CRUDE OIL EXPORT & EXPORT HOSE SYSTEM

COMMISSIONING PROCEDURE OF SAGAR SAMRAT

CONVERSION PROJECT

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.

SCOPE: (SYSTEM NO. 30)...............................................................................................................3

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

TEST EQUIPMENT AND SPECIAL TOOLS.............................................................................6

5.7

VENDOR ASSISTANCE............................................................................................................6

5.8

COMMISSIONING ACTIVITIES.................................................................................................7

5.9

SYSTEM COMPLETION AND HANDOVER...........................................................................11

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.

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)
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

Doc. No. 030001910170-PR-001

2. Cause & Effect Charts

Doc. No. 4301-02-PC-T-I-0002-001

3. Emergency and Shutdown Philosophy

Doc. No. 4301-02-PC-T-B-0003-000

4. Process Flow Diagrams

Doc. No. 4301-02-PC-T-G-0001 to 0018

5. Basis of Design

Doc. No. 030001910170-GB-001

6. UFD's

Doc. No. 4301-02-PC-T-G-0019 to 0035

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

-OIL AND NATURAL GAS CORPORATION LIMITED

CA

-CERTIFICATION AGENCIES

LOTO

-LOCK OUT & TAG OUT

PC

-PRE-COMMISSIONING CERTIFICATE

MC

-MECHANICAL COMPLITION CERTIFICATE

MCC

-MOTOR CONTROL CENTRE

RFC

-READY FOR COMMISSIONING

MOGL

-MERCATOR OIL AND GAS LTD

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

Oil Booster Pump

30.02

Oil Export Pump

See marked-up P&IDs as defined in the commissioning system limits procedure.

5.3 SYSTEM DOCUMENTATION
The 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. Description

Type

Drawing / Doc. No

Oil Booster Pump

P&ID

4301-02-PC-T-V-0027-001

Export Oil pump

P&ID

4301-02-PC-T-V-0028-01

5.4 SYSTEM PRE-REQUISITES

It is the responsibility of the assigned system commissioning engineer to ensure the following
checks have been completed before start of actual commissioning activities
No.
1.

Description
System RFC certificate duly signed off by COMPANY.

Checked
Yes

A line-walk has been carried out to confirm system status, and a

2. 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.
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

System Commissioning Engineer: (Print)

Signature

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.

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 TOOLS
Digital Sound level meter,Vibration measurement meter &Infrared Thermometer

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

5.7 VENDOR ASSISTANCE

Vendor for crude oil export systemmay be mobilized to assist in package pre-commissioning
and commissioning activities if required.
5.8 COMMISSIONING ACTIVITIES
Leak Test at Operating Pressure
Perform Operating pressure leak test of System with process fluid (HC). Line up system as per
the system P&ID.
Sr No.
1.

Description

Status

Line up system as per System P&ID

Yes

2.

Ensure all PSV are taken in-line

Yes

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

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-A23-1039

Healthy
Yes

2. All other valves to be in position as marked in mark-up

P&ID

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

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

1.
2.

Signals PALL-2701A and PALL-2701B

Signals PALL/HH-2704A and PALL/HH-2704B

Healthy
Yes
Manually
override

Yes

3. 3 FCV-2702 Recycle to 3-Phase Separator on line 4- Set at Min.

P-A23-1150
recirculation Yes
4. MOV (M-2701) at Suction of P-2000A on line 6-P-A23- Closed
1039

Yes

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

1032

Yes

6. 6 V2799 isolation valve at Discharge of P-2100A on Closed

line 6-P-D23-1045

Yes

7. 6 V2798 isolation valve at Discharge of P-2100A on Closed

line 6-P-D23-1044

Yes

8. All other valves to be in position as marked in mark-up As per

P&ID
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-A23-1042

Open
Yes

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

1056

Yes

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

1055

Yes

4. 6 V2899 isolation valve at Discharge of P-2100A on Closed

line 6-P-D23-1045

Yes

5. 6 V2898 isolation valve at Discharge of P-2100A on Closed

line 6-P-D23-1044

Yes

6.

Signals PALL2804A and PALL-2804B

7. Signals PALL/HH-2807A and PALL/HH-2807B

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

8. 2 FCV-2802 Recycle to 3-Phase Separator on line 4- Set at Min.

P-D23-1052.
recirculation Yes
9.

3 LCV-2801 on line 6-P-D23-1044 (Manually Close)

Closed

10. All other valves to be in position as marked in mark-up As per

P&ID
P&ID

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

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

B (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

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

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

pumps discharge.
Yes
8.

Switch the pump unit to manual mode.

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

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

Open the selected duty pump suction discharge and then

12.
start the duty pump motor by pressing the start push button on
the pump in accordance with vendor's recommendations.

Yes

9.

Open Inlet Isolation Valve MOV-2701/2702 (Depending Upon

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

Yes

Yes

15.Set the AUTO/MANUAL Selector switch of P-2000A to Manual

mode for starting the pump from the field.

Yes

Start the Oil Booster pump (P-2000A/B) as per Vendor Start-up

& Operating Manual (Refer Vendor Doc.) with Recycle line FCV16.
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

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

Once the Booster oil pump is running smoothly in stabilized

condition Open Inlet Isolation Valve MOV-2801/2802 (Depending
17.
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
18.during
Checkstart-up.
the readiness of Oil Export pumps (P-2001 A/B) as
per Vendor check list (Refer Vendor Doc)

Yes

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

Start the Oil Booster pump (P-2001A/B) as per Vendor Start-up

& Operating Manual (Refer Vendor Doc.) with Recycle line FCV21.
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

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,

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.

6. ATTACHMENTS
I.

Mark-up P&ID.

II.

Certificates.

III.

Operability Test Log Sheet.

IV.

Punch List Format.