIC
3 Pre flash Vessel (010-V-003) pressure controller 010-PV-1021 will come to fail close
position .
EA/JEA
Keep 010-V-003 pressure under control by opening the B/P block valve of PV-1021
ENSURE:
SIC
4 Crude column overhead receiver (010-V-005) controller 010-PV-1072 will come to fail EA/JEA
close position.
Keep 010-C-001 pressure under control by opening the B/P valve of 010-PV-1072B. ENSURE:
SIC
5 010-C-001: All PA C/V including TPA will be in completely open condition
Check amperage of all PA pumps 010-P-004/005/006/030 and throttle the discharge PANEL
accordingly. OFFICER
EA/JEA

ENSURE:
SIC
6 Stripping steam control valves at 10-C-001/C-002/C-003/C-008 will close. EA/JEA
Close stripping steam block valves of 010-C-001 and all strippers.
ENSURE:
SIC
7 Vacuum section shutdown due to firing cutoff in furnace. EA/JEA
Take emergency shutdown of vacuum section :
ENSURE:
 Isolate vapor inlet valves of ejectors and isolate ejectors as per standard procedure. SIC
 Ensure off gas line to atmospheric vent at 010-V-11 is closed.
 Lined up Nitrogen to 10-C-007and break vacuum.
 Close 10-C-007 stripping steam body B/V in proper co-ordination with
Vacuum charge heater area in charge and panel in charge

8 All run down product control valve close . EA/JEA

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 If shut down is for longer duration, pump out the strippers by opening the bypass of
product run down control valves. ENSURE:
SIC
9 Stabilizer section EA/JEA
Feed C/V will close. Fuel gas ex 010-V-004 C/V will close. Re-boiler will be by-passed.
Reflux C/V will full open. ENSURE:
Stabiliser pressure to be monitored. If stabiliser pressure increases, release the pressure to SIC
FG header by opening the by-pass of PV-2018A mounted on 010-V-008.

10 Desalter EA/JEA
 Water inlet valve closes.
 Brine outlet valve closes. ENSURE:
 Isolate desalter brine outlet Level control valves & also water injection B/V SIC
 Stop chemical injection

11

12

13

14

15

16

17

18

19 If the failure is for longer duration, say more than one hour, flush the heavy oil lines with flushing
oil and keep the units bottled up under positive pressure.

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Sl
Description of Action point Action By Time Remark
No.
20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

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 Individual Performance Report
Overall
Sl Promptness Accuracy Communication
No.
Name Designation Performance
High Medium Low High Medium Low High Medium Low Rating
1 ANIL KR
2 GYAN
3 DHEERAJ
4 ARVIND
5 GIRIRAJ
6 DHARMENDRA
7
8 RAJAKUMAR
9 SUBIN KR
10 MD ARIF

Overall marks are given based on the following points:

Marks
Actions and communication during emergency was not proper 3
Meeting the requirements of emergency 4
Very accurate & perfectly executing the emergency 5

Post Mock Drill Skill Development Report:

GAPS IDENTIFIED
Sl
Description of Gap Action By
No.

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RECOMMENDATIONS
Sl
Recommendations
No.

Sl
No.
Name & Designation Signatures NAME & DESIGNATION Signatures

1 MOCK DRILL COORDINATOR

2

4 INTERNAL OBERSERVER
5

7 EXTERNAL OBERSERVER
8

10

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