Documente Academic
Documente Profesional
Documente Cultură
00
Rev
13/08/201
Issued for
Review
Date
Purpose of
Issue
Abdul Haseeb
Irshad Ali
V.K.Gajinkar
Prepared By
Checked By
Approved By
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
Table of Contents
1.
PURPOSE..........................................................................................................................................3
2.
3.
REFERENCES...................................................................................................................................3
4.
ABBREVIATIONS..............................................................................................................................4
5.
PROCEDURE.....................................................................................................................................4
6.
5.1
SYSTEM DESCRIPTION...........................................................................................................4
5.2
SYSTEM LIMITS........................................................................................................................4
5.3
SYSTEM DOCUMENTATION....................................................................................................5
5.4
SYSTEM PRE-REQUISITES.....................................................................................................5
5.5
SAFETY......................................................................................................................................6
5.6
5.7
VENDOR ASSISTANCE............................................................................................................6
5.8
COMMISSIONING ACTIVITIES.................................................................................................7
5.9
ATTACHMENTS...............................................................................................................................12
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
1. PURPOSE
The 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.
2. 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.
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)
3. REFERENCES
In 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 report
5. Basis of Design
6. UFD's
7. API 700
8. ONGC FS 5103
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
4. ABBREVIATIONS
ONGC/COMPANY
CA
-CERTIFICATION AGENCIES
LOTO
PC
-PRE-COMMISSIONING CERTIFICATE
MC
MCC
RFC
MOGL
5. PROCEDURE
5.1 SYSTEM DESCRIPTION
Oil 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 LIMITS
The Crude Oil Export system is comprised of the following Sub Systems:
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
System No
System Name
30.01
30.02
Type
Drawing / Doc. No
P&ID
4301-02-PC-T-V-0027-001
P&ID
4301-02-PC-T-V-0028-01
Description
System RFC certificate duly signed off by COMPANY.
Checked
Yes
Yes
3. Confirm hot loop check for all associated instruments has been
completed &Instruments are Energized.
Yes
Yes
5. Confirm that System Cause and effect check has been completed.
6. Confirm All downstream Inter Connected System are Ready For
Yes
Yes
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
Commissioning.
7. Confirm the Job Safety Analysis (JSA) for System start-up is
prepared & Signed off by all the relevant parties.
Yes
Date
5.5 SAFETY
The 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.
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
Description
Status
2.
3.
4.
5.
Introduce Process Gas into the System By slowly opening the inlet
isolation valve.
Yes
Increase system pressure in steps of 2 bar (g) and observe for any
leakage. Repeat the Leak test until the system operating pressure.
Yes
Once leak test completed depressurize the system process gas into
flare system
Yes
Line Up
All 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.
Description
Status
Remark
Healthy
Yes
As per
P&ID
Yes
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
Healthy
Yes
Manually
override
Yes
Yes
Yes
Yes
Yes
Yes
Open
Yes
Yes
Yes
Yes
Yes
6.
Healthy
Yes
Manually
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
override
Yes
Closed
Yes
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.
No
STEP
Checked
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
Yes
Yes
Confirm that the Upstream systems (Inlet Separator & 3phaseSeparator) are healthy & in operating condition.
Yes
4.
5.
6.
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.
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
Yes
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
Yes
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
Yes
Yes
Yes
9.
Yes
Yes
Yes
Yes
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
Yes
Yes
Yes
Yes
Yes
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
Yes
25.Tune all the Controllers in the system. Once the system is stabilized,
send the sample for analysis
Yes
Yes
Yes
COMMISSIONING
PROCEDURE OF CRUDE OIL
EXPORT & EXPORT HOSE
SYSTEM
Project No.
MR/OW/MM/SSCP/10/2011 (P855C11004)
Document No.
MLL-MOG-GEN-SSCP-GEN-PCM-004-019
Rev
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 HANDOVER
On satisfactory completion of all the described commissioning test activities, the system
commissioning dossier shall be completed by including the following documents,
Operating Pressure Leak Test Certificate ( Operating pressure with system fluid)
6. ATTACHMENTS
I.
Mark-up P&ID.
II.
Certificates.
III.
IV.