Critical equipment change over plans /

handing over procedure

 Critical equipment change over plans / Handing over procedure

Why is a changeover needed?

 Changeovers provide an opportunity to replace worn-out

components and perform the maintenance of the equipment.

 Changeover are done during breakdown of running equipment

which should not effect the operating Unit.

 Changeovers are part of a proactive approach to lifecycle

management.

 Advances in technology and engineering may offer opportunities

to enhance the performance and efficiency of critical equipment.

 Changeovers of critical equipment in a refinery are necessary to

ensure the ongoing safety, reliability, and efficiency of operations.
 Critical equipment change over plans / handing over procedure

AGENDA
 Compressor change over procedure

 Filters change over procedure

 Critical Pump change over procedure

 Critical equipment handing over procedure

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 Critical equipment change over plans / handing over procedure

MUG Compressor change over

Pre-checks:
Jacketing oil
 Ensure all the auxiliaries energised condition. pump

 Ensure no liquid level in suction and discharge KODs. Cylindrical

lubricator Hydrocom
 Main motor purge control pressurisation is healthy.
 Ensure N2 to packing & distance piece is healthy.
N2 Flare

 Run all the auxiliaries for 5min and observe the performance. MUG
 MGC stage I & stage II spillback C/V s in manual and 100%
Cooling Lube oil
open. Confirm in field and do stroke check.
water system skid
 Barring of compressor completed in depressurized condition if
starting after more than a week. Auxiliary network
 Ensure all the PSVs are lined up condition.
 Critical equipment change over plans / handing over procedure

MUG Compressor change over

 Pressurize and float the compressor on H2 header at compressor
suction pressure of 21.5ksc.
 Ensure release of stop push button on LCP and press annunciator
acknowledge, press reset on LCP. Check for start permissive.
 Take CPP, SS-71 clearance. Ensure voltage step-up is done at Substation.
 Press start button on LCP,compressor will start rolling after
60sec.Hydrocom gets loaded to 30% automatically after 90sec.
 Monitor compressor rod drop and vibrations. Bearing temperatures to
be noted. Barring
 Critical equipment change over plans / handing over procedure

MUG Compressor change over

 Load the compressor gradually till the final discharge pressure is greater by
2ksc than that at running compressor.
 Open the II stage 1st discharge block valves equalisation valve,later open the
discharge block valve.
 Now gradually open the 2nd discharge block valve after pressure equalising
with equalisation valve.
 Maintain the system pressure by parallely unloading the other compressor and
maintaining the make-up hydrogen flow to the reaction loop.
 Once the other compressor gets unloaded completely, close it’s discharge
valve.
 Throttle the suction of the other compressor to 2 turns and stop the
compressor
 Critical equipment change over plans / handing over procedure

MUG Compressor change over

1st stage spill back

MUG-A 2nd stage

90-E-09A
Discharge to RGC suction

90-V-08A 2nd stage spill back

MUG-A 1st stage

1st stage spill back

MUG-B 2nd stage
90-E-09B
H2 from B/L

2nd stage spill back

MUG-B 1st stage
90-V-07
 Critical equipment change over plans / handing over procedure

Charge pump changeover

Pre-checks:
 Keep AOP in local mode & start the AOP. Ensure discharge pressure and flow through
return sight glass of pump(DE&NDE),motor and HPRT. Keep AOP in remote mode.
 Ensure primary and secondary seals are healthy and lined up condition.
 Bearing cooling water lined upto motor chamber cooling system.
 Main motor purge control pressurisation is healthy.
 Line up AOP, MOP supply and return to Charge pumps, lube oil cooler, AOP & MOP
discharge PSVs.
 Ensure suction lined up condition.
 Pump is primed and filled up with oil upto discharge block valve.Vent the system to
release entrapped vapours or air.
 Critical equipment change over plans / handing over procedure

Charge pump changeover

 Open pump first discharge valve while ensuring the other discharge block valve closed.
Also line the mechanical spill back of stand by pump min 30%.
 Take CPP&SS-71 clearance.
 Press startup button on LCP, ensure MOP discharge pressure is healthy and AOP stopped
after 5min after start of the charge pump.
 Slowly wide open pump discharge block valve monitoring motor amps.
 Gradually open the discharge of the standby pump parllely closing the mechnical spill
back.
 Once the mechanical spill back is full open, throttle the pump discharge block valve
parallely throttle the minimum recirculation valve of the pump taken in service
 Completely close the discharge block v/v of the other pump, once all the parameters are
steady, stop the second pump.
 Critical equipment change over plans / handing over procedure

Charge pump changeover

90-E-05A/B/C

90-V-02

Mechanical
Spill back
90-P-01A 90-P-01B

Mechanical
Spill back

Spill back C/V

 Critical equipment change over plans / handing over procedure

Lean Amine pump changeover

 Lean amine pump spill back control valve in manual and 100% open. Confirm in field and stroke check if
required.
 Line up LG, LT, PT of seal pot, BCW supply and return to primary and secondary seal coolers. Ensure 80%
level in seal pot.
 Monitor pressure and level indications of seal pot. Pressure above 3ksc indicates primary seal leak whereas
activation of low level indicates secondary seal leak.
 Lean amine surge drum pressure is 2ksc and temperature below 60degC.
 Line up lean amine pump suction valves,min.recirculation valves
 Pump is primed and filledup to discharge block valve.Vent the system to release entrapped vapours or air
 Critical equipment change over plans / handing over procedure

Lean Amine pump changeover

 Open pump first discharge valve while ensuring the other discharge valve is fully closed.
 Take pump discharge flow low-low switch &Recycle gas scrubber,off gas scrubber flows low-low switches in
bypass.
 Take CPP&SS-71 clearance
 Press start button on LCS.
 Check for healthiness of seal pot level,pressure,pump discharge pressure, suction strainer DP.
 Slowly wide open pump discharge block valve by keeping watch on motor amps
 Critical equipment change over plans / handing over procedure

Lean Amine pump changeover

 Gradually throttle mechanical spill back valve and parallely open the mechnical spill back valve of the other
pump watching the amine flows to the system.
 Throttle and close the other pump discharge block valve, once the flows are stabilised stop the second
pump.
 Critical equipment change over plans / handing over procedure

Change over procedure - RGC lube oil pump

 Stand by oil pump (SOP) to be taken into local mode in LCP.

 Pump to be started in local mode from LCP.
 Main pump (MOP) to be stopped from LCP panel (ensure SOP discharge pressure above 8 kg/cm2) and keep
it in Auto mode.
 Check Standby Oil pump discharge pressure and Lube oil header pressure are healthy.
 Critical equipment change over plans / handing over procedure

Change over procedure – RGC/MUG lube oil filters

 Inform DCS officer regarding preparation of standby filter “b”.

 Keep the vent valve crack open (vent will be connected to tank or atmosphere)
 Slightly open the pressurisation valve to fill the standby filter “b”.
 Close the vent once you see the flow through sight glass.
A B
 Allow the filter to pressurise up to system pressure (allow for at least 5 minute).
 Close pressurisation valve and inform DCS regarding filter change over.
 After clearance from DCS, change the lever of 3 way valve towards standby filter “b”.
 Now filter “b” comes into line and filter “a” is isolated.
 Filter “a” is ready for replacement after depressurisation.
 Critical equipment change over plans / handing over procedure

Equipment handing over procedure – Hot Service Pumps (90-P-05 & 12)

 Isolate the pump (suction, discharge, spill back, warm up).

 Allow the pump to cool down for enough time.

 Drain the liquid to CBD and counter check that no valves are passing.

 Once blinding completed, pump is ready for handing over.

 Pump to be electrically isolated.

 In field check once again whether pump is isolated correctly or not.

 Hand over the pump for Maintenance.

Critical equipment change over plans / handing over procedure

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Critical equipment change over plans / handing over procedure

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