COMMISSIONING PROCEDURE OF CRUDE OIL EXPORT & EXPORT HOSE SYSTEMProject No.MR/OW/MM/SSCP/10/2011 (P855C11004)

Document No.MLL-MOG-GEN-SSCP-GEN-PCM-004-019

Rev0

CRUDE OIL EXPORT & EXPORT HOSE SYSTEM COMMISSIONING PROCEDURE OF SAGAR SAMRAT CONVERSION PROJECT

0013/08/2015Issued for ReviewAbdul HaseebIrshad AliV.K.Gajinkar

RevDatePurpose of IssuePrepared ByChecked ByApproved By

Table of Contents1.PURPOSE32.SCOPE: (SYSTEM NO. 30)33.REFERENCES34.ABBREVIATIONS45.PROCEDURE45.1SYSTEM DESCRIPTION45.2SYSTEM LIMITS45.3SYSTEM DOCUMENTATION55.4SYSTEM PRE-REQUISITES55.5SAFETY65.6TEST EQUIPMENT AND SPECIAL TOOLS65.7VENDOR ASSISTANCE65.8COMMISSIONING ACTIVITIES75.9SYSTEM COMPLETION AND HANDOVER116.ATTACHMENTS12

PURPOSEThe purpose of the Crude Oil Export System commissioning procedure is to identify and describe the method statement for the activities required during commissioning. The commissioning of the Crude Oil Export System is based on vendor protocol and procedure and Pre-comm. check sheets.SCOPE: (SYSTEM NO. 30)The scope of this procedure covers the activities required to complete the commissioning of all equipments, Instruments and electrical interfaces within the system as marked in system P&Ids. Oil Booster pump (P-2000A/B) Oil Export Pump (P-2001A/B)This procedure will also cover preparatory work involved from system commissioning to obtaining commissioning Certificate followed by acceptance of the system.(Signing off System Handover Certificate by ONGC)REFERENCESIn the preparation of the procedure and while execution of commissioning activities, MOGL shall refer to relevant Technical Specification.Listed below are main technical specification and engineering documents.1. Process facilities definition reportDoc. No. 030001910170-PR-0012. Cause & Effect ChartsDoc. No. 4301-02-PC-T-I-0002-0013. Emergency and Shutdown PhilosophyDoc. No. 4301-02-PC-T-B-0003-0004. Process Flow DiagramsDoc. No. 4301-02-PC-T-G-0001 to 00185. Basis of DesignDoc. No. 030001910170-GB-0016. UFD'sDoc. No. 4301-02-PC-T-G-0019 to 00357. API 7008. ONGC FS 5103

ABBREVIATIONSONGC/COMPANY-OIL AND NATURAL GAS CORPORATION LIMITED CA-CERTIFICATION AGENCIESLOTO -LOCK OUT & TAG OUTPC-PRE-COMMISSIONING CERTIFICATEMC-MECHANICAL COMPLITION CERTIFICATEMCC-MOTOR CONTROL CENTRERFC-READY FOR COMMISSIONINGMOGL-MERCATOR OIL AND GAS LTDPROCEDURE5.1 SYSTEM DESCRIPTIONOil Booster pump (P-2000A/B)Oil stream from three phase separator is pumped first by Booster Pumps (P-2000A/B) which are in (2 x 100%) configuration with rated capacity of 150 m3/hr (each) @ 6.5 bar (g). Oil booster pumps are protected by PALL-2701 A/B on the suction side of each pump. It causes trip of the pumps to avoid damage due to cavitation or blocked discharge. Oil booster pumps are protected by PAHH/PALL-2704A/B on discharge line which will trip the pumps in case of activation. This will prevent pump overheating and cavitation. Pump is protected by minimum flow line which recycles flow from discharge of pump to Three Phase Separator. Pumps are provided with push buttons to start/stop from control room as well as running/off light indications to show pump status. Oil booster pumps are required as high pressure export oil pumps need high NPSH and due to high vapour pressure of oil, it is not possible to feed this oil stream directly to suction of export oil pumps.Export Oil pump (P-2001A/B)Oil from oil booster pumps enters the suction of high pressure oil export pumps. This arrangement provides Oil Export Pumps with sufficient NPSH to operate efficiently in (2x100%) configuration with rated capacity of 150 m3/hr (each) @54 bar (g). Oil Export Pumps are protected by PALL-2804A/B on suction to avoid blocked flow or cavitation. 5.2 SYSTEM LIMITSThe Crude Oil Export system is comprised of the following Sub Systems:System NoSystem Name

30.01Oil Booster Pump

30.02Oil Export Pump

See marked-up P&IDs as defined in the commissioning system limits procedure.5.3 SYSTEM DOCUMENTATIONThe P&IDs relevant to the system covered by this commissioning procedure are listed below. It is the responsibility of the system commissioning engineer assigned to this system to ensure that the latest revisions are being used for the system Commissioning activities.Drawing/Doc. DescriptionTypeDrawing / Doc. No

Oil Booster PumpP&ID4301-02-PC-T-V-0027-001

Export Oil pumpP&ID4301-02-PC-T-V-0028-01

5.4 SYSTEM PRE-REQUISITESIt is the responsibility of the assigned system commissioning engineer to ensure the following checks have been completed before start of actual commissioning activitiesNo.DescriptionChecked

1. System RFC certificate duly signed off by COMPANY.Yes

2. A line-walk has been carried out to confirm system status, and a jointpunch list has been agreed with the COMPANY representative. There are no A punch list items outstanding and a minimum number of B items.Yes

3. Confirm hot loop check for all associated instruments has been completed &Instruments are Energized.Yes

4. Confirm that LOTO procedure has been followed before energizing of Compressor Electric motor from MCC.Yes

5. Confirm that System Cause and effect check has been completed.Yes

6. Confirm All downstream Inter Connected System are Ready ForCommissioning.Yes

7. Confirm the Job Safety Analysis (JSA) for System start-up is prepared & Signed off by all the relevant parties.Yes

System Commissioning Engineer: (Print)

SignatureDate

5.5 SAFETYThe system commissioning engineer is responsible for ensuring that all safety aspects associated with the proposed commissioning activities have been addressed. These include but are not limited to: Personnel working within the commissioning team must be fully aware of their duties, responsibilities and potential hazards associated with the systems to be tested. Restriction of access notices and barriers must be posted in accordance with the permit to work system. Appropriate firefighting equipment must be available at the worksite. On handover from construction to commissioning, all electrical and mechanical isolations will be made by the commissioning group using commissioning locks. These locks will be controlled under the Permit to Work system. H2S safety protocol must be followed.NOTE: Well fluid may contains Hydrogen Sulphide Gas (H2S) in lethal concentration, all safety precautions shall be taken as per HSSE manual and proper PPEs to be used all the times. All personnel involved must carry portable H2S detector and move in buddy system.5.6 TEST EQUIPMENT AND SPECIAL TOOLSDigital Sound level meter,Vibration measurement meter &Infrared Thermometer5.7 VENDOR ASSISTANCEVendor for crude oil export systemmay be mobilized to assist in package pre-commissioning and commissioning activities if required.5.8 COMMISSIONING ACTIVITIESLeak Test at Operating PressurePerform Operating pressure leak test of System with process fluid (HC). Line up system as per the system P&ID.Sr No.DescriptionStatus

1. Line up system as per System P&ID Yes

2. Ensure all PSV are taken in-line Yes

3. Introduce Process Gas into the System By slowly opening the inlet isolation valve. Yes

4. Increase system pressure in steps of 2 bar (g) and observe for any leakage. Repeat the Leak test until the system operating pressure. Yes

5. Once leak test completed depressurize the system process gas into flare system Yes

Line UpAll valve positions to be maintained as specified in drawing except below mentioned line up. All control and tripping signals shall be in place except for those mentioned for override below. Once the system has been commissioned with Hydrocarbon these valves/signals shall be reinstated.Sr. No.DescriptionStatusRemark

Crude Oil Export system

P&ID No. 4301-02-PC-T-V-0026-001(3-Phase Separator)

1. 6 XSDV-2602 on line 6-P-A23-1039Healthy Yes

2. All other valves to be in position as marked in mark-up P&IDAs per P&ID Yes

P&ID No. 4301-02-PC-T-V-0027-001 (Oil Booster pump)

1. Signals PALL-2701A and PALL-2701BHealthy Yes

2. Signals PALL/HH-2704A and PALL/HH-2704BManually override Yes

3. 3 FCV-2702 Recycle to 3-Phase Separator on line 4-P-A23-1150Set at Min. recirculation Yes

4. MOV (M-2701) at Suction of P-2000A on line 6-P-A23-1039 Closed Yes

5. MOV (M-2702) at Suction of P-2000B on line 6-P-D23-1032 Closed Yes

6. 6 V2799 isolation valve at Discharge of P-2100A on line 6-P-D23-1045Closed Yes

7. 6 V2798 isolation valve at Discharge of P-2100A on line 6-P-D23-1044Closed Yes

8. All other valves to be in position as marked in mark-up P&IDAs per P&ID Yes

P&ID No. 4301-02-PC-T-V-0028-01 (Oil Export system)

1. 6 DB2813 Ball Valve on line 6-P-A23-1042Open Yes

2. MOV (M-2801) at Suction of P-2100A on line 6-P-D23-1056 Closed Yes

3. MOV (M-2802) at Suction of P-2100B on line 6-P-D23-1055 Closed Yes

4. 6 V2899 isolation valve at Discharge of P-2100A on line 6-P-D23-1045Closed Yes

5. 6 V2898 isolation valve at Discharge of P-2100A on line 6-P-D23-1044Closed Yes

6. Signals PALL2804A and PALL-2804BHealthy Yes

7. Signals PALL/HH-2807A and PALL/HH-2807BManually override Yes

8. 2 FCV-2802 Recycle to 3-Phase Separator on line 4-P-D23-1052.Set at Min. recirculation Yes

9. 3 LCV-2801 on line 6-P-D23-1044 (Manually Close)Closed Yes

10. All other valves to be in position as marked in mark-up P&IDAs per P&ID Yes

Commissioning Steps:The following activities must be carried out in order to successfully commission the new equipment and pipe work associated with the Crude Oil Export system.Vendor Operating Manual (Refer Vendor IOM) shall be followed for commissioning of Crude Oil Export system.NoSTEPChecked

A / BOIL BOOSTER PUMP(P-2000A/B) /OIL EXPORT PUMP (P-2001A/B):

1. Confirm that the system is lined up for service as per the latest P&ID's, all instrumentation isolation valves are in their correct Position and instruments circuits are energized. Yes

2. All checks to be carried out under the supervision of the system engineer. Yes

3. Check the readiness of Oil Booster pumps (P-2000 A/B) as per Vendor check list (Refer Vendor Doc) Yes

4. Confirm that the Upstream systems (Inlet Separator & 3-phaseSeparator) are healthy & in operating condition.

Yes

5. Ensure that the Crude oil Export system is initially filled with water & all the entrapped air & gases is removed from the top most point of the system prior to its start-up. Yes

6. For Commissioning Line-up only one Oil Booster (P-2000A) & Oil Export Pump (P-2001 A) at a time & keep the stand by Pumps in ready to start position. Yes

7. Override the pressure (PZT-2704A/B) shut down signal for the pumps discharge. Yes

8. Switch the pump unit to manual mode. Yes

9. The pumps can only be started when crude level in the separator is build-up above the minimum low operating level. (When the Operating level reaches XSDV-2602 will open automatically). Yes

10. Ensure discharge Isolation valve is closed before starting the pump. Yes

11. Ensure that the 8 Flexible transfer hose going to WO-16 is properly connected. Yes

12. Open the selected duty pump suction discharge and then start the duty pump motor by pressing the start push button on the pump in accordance with vendor's recommendations.

Yes

13. Open Inlet Isolation Valve MOV-2701/2702 (Depending Upon Selection) at the suction of P-2000A/B from DCS to introduce the pumping liquid into the system. Vent the entrapped gases if any from pump casing top point to avoid cavitation during start-up. Yes

14. Check the suction pressure in PT-2702A/B (2-3 barg) to meet with the NPSH requirement of the pump. Yes

15. Set the AUTO/MANUAL Selector switch of P-2000A to Manual mode for starting the pump from the field. Yes

16. Start the Oil Booster pump (P-2000A/B) as per Vendor Start-up & Operating Manual (Refer Vendor Doc.) with Recycle line FCV-2702 line up & set in Auto mode with set point (.. M3/Hr) as per pump minimum flow requirement. Open Discharge valve slowly to avoid FLC tripping of Motor. Yes

17. Once the Booster oil pump is running smoothly in stabilized condition Open Inlet Isolation Valve MOV-2801/2802 (Depending Upon Selection) at the suction of P-2001A/B from DCS to introduce the pumping liquid into the system. Vent the entrapped gases if any from pump casing top point to avoid cavitation during start-up. Yes

18. Check the readiness of Oil Export pumps (P-2001 A/B) as per Vendor check list (Refer Vendor Doc) Yes

19. Check the suction pressure in PT-2803A/B (5-6 barg) to meet with the NPSH requirement of the pump. Yes

20. Set the AUTO/MANUAL Selector switch of P-2001A/B to Manual mode for starting the pump from the field. Yes

21. Start the Oil Booster pump (P-2001A/B) as per Vendor Start-up & Operating Manual (Refer Vendor Doc.) with Recycle line FCV-2802 line up & set in Auto mode with set point (.. M3/Hr) as per pump minimum flow requirement. Open Discharge valve slow to avoid FLC tripping of Motor. Yes

22. Line up LCV-2801 initially in manual mode and stabilize the level of 3-phase separator. Once stabilized switch it to auto mode. Yes

23. Ensure XSDV-4002 & V4003 isolation valve are open, So that Export oil pump discharge is routed to WO-16 via 8 Flexible hose. Yes

24. Start OCI injection to the Export oil header as required by opening the isolation valve on the line 2-CO-E22-8004. Yes

25. Tune all the Controllers in the system. Once the system is stabilized, send the sample for analysis Yes

26. Record all the data in Log sheets. Yes

27. Perform Operability Test for 4 Hours Yes

Following the successful completion of all commissioning activities, Crude Oil Export system (30) including all sub subsystems can now be considered as fully commissioned. The system can be put into service or shut down as operationally required.

5.9 SYSTEM COMPLETION AND HANDOVEROn satisfactory completion of all the described commissioning test activities, the system commissioning dossier shall be completed by including the following documents, Signed RFC certificate Filled and duly Signed Commissioning test Procedure Agreed outstanding punch list items. Operating Pressure Leak Test Certificate ( Operating pressure with system fluid) System Line-up Certificate. 4hr Operability Certificate.(DCS Log Sheets) Commissioning Completion Certificate. System Handover Certificate.ATTACHMENTSI. Mark-up P&ID.II. Certificates.III. Operability Test Log Sheet.IV. Punch List Format.