005 LPG Om & Sop PDF

Operating Manual and Standard Operating
Procedures for LPG
1|Page
TABLE OF CONTENTS
PART-I
1.0 Introduction
1.1 Overview of paradip BOOT facility for LPG
A) Activities of the LPG facility
B) Facilities for handling LPG
1.2 Purpose
1.3 Scope and Applicability
2.0 Design Basis

2.1 Overview
2.2 Receipt details
2.3 Dispatch details
3.0 Process Description

3.1 Overview
3.1.1 Process Flow Diagram (PFD) for LPG storage facility
3.1.2 Instrumentation
3.2 Integration between Refinery and LPG facility
4.0 Facilities for LPG Handling

4.1 Mounded bullets
4.2 Pumps
4.3 Pipeline Details
4.4 LPG Blending system
4.5 Ethyl Mercaptan Dosing
4.6 Instrumentation and Automation
4.7 Tank Truck Loading
4.8 Tank Truck Unloading/ Vapour Compression
4.9 LT Flare
4.10 Water Drain Pot
4.11 Electrical system
4.12 Fire fighting system
4.13 Utility system
5.0 Operating Philosophy
5.1 LPG Receipt

5.2 LPG Dispatch
5.3 LPG Inter Bullet Transfer
5.4 Water Draining
5.5 Ethyl Mercaptan Dosing
5.6 Off Spec LPG handling
5.7 Tank Truck Unloading
6.0 Control Philosophy

6.1 LPG receipt and dispatch system
6.2 Safety Interlocks (ESD)
6.3 Alarms And Trips
6.4 Relief Valve Setting
2|Page
7.0 Roles and Responsibilities
Part-II
Standard operating procedures
9.0 Modes of Operation and Operating Procedure

9.1 Operation Mode for Receipt and Dispatch:
9.2 Operating Procedure
9.2.1 Bullet Operations in Normal Condition
9.2.2 Bullet Operations in Emergency Conditions
9.3 Documented ProcedureOperational Activities
10. LPG (ON-SPEC/ BLENDING SPILLAGE) RECEIPT

11. Mercaptan Dosing to LPG
12. Off-Spec LPG Receipt
13. Batch Formation / Bullet Preparation
14. Inter Bullet Transfer
15. LPG Dispatch To Marketing Pipe Line
16. LPG Tank Truck Loading
17. LPG Dispatch To Pipe Line Off-Take
18. Sick Truck Handling/ Tank Truck Unloading
19. Off-Spec LPG Pumping To Alkylation/ DCU Units
20. Off-Spec LPG Pumping To Fuel Gas Pool
PART III
APPENDIX
APPENDIX-1 : BULLET DETAILS
APPENDIX-2 : BULLET WISE NOZZLES AND ASSOCIATED FITTINGS
APPENDIX-3 : RECEIPT/ DESPATCH DETAILS
APPENDIX-4 : PUMP
4.1 WATER DRAIN POT
4.2 MERCAPTAN DOSING SYSTEM
4.3VAPOUR COMPRESSION PACKAGE
4.4 RVP ANALYSER
4.5 LT FLARE
APPENDIX-5 : 5.0 UTILITY DETAILS
APPENDIX-6 : 6.0 XZV DETAILS
APPENDIX-7 : 7.0 MOV/ HOV DETAILS
APPENDIX-8 : 8.0 LIST OF PSVS
APPENDIX-9 : INTEGRATION BETWEEN REFINERY AND STORAGE FACILITY
APPENDIX-10 : 10.0 INSTRUMENTATION DETAILS (LEVEL TRANSMITTER,
PRESSURE TRANSMITTERS ETC)
APPENDIX-11 : TRIPS AND ALARMS
APPENDIX-12 : SAFETY INTER LOCKS
APPENDIX-13 : FIRE PROTECTION DETAILS
APPENDIX-14 : FIRST AID FIRE FIGHTING DETAILS
APPENDIX-15 : AGDC (ALARM AND GAS DETECTORS COMBUSTIBLE)
15.1 FDAS (FLAME DETECTOR AND ALARM SYSTEM)
15.2 GAS ALARM BEACON WITH HOOTER-AGB
15.3 MANUAL CALL POINT-MCP
15.4 GAS ALARM SIREN-AGS
15.5 FIRE ALARM BEACON-AFB
15.6 FIRE ALARM SIREN-AFS
3|Page
APPENDIX-16 : TANK TRUCK CHECK LIST
4|Page
PART-I
OPERATING MANUAL
5|Page
CHAPTER-1
INTRODUCTION
1.0 INTRODUCTION
IOT Utkal Energy Services Limited is a consortium of IOT, OT and IVRCL. IOT is a 50:50 joint
venture company of Indian Oil Corporation Limited (IOC) and Oiltanking Gmbh (based
in Hamburg, Germany).
The contract for Installation, Operation and Maintenance of crude and finished product
tankage facility at Paradip Refinery Project, Paradip is awarded to IOT Utkal Energy
Services Limited (IOTUESL) on Build-Own- Operate-Transfer (BOOT) Basis for 15 years from
the date of commissioning.
IOT, one of the parent companies of IOTUESL is handling Petroleum storage and
distribution, related Operations and Engineering activities for Oil Industries in India and
Abroad.
The LPG handling facility at Paradip is built in the year _________ and commissioned in
the year __________ for receipt, storage and dispatch of LPG.
This facility is constructed as state-of-art technology which is fully automated. It meets

the requirements of all applicable standards, established by Oil Industry Safety
Directorate standards.
This manual gives operating guidelines for the various operations at the Offsite facilities
for IOT Paradip tankage facility to handle LPG. It consists of Design basis, Facility Details,
Process Description, Operating Philosophy, Operational Modes and Activities, and SOP
for all Operational Activities and PFD.
This Operating Manual is meant for the purpose of references of contents in connection
with LPG handling facility alone.
LPG stands for Liquefied Petroleum Gas. It is a mixture of mainly propane and butane
and contains some percentage of unsaturated hydrocarbons like Propylene and
Butane. As per Indian Standard Specifications, it is characterized any of the three
categories:
a) Commercial Butane
b) Commercial Propane and
c) Commercial Butane and Propane Mixture
LPG produced at Paradip Refinery falls in the category of Commercial Butane and
Propane mixture(c).
LPG at ambient temperature is in gaseous state, but it is liquefied under pressure.
LPG is highly flammable. It is used as a domestic fuel for cooking. It is also used for
industrial purpose.
Handling of LPG requires basic knowledge of its behaviour and properties at different
6|Page
conditions. With the knowledge and experience on LPG, it can be safely handled both
in liquid state when it is produced or dispatched and in gaseous state when it is used as
a fuel.
1.1 OVERVIEW OF PARADIP BOOT LPG FACILITY
A) Activities of the LPG facility:
The principal activities of the LPG handling facility are -

Receipt of LPG through rundown lines from the refinery through blending unit
Storage in horizontal mounded bullets.
Ethyl Mercaptan dosing during receipt/ during batch formation as an odouriser.
Preparation prior to dispatch – batch formation, water draining and sampling.
Off-spec LPG / blending spillage receipt to bullets.
Inter Bullet Transfer
LPG dispatch to Marketing Terminal through pipe line transfer.
LPG transfer to PBKD pipe line off-take.
LPG dispatch to Tank Trucks.
Pressure relief/ blow system to LT Flare
There is no manufacturing process involved in this facility and it is only an intermediate

storage facility for IOCL Paradip Refinery.
B) FACILITIES FOR HANDLING LPG:
The facility is comprised of the following or hooked up with other off site facilities to
handle LPG.
8 nos of Rundown lines (3”, 3”, 3”, 4”, 4”, 6”, 8” & 10”) from different refinery units for
the receipt of LPG from Refinery to the mounded bullets via blend header.
Inline static mixer with RVP (via blend header) analyser for the receipt of LPG from
the refinery.
Dedicated pipelines with online CTMS for the product delivery to marketing and pipe
line off-take.
9 nos of Mounded bullets for LPG storage in two different mounds.
7 bays at loading gantry for Tank Truck loading out of which 4 bays are common for
propylene/ LPG and 3 bays are dedicated for LPG.
Dedicated Metering Skid and 2 no weigh bridges for tank truck loading.
Utility system viz. Instrument Air, Plant Air, Nitrogen, Service Water and Drinking Water.
Variety of pumps of assorted capacities to carry out dispatch operations.
Fully computerized central control room – OMS and SRRs.
Fully Integrated Control System (ICS)
66 kVA Electrical supply for Product tankage facility through transformers.
1 no 350 kVA DG set to meet the emergency backup requirement for maintaining
continuous supply to UPS system.
Fire fighting system hooked up to main system of IOC for hydrant/ water monitor.
LT Flare for pressure relieving/ blow down system.
Water Drain Pot to collect water drained from the bullets.
LPG Blending System.
Ethyl Mercaptan dosing system.
1.2 PURPOSE
7|Page
The purpose of this manual is to ensure
that all operations are carried out as per standard operating procedure so that LPG
is received, stored and delivered through the facility in accordance with the
respective specifications.
To achieve highest level of safety and security in operations as per HSSE guidelines.
Meeting best possible working conditions and achieving preset operational goal
successfully.
To achieve greater satisfaction for IOCL Paradip Refinery by ensuring that facilities
are handled as per the best operating practices.
1.3 SCOPE AND APPLICABILITY
This Standard Operating Procedure is applicable to IOT Utkal‟s Paradip BOOT facility, to
be operated by IOT for all associated facilities and shall apply to all its employees,
contractors, visitors and other agencies operating within this facility.
8|Page
CHAPTER-2
DESIGN BASIS
2.0 DESIGN BASIS:
Storage and pump capacities for LPG are based on the Paradip refinery block flow
diagram and production capacities. The LPG facility is based on the criterion for receipt
of LPG (on-spec/ off-spec/ blending spillage) from refinery.
2.1 This document (Design Basis) indicates the requirements for design of the facilities
required for receiving, storage and pumping of LPG.
The design of this facility is based on refinery maximum production of 1059 KTPA (design
case).
09 numbers of mounded storage bullets as below of each 2700 m³ (1500 MT) working
capacity are provided for the storage of refinery‟s pressurized LPG product.
Mound I: Six bullets (205-V-003/004/005/007/008/009) located together.
Mound II: Three bullets (205-V-012/013/014) located together
These LPG bullets are also designed to store pure propane, which may be required for
the initial and subsequent black start-ups.
A provision exists to receive propylene in LPG bullets from Inter bullet transfer header of
propylene system; however this needs to be done in a controlled manner such that the
resultant vapor pressure of the LPG mix in bullets doesn‟t exceed the design pressure
corresponding to pure propane.
LPG bullets will also store off-spec LPG and blending spillages so that maximum usage
provided by these bullets is utilized under normal operation.
From the bullets, pressurized LPG is pumped to the Marketing Terminal (or truck loading)
and pipeline off take using 6 No (205-P-001A/B/C/D/E/F) of Can Type Centrifugal vertical
pumps located in two pump houses (PH-05 & PH-06) in each consisting of 3 pumps.
Product transfer can be achieved by using 2 pumps running and one stand by with a
discharge rate of 190 m 3/ hr of each pump.
When one set of bullets in any Mound is empty and product has to be transferred using
two pumps, one for marketing terminal and other for pipeline off take simultaneously, we
shall use one of the three pumps 205-P-001 A/B/C for marketing terminal and one of the
other three pumps 205-P-001 D/E/F for pipeline off take and vice-versa. A hook up
between the suction headers of pumps 205-P-001 A/B/C & 205-P-001 D/E/F serves the
purpose.
These Pumps also serve for Inter bullet transfer of LPG .(Between 205-V-003/4/5/7/8/9 via
205-P-001 A/B/C & between 205-V-012/13/14 via 205-P-001 D/E/F). However, only one
pump shall be used for Inter bullet transfer service at a time. A hook up between the two
inter bullet transfer return headers is also provided to facilitate transfer from one set of
bullets to other.
9|Page
Accounting of product transferred to Marketing Terminal, Tank Truck loading and Pipe
line off-take will be done by the flow meter provided in Metering Package.
Ethyl Mercaptan dosing facility was provided to odourise the product either during
receipt or during batch formation.
The off-spec LPG from bullets (205-V003/4/5/7/8/9/12/13/14) is pumped through 3 no of

off-spec LPG transfer pumps 205-P-027A/B/C to the Fuel Gas Pool at a rate of 20 m3/ hr
where two pumps running and one stand by.
All PSV outlets are connected to LT Flare.
Each bullet is provided with a separate water draining and sampling provisions. Water
drained from the bullet will be routed to Water Drain Pot.
2.2 RECEIPT DETAILS
DESIGN PRESSURE DESIGN TEMPERATURE LINE SIZE

REFINERY UNIT FLOWRATE
(kg/cm 2) (Deg C) (Inch)
FCC 39.2 98 10
CCR 39.2 98 3
AVU – C3 39.2 98 3
PROPANE- 39.2 98 3
ALKYLATION
AVU-BUTANE 39.2 98 4
C4 39.2 98 6
LPG- ALKYLATION 39.2 98 8
PROPANE – PRU 39.2 98 4
BLENDING HEADER 39.2 98 12
INLET COMMON
39.2 98 12
HEADER
2.3 DISPATCH DETAILS
MARKETING PIPE LINE OFF- TANK TRUCK FUEL GAS

PARAMETER
TERMINAL TAKE LOADING POOL
DESIGN PRESSURE 39 39 32.3 22.3
(kg/cm2)
DESIGN TEMP. -45 to 65 -45 to 65 -45 to 65 -45 to 65
(Deg Cent.)
PUMP TAG NO. 205-P-001 205-P- 205-P- 205-P- 205-P- 205-P- 205-P-027
A,B,C, 001 001 001 001 001 A,B,C
D,E,F A,B,C D,E,F A,B,C D,E,F
LINE SIZE (Inch) 12 12 12 4
10 | P a g e
PUMP FLOW RATE 190 m 3/hr 190 m 3/hr 190 m 3/hr 20 m 3/hr
BULLETS V- V- V- V-012, V- V-012, V-
003,004,0 012,013, 003,004, 013, 003,004, 013, 003,004,005
05,007,00 014 005,007, 014 005,007, 014 ,007,008,00
8,009 008,009 008,009 9,012,013,0
14
11 | P a g e
CHAPTER-3
PROCESS DESCRIPTION
LPG rundown from the different refinery units is blended on-line to achieve the required
product specifications, controlled by a Blending Control System which regulates the
vapor pressure of final blended stream by monitoring three highest vapor pressure feed
streams (AT-006) .
LPG blending streams are:
1. FCC LPG
2. CCR LPG
3. AVU Depropaniser C3
4. Propane from Alkylation Unit
5. AVU Depropaniser Butane
6. Unsaturated C4 from Intermediate storage area
7. LPG from Alkylation Unit
8. Propane purge from PRU.
The component streams‟ rundowns are routed to the LPG Blending Header. An in-line
static mixer (204-JS-001) is provided to achieve blend homogenization. The LPG product
after blending is routed to designated Bullets. Blending spillage will be lined up to
another designated bullet.
If off-spec LPG receipt is there, it will be directly routed/ lined up to the designated
bullet.
Ethyl Mercaptan dosing is provided for product odorizing downstream of LPG blending
and at LPG Pump Suction.
After receipt, product recirculation will be done for minimum 4 hours and then one hour
settlement time will be given. After settlement time, water draining/ checking will be
done. If no water is there then product sampling will be done as per the SOP PBT/ Ops/
M/ V-03 Chapter 8.0 to ensure that the receipt LPG meets the required quality standard
of domestic LPG as per IS4576 – 2004.
Once the product passes the quality test, it can be delivered to marketing / pipe line off-
take/ tank truck loading as per the IOC requirement.
From the bullets, pressurized LPG is pumped to the Marketing Terminal (or truck loading)
and pipeline off take using 6 nos (205-P-001A/B/C/D/E/F) of Can Type Centrifugal
vertical pumps located in two pump houses (PH-05 & PH-06) in each consisting of 3
pumps. Product transfer can be achieved by using 2 pumps running and one stand by
with a discharge rate of 190 m 3/ hr of each pump.
Accounting of product transferred to Marketing Terminal/ pipeline off take and Tank
Truck will be done by the flow meter provided in Metering Packages 205-A-035/ 205-A-
051and 205-A-002 to 005 respectively.
All 7 loading bays are provided with Tank Truck unloading facility. A vapour compressor
has been provided for this operation which is a common facility for both LPG and
Propylene. For Tank Truck unloading without disturbing the operations in other bays,
dedicated line up was given in Bay no. 1.
12 | P a g e
Pump Minimum Flow protection is ensured by the control loop recycling back to the inlet
of Bullets.
The off-spec LPG from bullets (205-V003/4/5/7/8/9/12/13/14) is pumped by 3x50% Off-

spec LPG transfer pumps 205-P-027A/B/C to the Fuel Gas Pool.
3.1 INSTRUMENTATION:
Each bullet is provided with two nos. of Level transmitters (One Servo and one Guided
Wave Rader gauge).The servo gauge is associated with multipoint temperature
transmitters which feeds the TGS. It also consists of a pressure transmitter which
generates High, High High, Low and Low Low alarms. High and Low level alarm is
provided in the TFMS for all the bullets. For High High and Low Low level in the bullet
safety interlocks has been provided. Details of all the safety interlocks are given in
Appendix-11
Instrument details for each bullet is furnished in Appendix-10
Each bullet consists of two PSVs to protect bullet from over pressurization. All lines are
provided with PSVs wherever necessary for protection against over pressurization during
thermal expansion. All PSV outlets are connected to LT flare. Detailed PSV location and
set pressures are given in Appendix-8
Flow control valves are provided at all pump discharge headers for pump minimum flow
by-pass.
Facility is also provided with Flame detectors and Gas detectors to detect flame and LEL
of air gas mixture at LPG pump house area, Tank truck loading area and Mound area.
The bullet inlet XZV in the receipt line closes at the High -High Level and the outlet XZV in
the dispatch line closes and pump trips at the Low-Low Level.
All LPG pumps are provided with pressure transmitters in the discharge line which trips
the pump at High High and Low Low pressure with alarm.
3.2 INTEGRATION BETWEEN REFINERY AND LPG STORAGE FACILITY:
The LPG storage facility has the following process streams and utility streams in
connectivity with the refinery.
The process streams are:
1. Receipt from refinery is from the following rundowns

FCC LPG
CCR LPG
AVU Depropaniser C3
Propane from Alkylation Unit
AVU Depropaniser Butane
Unsaturated C4 from Intermediate storage area
LPG from Alkylation Unit
Propane purge from PRU.
2. Off-Spec LPG transfer to Refinery Fuel Gas Pool, Alkylation and DCU.
13 | P a g e
The utility streams are:
1. Service water
2. Potable water
3. Plant air
4. Instrument air
5. Nitrogen.
For detailed parameters of the above streams refer APPENDIX-5
14 | P a g e
CHAPTER- 4
LPG STORAGE FACILITIES
4.0 LPG Storage facility has been equipped with the latest and state-of-art systems in
order to facilitate the receipt of LPG into mounded storage bullets, odourising, water
draining, dispatch to Marketing terminal, pipe line off-take and to tank trucks.
The facilities/systems are as under:
1. Mounded Bullets
2. Pumps
3. Pipelines
4. LPG Blending System
5. Ethyl Mercaptan Dosing
6. Instrumentation and Automation
7. Tank Truck Loading
8. Tank Truck Unloading/ Vapour Compression
9. LT Flare
10. Water Drain Pot
11. Electrical System
12. Fire Fighting System
13. Utility System
14. Fire & Gas detection system
4.1 MOUNDED STORAGE BULLET
LPG storage facility is provided with 09 mounded bullets, each having 2700 m³ (1500 MT)
working capacity.
The entire bullet assembly is placed inside a concrete mound filled with highly
compacted sand, which will act as protecting medium in case of any mishaps.
Mounded bullets are erected / placed on the compacted sand without any concrete
support. Mound is filled with compacted sand up to the top of the mounded bullets.
PVC and Terram sheets are provided over the compacted sand to prevent water
ingress. To drain out rain water, perforated PVC drain pipes are provided all around the
top of the mounded bullet. Since mounded tanks are completely buried, there is no risk
of any external source of fire impingement or thermal radiation affecting the safety of
the large capacity storage. So this type of storage will eliminate the possibility of Boiling
Liquid Expanding Vapour Explosion (BLEVE). This will reduce risk substantially compared
to the over ground pressurized Horton sphere or Bullets.
Bullets details are given in APPENDIX-1
4.2 PUMPS
The facility has different capacities of pumps used for product delivery to marketing
terminal, pipe line off-take, tank trucks and off-spec pumping to fuel gas pool/ alkylation
unit/ DCU.
Pump details are provided in APPENDIX:
4.3 PIPELINE DETAILS
15 | P a g e
Various sizes of pipe lines as detailed in APPENDIX- 3.0 & 3.1 are provided for receipt and
dispatch of LPG.
4.4 BLENDING SYSTEM:
The Blending System comprises of:
The LPG rundown streams are routed to the LPG auto Blender. LPG Blender consists
of BRCs, RVP analyzer & Blend Control System to maintain the desired RVP. 'LPG
Blending Control System' controls the recipe blending operation based on product
RVP.
(Refer Equipment Operating Manual for details).
4.5 ETHYL MERCAPTAN DOSING:
Ethyl Mercaptan is commonly used as the odorant for LPG because of its distinctive
smell. The assessment of odour level and the amount of ethyl Mercaptan to be
dosed are determined as per the guidelines given in IS :1448 - 1968 (P : 75) or
instructed by IOCL.
Dosing unit consists of a vertical cylindrical tank with nitrogen blanketing facility and
PSV connected with its out let to LT Flare.
Two nos of double diaphragm dosing pumps are provided (one running and one
stand by) and the delivery of the pumps is connected with a rotameter to know rate
of dosing inline with the requirement. Details of the facility given below.
Ethyl Mercaptan charging to the storage tank is done through an air operated
pump. Detailed procedure for dosing/ charging was given in SOP- .
205-P-105
ETHYL MERCAPTAN TRANSFER PUMP
CAPACITY @ suction cond. 0.40 m 3/hr
DIFFERENTIAL PRESS 2.0 Kg/cm 2
DIFFERENTIAL HEAD 23.8 mlc
205-VT-105
ETHYL MERCAPTAN STORAGE VESSEL
ID 750 mm
HEIGHT 1500 mm
DESIGN PRESSURE 3.5 Kg/ cm 2g
DESIGN TEMPERATURE 650C
205-P-043 A/B
ETHYL MERCAPTAN DOSING PUMP
CAPACITY @ suction cond. 15 LPH
4.6 INSTRUMENTATION AND AUTOMATION

4.6.1 AUTOMATION
16 | P a g e
LPG Storage Facility is equipped with State of Art Automation. It comprises of:
Fully Automated Tank Gauging System (TGS).

Distributed Control System,
Emergency Shutdown System (ESD) and Gas Detection System (GDS).
Fire Detection and Alarm Systems.
In-Line LPG Blending System during receipt.
Field Instrumentation and communication system
CCTV system
Paging communication system
VHF and Base station
Gas Detectors & Flame Detectors
Heat Detectors & Quartz bulb Detectors
CTMS
Pressure Relief and Blow Down System
Refer Manual on Automation for details.
4.6.2 Detailed list of XZVs Furnished in APPENDIX-6
4.6.3 PRESSURE RELIEF / BLOW DOWN SYSTEM
Each bullet has two safety relief valves at top vapour zone of the bullet to release LPG to
flare system in case of over pressurization of Mounded bullet. PSVs are designed for Fire
condition with each PSV having 100% relieving capacity.
Set pressure of safety valve is 18.5 kg/cm 2(g). Discharge of PSVs is connected to flare
system with lock open type isolation valves on both side of PSV.
PSV by pass line with double isolation valve is provided for manual depressurization
especially for M&I preparation etc.
Pipe Lines are also provided with PSVs where ever necessary. Details, location and set
pressures are given in APPENDIX-8
Tank truck loading facility, loading arms are also connected with LT Flare to blow down
the small portion between loading arms and tank truck inlet flange connection during
disconnection.
4.6.4 GAS DETECTION
GAS DETECTORS & FLAME DETECTORS
Gas detector & UVIR (ultra violet & Infrared) Flame detectors are provided which are
connected to Emergency Shut Down System. In case of any leak, gas detector system
sense the leak & give alarm in control room DCS.
4.6.5 HEAT DETECTORS & QUARTZ BULB DETECTORS:
Heat detectors & QBDs are also installed at various locations of LPG area. These are set
to blow off at 79 Deg. C or rate of rise in temperature is more than 15 Deg. F/Min.
Actions arising out of blowing off the detectors are connected to deluge valves and
17 | P a g e
indication of deluge sprinkler operation will be sounded in the Control Room.
1. All ROVs will be closed

2. Running pumps will trip
3. Deluge valves will open to start sprinklers
4.6.6 SAFETY INTERLOCKS, TRIPS AND ALARMS.
LPG facility is provided with various safety interlocks, trips and alarms system during
various operations carried out within the plant during receipt, storage and dispatch.
Detailed list of the above is given in APPENDIX-11
4.6.7 METERING SKIDS
During LPG dispatch to marketing terminal, pipe line off-take and tank truck loading
accounting of product will be done by the flow meter provided in Metering Package.
(Refer Equipment Operating Manual for details).
4.7 Tank Truck Loading/ Unloading Facility.
Fully Automated Truck Loading Bays comprising 22 Loading Arms (7 + 4 liquid loading
arms for LPG and Propylene respectively, 7 + 4 vapour balance arms for LPG and
Propylene respectively) 7 loading Bays: 7 LPG Bays (out of 7 bays, 4 are common for
LPG and Propylene) along with Metering Skid Facility. Additional two weigh bridges
installed at entry gate of each 50 MT for Tank truck weight measurement.
There are 2 Liquid headers from LPG and Propylene Pump House to respective Metering
Skids of 12” size, from Metering Skids to TLF 3” size. Each header along with bay/s is
dedicated for a particular product (LPG and Propylene).
There are 2 vapour headers from LPG and Propylene Bullet to vapour compressor is of 8”
size, vapour compressor to TLF 3” size. Each header along with bay/s is dedicated for a
particular product (LPG and Propylene).
For details of pumps, header and loading bay, please refer P & ID of PH and TLF bays in
the appendix.
Liquid and Vapour loading arms are connected to Flare, for venting of LPG within spool
between loading arms and Tank Truck after loading/ unloading completion. All the bays
are provided with SDV‟s to shutdown the loading in case of emergency.
There is a provision for unloading tank trucks in all bays, where as bay no. 1 can be
especially used for unloading operation without disturbing the operations in other bays.
4.8 LT FLARE
All the PSV outlets are connected with LT Flare.

Following Major Facilities are installed for the LT Flare System:
1. Flare Header
2. LT Flare Stack (220-FL-007 A/B)
3. LT Flare Tip (220-A-007 A/B)
4. Flare ignition control package (220-A-008)
18 | P a g e
5. Flare Meter (Ultrasonic flow meter with Pressure & temp. compensation)- with alarms
at Low & High figures (FIA-0036, PIA-0051, TIA-0027)
6. Provision of Steam/Instrument air lines
7. Provision of Fuel gas/N2 supply line
8. Piping system including valves, fittings etc. connecting LPG Pressurized Storage &
Propylene mounded storage area
4.10 WATER DRAIN POT
If any water is found in LPG bullet will drained as per the SOPXXXXX. The drained water
will be routed to Water Drain Pot through a closed loop system.
(Refer bullet water draining procedure for details).
Details of the Water drain pot is as under:

205-VT-110
WATER DRAIN POT
ID 1900 mm
HEIGHT 4300 mm
DESIGN PRESSURE 3.5 Kg/cm 2g
DESIGN TEMPERATURE -450C/ 650C
4.11 ELECTRICAL SYSTEM
The electrical set-up in the Product side is as follows:
Power Transformers (312N-205-TR-301/302)
There are two 66 KV / 6.6 KV Power Transformers for the incoming power source. The
secondary of the Power transformer is fed to 6.6 KV HT Panel 312N -205-SG-301.
Distribution Transformers (312N-205-TR-401/402/403/404)
There are four numbers of 6.6 KV / 0.415 KV Distribution Transformers. The incomer of the
Distribution Transformers is from the 6.6. KV HT Panel and the outgoing are fed to the
PMCC Panels.
6.6 KV HT Panel (312N-205-SG-301)
The HT Panels includes power feeder to the HT Motors and also to the Distribution
Transformers. There are 30 no HT Motors in all.
Power & Motor Control Centre (312N-205-SG 401/402)
There are two PMCCs which are utilised for feeding the power to Motor Control Centres,
LT motors, Power Distribution Boards and Main Lighting Distribution Boards.
Motor Control Centres (312N-205-MCC-401/402)
There are two Motor Control Centres for LT motors power feeding.
Main Lighting Distribution Boards (312N-205-DB-401/403/405)

19 | P a g e
There are three numbers of MLDBs to feed power for Building lighting, Tank Lighting,
Pump House Lighting, High mast lighting.
Power Distribution Boards (312N-205-DB-402/404/406/407)
The Power Distribution Boards are utilised to feed the power to Welding Sockets,
Metering House, Pressurisation Units, and Power Panels in buildings, EOT cranes, Air
Monitoring Station, Flare package, MOV Distribution boards and others.
Essential Services Board (312N-205-DB-501)
The Essential Services Board is utilised to distribute power from the DG set during power
failure.
350 KVA DG set (312N-205-DG-501)
One 350 KVA DG set is located near the Substation for power supply in case of failure of
the main incomer supply. The DG set is synchronised with the main power via AMF Panel
and supplies the power at critical locations through Essential Services Board. The DG
power is for the below mentioned purposes -
i) Emergency Lighting for Substation SS312N, SRR 819, OMS 801, SMB 492, Operator‟s
Shelter room 485-7.
ii) Supply for UPS in SRR & OMS Rooms: 801 –205-UPS-501 , 801 –205-UPS-601,
819 –205-UPS-501, 819 –205-UPS-601
iii) Substation DCDB (110V): 312-205-DCB-701
Uninterrupted Supply System
The terminal consists of four nos of UPS systems for Critical services. They are as under:
801 –205-UPS-601: Supply for DCS , ESD, GDS, F&G, Metering House I,II,III & IV, Analyser
Shelter for LPG & Diesel.
801 –205-UPS-501: Supply for Telecommunication, PA/GA system and PMS
819 –205-UPS-601: Supply for DCS, ESD, GDS, F&G and Tank Gauging System
819 –205-UPS-501: Supply for Telecommunication, PA/GA system and PMS
Substation Automation System:
The SAS panel (312N-205-SAS-901) shall regulate and monitor the complete
integration of the substation 312N. Consisting of Numerical relays and SCADA, SAS
will mainly perform the following functions:
Protection of the equipments
Fault monitoring and fault distance calculation.
Creating and Monitoring the Switching sequences for optimal efficiency.
SRR & OMS buildings
The SRR & OM&S control room shall be the centralized operating point for oil
movements/ storage and transfer which will be interfaced to MCR, utility services control
room and the jetty side control room at the port. The other specialized control system
20 | P a g e
shall be for machine monitoring, custody transfer flow metering system, GDS (Gas
Detection System) and TGS (Tank Gauging System).
The control systems requirements for the project are outlined herein.
The following facilities shall be provided:-
1. Distributed Control System

2. Emergency Shutdown System
3. Fire Detection and Alarm System
4. Gas Detection System
5. Machinery Monitoring System
6. Analyzer Systems
7. Metering Systems
8. Auxiliary Systems (e.g. Tank Gauging etc)
9. Other Control and Instrumentation Systems as required
10. Field Instrumentation
CATHODIC PROTECTION SYSTEM
Prevention of corrosion of Bullets in sand mounded structures very important both from
the safety and life time operational point of view. The Cathodic Protection System
implemented here is the Impressed Current Cathodic Protection System.
Purpose Description Qty.

CP Transformer Rectifier Unit 02
Mounded Bullets Anode Junction box 04
Cathode Junction box 02
4.12 FIRE FIGHTING SYSTEM
The Fire Fighting System comprises of Fire water ring main, deluge and sprinkler system,
double hydrant with hose box, water monitors, DCP, CO2 and manual call points etc.
For the detailed operation of the system refer Fire Fighting Manual.
Location and nos are provided in APPENDIX-13,14,15
4.14 UTILITY SYSTEM:
Utilities required for this facility is received from IOCL Refinery.
The following Utility facilities have been provided in the battery limit:
Service water: Service water is supplied through a 2" piping network and to the bullets
and tank truck loading area through a 3/4" piping network.
Cooling water: There is a provision of 3" piping network to supply and return cooling
water to the facility.
Plant Air: There is a 2" plant air header connected with Ethyl Mercaptan dosing facility.
Instrument Air: There is a 2" instrument air header in the battery area.
21 | P a g e
Nitrogen: There is a provision to supply Nitrogen to tanks through a 2" piping network, also
there is a 1" piping network to supply nitrogen to pump house.
Potable water: There is a provision of 2" piping network to supply potable water to the
facility.
For details on parameters of utility system refer Appendix-5
22 | P a g e
CHAPTER-5
OPERATING PHILOSOPHY
The operating philosophy for LPG receipt, dispatch, Inter Bullet Transfer(within same
Mound Bullets or between the Bullets in Mound-1 & Mound-2), Water Draining and
sampling are described as under:
5.1 LPG RECEIPT:
LPG on-spec, off-spec and blending spillage is received through rundown lines from
refinery. Receipt finalization will be done after water draining if any, using bullet level,
temperature, pressure and density.
LPG receipt from the refinery will be on round the clock basis from different units through
different dedicated rundown lines depending upon their plant running and production
basis. The LPG receipt through pipeline from the refinery is hooked up with the Mound -1
(6 bullets) and Mound-II (3 bullets) inlet common header to enable the receipt to all
bullets as per the receipt plan.
5.2 LPG DISPATCH:
LPG dispatch will be done to Marketing Terminal, Pipe line off-take (PBKD) and tank truck
loading.
From the bullets pressurized LPG is pumped to the Marketing Terminal, pipeline off take
and truck loading using 6 nos (205-P-001A/B/C/D/E/F) of Can Type Centrifugal vertical
pumps located in two pump houses (PH-05 & PH-06) in each consisting of 3 pumps.
Product reconciliation during this dispatch operation will be done by the flow meters
provided in Metering Package (205-A-035, 205-A-051 & 205-A-053)
The off-spec LPG from bullets is pumped back to refinery using Off-spec LPG transfer
pumps (205-P-027A/B/C) and the product reconciliation will be done using bullet level,
temp and pressure (opening and closing).
5.3 LPG Inter Bullet Transfer:
For LPG product transfer between the bullets within the same mound (Mound-I or Mound
–II) and within the bullets of different mounds (Mound-I & Mound –II) can be done using
the same product transfer pumps (205-P-001 A/B/C/D/E/F). However, only one pump
shall be used for Inter bullet transfer service at a time. A hook up between the two inter
bullet transfer return headers is also provided to facilitate transfer from one set of bullets
to other.
Product reconciliation (receipt bullet/ dispatch bullet) will be done based on bullets
level, temperature, pressure and density.
5.4 WATER DRAINING:
After LPG receipt bullet re-circulation will be done for minimum 4 hours (batch formation)
and then one hour settlement time will be given.
23 | P a g e
After settlement check for the water presence, if found then water draining will be done
as per the procedure.
5.5 ETHYL MERCAPTAN DOSING:
To odourise LPG prior to dispatch, Ethyl Mercaptan was used as odourising agent during
receipt/ batch formation of the product.
For this purpose, dosing system was provided with two sets of pumps.
Quantity of Ethyl Mercaptan added to LPG will be assessed through the dosing tank
calibration.
5.8 LT Flare
The LT flare system disposes off low temperature (below 0°C) & low pressure
(atmospheric) discharges which originate mainly from LPG and Propylene storage &
transfer system.
The pilot burners (at flare tip) are fed by fuel gas & instrument air (from battery limit with
flow monitoring); the ignition panel ignites the pilot burners by flame-front ignition. Each
pilot is fitted with its dedicated flame detector to monitor the constant flame presence
since that sustains stable combustion under all flaring and design conditions.
24 | P a g e
CHAPTER- 6
CONTROL PHILOSOPHY
6.1 LPG Storage and Transfer System
Product area has got two control rooms OM&S 801 and SRR 819. OM&S 801 comprises of
DCS (redundant), a common PLC for ESD and GDS with a redundant one, PLC for FDAS
(redundant), TGS, PA system and CCTV. In the building 801 there are about fifteen
operator consoles are present for all above mentioned systems.
The control system is powered by two UPS system having rating of 125kva and 25kva
respectively. DCS is the primary operating window for tankage facilities and other field
equipments. ESD+GDS system is also connected to DCS network through serial
communication. The FDAS PLC is also connected to the DCS network through serial
communication. All substation (SS 312N) signals like PMCC, MCC HT switch gear are also
connected through serial communication. The DCS and PLC networks are of Ethernet .
Fire alarm panels are provided for buildings (OM&S technology, SS building and drivers
building) are all connected to FDAS system through Ethernet network.
ESD and GDS systems are having Common PLC (redundant) which takes the input from
different Field Transmitters. FDAS is controlled by separate PLC (redundant) with inputs
from across the field. OM&S 801, SS 312N and Operator drivers building and OM&S
technology building are having Fire Alarm Panels (FAP#1, FAP#3, FAP#2 and FAP#4
respectively) which are interfaced to FDAS system at OM&S, which also receives signals
from Field Mounted Fire Detectors through Marshalling cabinets.
Substation Automation System located in SS 312N (substation) is connected to DCS

Ethernet through Serial Gateways which in turn act as an Interfacing Unit between DCS
and MCC/PMCC/PMC(IOCL). Operator Shelter is equipped with one number of DCS
Operator Console from where Engineer can monitor the Tankage Operations.
SRR 819 also consists of DCS,PLC for GDS+ESD(redundant), PLC for FDAS,TGS , PA system
and CCTV facilities. The control system is powered by two UPS supply having rating of
35kva and 15 kva. The FDAS and ESD+GDS plcs of both OM&S 801 and SRR 819 are
interconnected via safety network (Ethernet).All the buildings are interconnected
through fibre optic cable. The operator shelter is also connected to SRR 819 through fiber
optic cable. The FAP of operator shelter and SMB building are connected to FDAS
system of SRR 819.
Bullet gauging system mainly comprises of two types of guided wave gauges one is
radar gauge and other one is servo gauge. Power Supply to these Gauges is from UPS.
The signals from Bullet Gauges come to Communication Interface Unit in SRR-819 and
which in turn is connected to DCS Ethernet Network and Tank Farm Management
System(TFMS) provided at control room. Hardware Consoles have been provided in
each control room to indicate the signals of field instruments in the control room.
6.2 SAFETY INTERLOCKS (ESD): Furnished in Appendix-8
6.3 ALARMS AND TRIPS: Furnished in Appendix -9
6.4 RELIEF VALVE SETTING: Furnished in Appendix –10
25 | P a g e
CHAPTER-7
ROLES and RESPONSIBILITY
This chapter describes the responsibilities to be assumed by IOCL Refinery, IOCL

Marketing Terminal, IOCL pipe line division and IOT during operations.
8.1 ROLE OF IOT and IOCL Refinery
ROLE OF IOT:
 Receipt, storage and dispatch of LPG, Off-spec LPG as per BOOT agreement
 Preparation of documentation related to stock accounting, logbook and Loss or
gain.
 Joint inspection of bullet level, temperature and pressure of Bullet, sampling with
IOCL refinery/ his representative before and after each receipt and transfer
operations.
 Coordination with IOCL Refinery for receipt and dispatch operations.
 Maintain reliable communication with IOCL refinery, Marketing and Pipeline division.
ROLE OF IOCL REFINERY

 Planning and Coordination with IOT, Marketing division, Pipeline division, Excise,
Surveyor for various activities related to receipt and dispatch of LPG.
 FAN and Invoice generation in SAP for LPG Tank Truck loading/ unloading against
IOT‟s TAS invoice in MT/ Kg.
 Nominating representative for initial/ final bullet out turn finalisation for the receipt/
dispatch operations, Bullet Sampling, monitoring of operations etc.
 Testing of samples in the Refinery Laboratory.
 Provide reliable communication between IOCL refinery main control room,
marketing and pipeline division and IOT.
 Excise related formalities.
 Round the clock security of pipeline beyond BOOT-3 battery limit.
8.2 RESPONSIBILITY OF IOT OFFICERS
1) OPERATIONS-IN-CHARGE: PRODUCT AREA
He is the FPR (First Person Responsible) who has the overall responsibilities of all
Operations and maintains the Work instructions.
His scope of work:
Execution of from refinery, storage and dispatch to marketing terminal, pipe line
division and tank trucks etc. as per SOP.
Regular Co-ordination with client (IOCL).
Stock loss control within target as per agreement with IOCL
All licenses maintenance and re-validation including payment of statutory fees as
applicable.
To maintain all As-Built drawings, certificates, license copies, etc
Daily inspection of the facilities through nominated officers
Housekeeping of facilities of both office and field
Facility modification work as required from time to time by IOC
To monitor all maintenance and AMC works
Automation and maintaining their efficiency
Quality and Quantity
Planning & Co-ordination
26 | P a g e
Reports/ Documentation.
2) SHIFT IN-CHARGE: PRODUCTS

He is the FPR (First Person Responsible) for overall implementation of all shift operations,
Disciplined by Operations-in-charge.
His scope of work:
Overall in-charge in the shift for all activities.
To monitor shift activities.
To ensure safe operations for all hot, cold, electrical and height work.
Stock Accounting and daily activity reporting.
Supervise all operations on regular and surprise basis and record to be maintained.
To assign duty to other engineers on daily basis.
Issuance of all work permits to be authorized by Ops – In charge.
Deployment of contract workers for assistance in various activities at various
locations.
Overall coordination and communication for various operations.
Coordinating and Communicating with IOCL Refinery, IOC marketing and pipe line
division, shift officers for smooth operation
Keep a close watch at the bullet levels and monitoring switching over activities.
Overall control of operations
3) SHIFT ENGINEER:
He is the FPR (First Person Responsible) for conducting the work specified within the
Work Instructions.
His scope of work:
Overall up keeping / housekeeping of the facility(Cleanliness/valve greasing/
painting/ Sign Boards/Fire extinguishers/Line indicators etc)
Supervise all operations
Ensure safe operations
To take care of / supervise all maintenance, modification jobs (Repair, Blinding/De-
blinding, Hot work, Cold work, Excavation, Confined space).
To ensure work-in-progress as per planning, as per SOP, as per Permits issued.
Get/verify issued proper permits for all maintenance jobs.
Leakages, defects and any abnormalities to be reported immediately to concerned
heads.
Ensure disposal of waste products, hoses, trays and drums to nominated area.
Illumination Status. Report if found insufficient. Initiate to solve the problem.
Ensure masking tapes and bonding (with copper strips/wires) for all flange joints.
Ensure Fire Extinguishers status (whether available at specified locations, working
conditions, and serviced status).
Section I/C to maintain Log Book on shift basis. Enter each and every defects, events,
leakages and action taken as rectification.
Compliance reporting with the help of Daily, Monthly, Quarterly, Half yearly and
Yearly Checklists.
Suggestions to improve operations and any other areas.
Ensure to start work only after acquiring relevant work permits. Maintain records of all
permits.
Preventive maintenance checks.
8.3 CONTACT DETAILS
IOT:
1) Occupier:
27 | P a g e
Name: Debashis De
Contact no.: +919937577158
Email id: debashis.de@oiltanking.com
2) Products Operations-in-charge
Name: NV Subrahmanyam
Contact no.: +919178466140
Email id:nimishakavi.subrahmanyam@iotinfraenergy.com
3) Maintenance-in-charge
Name: Madhukar Chatlawar
Contact no.:+919178466077
Email id: madhukar.chatlawar@oiltanking.com
4) Shift in-charge
Contact no.:
Email id: shiftinchargeproducts@gmail.com
5) HSSE in-charge
Name:
Contact no.:
Email id:
IOCL REFINERY:
1) Officer in charge
Name:
Contact no.
Email id:
2) Control Room Officer

Name:
Contact no.
Email id:
3) Fire Fighting Chief:

Name:
Contact no.
Email id:
IOCL Marketing Terminal:
1) Planning and Coordination Officer:

Name:
Contact no.
Email id:

Name:
Contact no.
Email id:
28 | P a g e
Name:
Contact no.
Email id:
IOCL Pipe line division:
1) Planning and Coordination Officer:

Name:
Contact no.
Email id:
Name:
Contact no.
Email id:
Name:
Contact no.
Email id:
29 | P a g e
PART-II
STANDARD OPERATING PROCEDURE
30 | P a g e
CHAPTER-8
MODES OF OPERATION and OPERATING PROCEDURE
OPERATION MODE FOR RECEIPT and DISPATCH:
8.1 RECEIPT MODE:
LPG is received from refinery via rundown lines through blending unit and inline static
mixer to the designated bullet.
Off-spec/ blending spillage will be received in another designated bullet.
Receipt Pipeline Set Up:
For receipt from refinery, nine rundown lines are laid of various sizes (3”, 4”, 6”, 8” and
10”) up to blending unit.
From blending unit, 12” line is running up to Mound-I. In this main header 12” tapping are
provided for individual bullet inlet.
Sampling:
Joint sampling Bullets is done after every receipt from Refinery and Inter Bullet Transfer
operation. Samples taken are sent to IOCL for lab analysis; receipt out turn is prepared
based on the density given in lab report.
Communication
For effective communication between Terminal, Refinery and Field VHF based station
along with handheld Radios are provided. Phone lines provide additional means of
communication between Refinery and Terminal. Before the commencement of
operation, ensure effectiveness of communication system.
Safety:
The entire safety requirement of the pipelines for the receipt operation of LPG beyond
the battery limit of BOOT-3 finished product site is fulfilled by IOCL and the entire safety
requirement of the Bullets, associated pipelines and equipments for receipt within BOOT-
3 limit is furnished by IOT.
PSV to be kept lined up to release pressure developed in the line due to thermal
changes.
Leakage of any kind should be arrested prior to PLT operation by IOCL outside battery
limit.
Documents:
Documentation related to receipt operations such as log sheets, Out Turn Reports etc to
be prepared by IOT and retained under custody of IOT.
8.2 DISPATCH MODE:
LPG is dispatched via Pipeline to Marketing terminal, Pipe line off-take and loading of
tank trucks at loading gantry.
31 | P a g e
Dispatch Pipeline Set Up:
For dispatch from individual bullets 18” discharge headers are connected with 18”
common discharge line up to pump house.
12'' dedicated pipeline setup is provided to transfer LPG from pump house to Marketing
Terminal and Pipe line division through Metering Skids 205-A-035 & 205-A-51 respectively.
10” tap off pipe line from 12” pump delivery header to TT loading gantry up to metering
skid 205-A-053 after that 3” pipe line to individual loading bays.
Sampling:
Prior to Tank truck loading/ dispatch to Marketing Terminal or Pipe line transfer
nominated Bullet sampling is done, if required; sent for lab analysis and out turn report is
prepared based on the density given in the lab report else the receipt finalized samples
with lab analysis report can be referred for Out Turn Finalisation and quality assessment..
Communication
For effective communication between Terminal, Refinery, Marketing, Pipe line division
and Field VHF based station along with handheld Radios are provided. Phone lines are
provide as additional means of communication between Refinery, Marketing, Pipe line
division and Terminal. Before the commencement of operation, ensure effectiveness of
communication system.
Safety:
The entire safety requirement of the pipelines for the dispatch operations of LPG beyond
the battery limit of BOOT-3 finished product site is fulfilled by IOCL and the entire safety
requirement of the Tanks, associated pipelines and equipments for dispatch operations
within BOOT-3 limit is furnished by IOT.
PSV to be kept lined up to release pressure developed in the line due to thermal
changes.
Leakage of any kind should be arrested prior to PLT operation by IOCL outside battery
limit.
Documents:
Documentation related to dispatch operations such as log sheets, Out Turn Reports etc
to be prepared by IOT and retained under custody of IOT.
8.3 Tank Truck entry set up & document.
Types of Tank Truck:
Generally Tank trucks are of standard type (OISD 159) only. Usually the Tanks have single
compartment.
Construction & fittings:

1. Tank : Cylindrical Steel tank.
2. Master Cut off Switch should be provided.
3. Wiring : Wiring should be double pole conduit and not exposed.
4. Double pole wiring should be provided.
32 | P a g e
5. Earthing Cleat should be provided.
6. Junction box provided & in working condition.
7. Fire Screen should be provided. It should fully cover the tank as per approved
drawing.
8. Spark Arrestor of ISI mark should be welded to exhaust pipe.
9. Pressure-safety valve provided.
10. Other fittings: Baffle plates inside tank, safety valve (PV valve), manhole cover,
pressure gauge, rota gauge, .
11. Drivers cabin made of steel and if made of wood then should be covered with Steel
(Fire Screen).
12. Hazchem sign, name of contractor with address and telephone No. displayed
prominently.
13. Locking arrangement as required by IOCL.
Requirements to be complied by TT are -

1. Valid Explosive License and drawing.
2. Driving license authenticated for hazardous goods.
3. VALID CERTIFICATE FROM „RTO‟ (R.C. AND F.C)
4. Valid Calibration Chart.
5. Liquid and Vapour nozzles with isolation valve in good condition.
6. Carries 2 nos. 10 Kg. DCP extinguishers in easily accessible and removable position
with Truck No. date of checking and charging painted on it and 1 no. of 2 Kg CO 2
extinguisher in the driver cabin.
7. First Aid Box and emergency kit (radium cone, safety ribbons etc.)
8. Shear section on discharge pipe should be provided.
9. Emergency information panel correctly displayed as MV Act 1988.
10. Transport Emergency Card (TREM CARD)
11. SPARE WHEEL
12. NO VISIBLE DENT OR CORROSION ON THE BULLET
13. Tool box containing Leather hand gloves and heat resistant hand gloves, Safety
Goggles , 2 nos. red flags non-metallic tools, wooden plugs of appropriate size and
sealing compound.
Capacity:
TTs come in capacities ranging from 6 MT to 18 MT.
Safety
TT should have all the fittings as mentioned in construction & fittings. TT should comply all
the requirements mentioned above. Overfilling is to be avoided for serious fire hazards.
Sick TTs are to be strictly rejected.
Document: Indent is to be registered with IOCL S & D for requirement of product by the
IOCL. IOCL will appoint suitable transporter who will provide TT that fits into above-
mentioned criteria.
8.4 OPERATING PROCEDURE BULLETS
8.4.1 BULLET OPERATIONS IN NORMAL CONDITION
Refer file-PBT/Ops/ M/ V-03, Chapter- 10
8.4.2 BULLET OPERATIONS IN EMERGENCY CONDITIONS
33 | P a g e
Refer file-PBT/Ops/M/ V-03, chapter- 11
8.7 DOCUMENTED OPERATING PROCEDURE:
REF. DOCUMENT OF OPERATING

OPERATIONAL ACTIVITY
PROCEDURE
BULLET COMMISSIONING IOT/ PBT/OM/03/ BULLET, Chapter- 4
BULLET PRE-COMMISSIONING IOT/ PBT/OM/03/ BULLET, Chapter- 3
BULLET DE-COMMISSIONING IOT/ PBT/OM/03/ BULLET, Chapter- 5
BULLET SAMPLING IOT/ PBT/OM/03/ BULLET, Chapter- 8
BULLET CLEANING IOT/ PBT/OM/03/ BULLET, Chapter- 6
BULLET WATER DRAINING IOT/ PBT/OM/03/ BULLET, Chapter- 7
BULLET STOCK ACCOUNTING IOT/ PBT/OM/03/ BULLET, Chapter- 9
PIPELINE COMMISSIONING
PIPELINE DE-COMMISSIONING
PIPELINE BLOWING
PIPELINE CLEANING
PIPELINE PRESSURE TESTING
PIPELINE STRIPPING
PUMP START UP
PUMP SHUT DOWN
LPG BLENDING SYSTEM
VAPOUR COMPRESSION
CTMS
LT FLARE
DCS/ ESD/ FDAS
WATER DRAIN POT
34 | P a g e
CHAPTER-09
OPERATIONAL ACTIVITIES
1) LPG Receiving from RUNDOWN LINES:
LPG is received from refinery through the run down lines. All operations for receiving of
LPG from refinery are done by IOT in co-ordination with IOCL.
(For detailed procedure refer LPG receipt SOP in Chapter-10)
2) Off-LPG Receipt from Refinery:
Off-LPG is received from refinery through a dedicated pipe line. All operations for
receiving of LPG from refinery are done by IOT in co-ordination with IOCL.
(For detailed procedure refer LPG receipt SOP in Chapter-11)
3) LPG bullet batch formation:
LPG recirculation: LPG recirculation for minimum 4 hours is done in order to circulate
product in the bullet using pump for homogenizing the product. Every Bullet is
recirculated before sampling and subsequent deliveries. (For detailed procedure refer
file-PBT/Ops/M/ V-03, Chapter-13)
Water Draining: After receiving LPG into the bullet, it is to be re-circulated and allowed
for minimum one hour settling. After settling, water is drained off from the bullet if
present. Bullet water draining implies to draining of accumulated alkaline water settled
in the bullet. The water is drained to water draining pot through a closed loop insulated
piping system. (For detailed procedure refer file-PBT/Ops/M/ V-, Chapter- 7)
Sampling: A liquid sample is transferred from the source into a sample container by
purging the container and filling it with liquid LPG to 80% of the capacity. Different
sampling bombs are to be used for drawing samples for different tests like vapour
pressure, density, volatility and copper corrosion.
4) LPG pumping to Marketing Terminal:
The LPG from the bullets is pumped to IOCL marketing terminal after getting clearance
from IOCL. Accounting of product transferred will be done based on Metering Skid. (For
detailed procedure refer SOP of Chapter-15)
5) LPG pumping to Pipe Line Division:
The LPG from the bullets is pumped to IOCL pipe line off-take (PBKD) after getting
clearance from IOCL. Accounting of product transferred will be done based on
Metering Skid. (For detailed procedure refer SOP of Chapter-17)
6) LPG product dispatch through tank trucks:
LPG transfer to tank trucks will be done through Metering Skid in 7 bays at tank truck
35 | P a g e
loading gantry.
7) LPG tank truck unloading:
LPG tank truck/ sick truck unloading is done in bay no.1 at tank truck loading gantry.
Bay no. 1 was having dedicated unloading facility to carry out unloading operation,
without disturbing the other bays loading operations.
For detailed procedure refer LPG tank truck unloading SOP chapter-18)
8) Off-spec LPG Transfer Refinery:
The Off-spec LPG from the bullets is pumped back to IOCL refinery after getting
clearance from IOCL. Accounting of product transferred will be done based bullet level,
temperature, pressure and density. (For detailed procedure refer SOP of Chapter-19&20)
9) Inter Bullet Transfer of LPG:
To resolve the ullage and quality problem if any, it is required to carry out inter Bullet
transfer of LPG (bullets within the same mound or between two mounds) on advice from
Refinery. IOT undertakes inter Bullet transfer of LPG. (For detailed procedure refer Crude
SOP- Chapter-14).
10) Ethyl Mercaptan Dosing:
To odourise LPG prior to dispatch, Ethyl Mercaptan was used as odourising agent. Ethyl
Mercaptan dosing will be done to LPG during receipt through the Mercaptan dosing
pumps.
If the Mercaptan dosing is not sufficient, provision is having for dosing operation during
batch formation.
THE FOLLOWING SAFETY, HEALTH AND ENVIRONMENTAL REQUIREMENTS TO BE FOLLOWED

IN ALL THE BOVE OPERATIONAL ACTIVITIES
 Only Authorised / Competent Personnel shall conduct the work outlined in this Work
Instruction.
 Use of Personnel Protective Equipment (PPE) as specified in the Terminal Health
Safety Security Environment (HSSE) Policy is mandatory.
 Material Safety Data Sheet (MSDS) of LPG is available and field officers should be
aware of the hazards and precautions to handle the cargo.
 Any leak found in the system is arrested immediately and the record of the same is
maintained.
 In case of Pipe line transfer operations, emergency stop procedure shall be clearly
communicated to Marketing/ Pipe line division and should stop the discharge
operation immediately any time at the request of the IOC officer.
36 | P a g e
CHAPTER-10
LPG (ON-SPEC/ BLENDING SPILLAGE) RECEIPT
10.1 OBJECTIVE:
The objective of the SOP is to define the general procedure for LPG receipt from IOCL
refinery division to LPG storage bullets via rundown lines.
10.2 SCOPE:
The SOP is applicable for all LPG receipt operation from IOCL refinery division to LPG
storage bullets through Blending Unit within LPG terminal.
10.3 DESCRIPTION:
The LPG rundowns streams from the process units shall be received in the offsite LPG
storage Bullets via Blender header. The LPG component rundown streams for blending of
LPG are as follows
1. FCC LPG
2. CCR LPG
3. AVU Depropaniser C3
4. Propane from Alkylation Unit
5. AVU Depropaniser Butane
6. Unsaturated C4 from Intermediate storage area
7. LPG from Alkylation Unit
8. Propane purge from PRU.
The LPG rundown streams are routed to the LPG auto Blender. LPG Blender consists of
BRCs, RVP analyzer & Blend Control System to maintain the desired RVP. 'LPG Blending
Control System' controls the recipe blending operation based on product RVP.
Blended LPG Product is routed to normally one of pressurized storage bullets (205-V-
3/4/5/7/8/9/12/13/14) lined up for receiving. The LPG product rundown line to bullet is
back pressure controlled at the downstream of static mixer near blender to maintain C3
streams in liquid phase.
10.4 SPECIFIC OPERATIONAL REQUIREMENTS:
1. No LPG receiving operation shall be conducted without instruction from Officer in-
charge of IOCL.
2. Receipt plan shall be developed (as per instructions of the IOCL Refinery) by IOT.
3. Receipt plan is verified by the Products Operations-in-charge and executed by Shift-
in-charge.
4. Control Room to ensure that the Field Officers are fully aware of all operation within
the LPG bullet area. Continuous, short, precise and clear communication is
maintained between Control Room Officer and Field Officers during Receipt
Operation.
5. All the activities in the storage facility are carried out as per the Work Instructions and
instructions from Control Room. Field Officer should notify the Control Room upon
completion of all tasks.
6. In case bullet is to be commissioned, to be reinstated to services after cleaning/
maintenance work, obtain “Bullet and connected pipeline fitness certificate” from
37 | P a g e
IOCL nominated surveyor/representative.
7. Pre-commissioning checklist to be checked when receipt to be done during
commissioning or in empty Bullet or after maintenance of the bullet.
8. Ensure that the receipt line and bullet is free from air (either purging with LPG vapour
is completed-refer bullet commissioning procedure for details).
9. Receiving operation shall commence at minimum rate to avoid generating static
electricity accumulation in empty bullets.
10. Receiving rate is maximized if the receiving bullet level reaching the inlet pipe inside
the bullet (1.2m).
11. Storage bullet should not be filled up above safe level. A high-level alarm is set below
safe level to warn the Control room officers. The High-high alarm is set at maximum
safe fill level which will automatically close the receiving SDV of bullet once it is
actuated. In the event that the level to be raised above safe level, a Management
of Change (MOC) must be raised prior to conducting the task with authorization
from IOC.
12. Positive flow rates to be ensured during receipt operation in one or two bullets as
there can be a reverse flow if any rundown line stops or reduces the discharge rate
or during receiving bullet switch over.
13. Communication- For effective communication between Refinery storage, IOCL
refinery Control room and IOT, VHF base station along with handheld radios and
telephones are provided. Before commencement of operation, ensure effectiveness
of communication system.
14. Continuous, short, precise and clear communication is maintained between Control
Room Officer and Field Officers during Receipt Operation.
15. Ensure next receipt bullet is ready prior to first bullet top up.
10.5 RESPONSIBILITY:
IOCL Refinery’s role:
 Production planning of LPG and dispatch to BOOT storage facility.

 Maintaining flow rates during initial start up if the lines are empty.
 Providing required data for blending ratios.
 Overall co-ordination for the smooth operation.
 Initial and final quantity assessment, out turns preparation in coordination with IOT for
the receipt operations.
 Excise related formalities, documentation etc for the receipt and storage operations.
 Appointing surveyor for sampling.
 Product quality assessment and samples retention.
 Providing sampling bombs.
 Supply of required quantity of Ethyl Mercaptan as required for odourising.
IOT’S ROLE:
 Coordinate with IOCL officers for receipt operations.

 Preparation of LPG bullet for receipt.
 Line ups from BOOT 3 battery limit to bullets for the receipt of on-spec/ off-spec LPG.\
 Joint reconciliation of the receipt operations with IOCL/ IOCL representative.
 Documentation and preparation of outturn reports (before and after receipt).
 The Operations-in-charge is overall responsible for maintaining the quality of this Work
Instruction.
 The Shift Manager is responsible for overall implementation of this Work Instruction.
38 | P a g e
 The CCR Officer and Field officers are responsible for conducting the work specified
within this Work Instruction.
10.6 PREPARATION
S.No. Description FPR

1 A Receipt plan developed in the control room and verified. SI/OI
The required order prepared for the Receipt operation and work
2 SI/OI
instructions are printed accordingly.
IOCL/ IOCL representative available at terminal prior to receipt
3 SI/OI
operation for initial out turn preparation.
Discharging nominations, initial rates and max rates agreed with
4 SI/OI
IOCL and documented in the receipt Logbook.
Close all the inlet and outlet valves of the receipt bullets (on-spec
and blending spillage). Note down the opening level,
5 FO/OI
temperatures, pressures and densities and prepare joint initial out
turn report.
Ensure next bullets (for the receipt of on-spec and blending spillage)
6 FO/SI/OI
are ready and the out turn report was prepared.
7 Confirm from IOCL, the qty of LPG receipt per hour and calculate
SI/OI
the qty of Mercaptan to be dosed during receipt.
8 Ensure sufficient quantity of Mercaptan is available in the dosing
tank, and the system is in working condition. If quantity of SI/OI
Mercaptan is not sufficient then charging to be done as per SOP……
9 Establish proper communication between refinery, field and control
SI/OI
room.
10 Ensure LPG blending system was taken in line and is in working
FO/SI/OI
condition.
11 Ensure vapour balancing was done to other bullet from the receipt
FO/OI
bullet.
12 Ensure all Hand Operated Valves in receipt line are in working
FO/OI
condition and no leaks.
14 Ensure all instrumentation and automation system provided in LPG
FO/SI/OI
receipt lines in working condition.
15 Open LPG receipt run down line valves at battery limit and ensure
FO/OI
no leaks.
16 Check all Flow Control Valve upstream and downstream valves are
FO/OI
open and bypass valves closed.
17 Open LPG blending unit upstream valves. (Confirm from IOCL about
FO/OI
the running units and open that particular run down line valves)
18 Open 12” upstream and downstream valves of PDV 1001 and ensure
FO/OI
no leaks.
19 Close 12” bypass valve for PDV 1001. FO/OI
20 Open 8” valve in vapour inlet/ outlet line of vapour balancing bullet. FO/OI
21 Open 8” valve in vapour inlet/ outlet line for LPG receipt bullet. FO/OI
22 Check other bullets 10” blending spillage valve is fully closed. FO/OI
23 Open 10” blending spillage inlet line for the blending spillage receipt
FO/OI
bullet and ensure no leaks.
24 Check other connected lines to inlet header of receipt bullet are in
FO/OI
fully closed position.
25 Check 12” main inlet line of other bullets is in close position. FO/OI
39 | P a g e
26 Check receipt bullet inlet XZV open position. FO/SI/OI
27 Line up Mercaptan dosing system as per SOP. FO/OI
10.7 PROCEDURE:
S. No. Description FPR

1 Inform Refinery about the terminal readiness for the receipt of LPG. SI/OI
Once refinery confirms the delivery, Open 12” main inlet valve of
2 LPG receipt bullet and ensure no leaks and start Mercaptan dosing FO/OI
pumps and adjust the stoke as per SOP.
Once the receipt starts, note the time of starting of discharge as
3 SI/OI
conveyed by the IOCL refinery.
Field officer/ control room officer confirms the receipt of product,
field officer observes and clears the area for any leak, intimate the
4 FO/OI
same, if found, to Control Room and do the necessary course of
action.
Once LPG (on-spec and blending spillage) starts filling the bullet,
5 check the bullet level is increasing and pumping rate and pressure SI/OI
of receipt.
TFMS report screen in the Officer Engineering station is checked for
6 SI/OI
any movement in the non-operational bullets.
During the receipt operation, regular monitoring of the following
items are required:-
Flow rate, pressure, temperature (lines and bullets)
Check for any leakages in the system
7 SI/OI
Blending system, RVP analyser
LT Flare system
Observance of safety rules and regulations
Verification of product receipt with IOCL refinery dispatch on

8 SI/OI
random basis to be done.
For any abnormal variation between the discharge qty and receipt
qty, investigate the reason. If the difference is more than 5%,
9 SI/OI
intimate the same, to concerned IOCL official for further course of
action.
Switching over of receipt bullet
It is required to change the receipt of the LPG from one Bullet to
1 another Bullet; this procedure can be carried out without stopping FO/SI/OI
the receipt operation.
As soon as the receiving bullet attains High Level, the next bullet for
receiving of LPG from should be lined up as under:
First open the valves (Body and header) of the Bullet which will be
lined up for receipt and then close the valve of the Bullet currently
under receipt.
2 FO/OI
Before closing, ensure that the valves of receipt bullet are open.
Generally after 10-15% of opening of the valve in new bullet, closing

of the previous bullet is done after ensuring smooth opening of
valves and rise of level for second receipt bullet and steady pressure
40 | P a g e
of the pipe lines.
The above same procedure to be followed for the next bullets to
3 FO/SI/OI
receive the product.
On filling of the first bullet, close the line-up of first bullet. Now make
4 the third bullet ready for receipt and so on for the next bullets to be FO/OI
filled.
Record the level, temperature and pressures of the First bullet to be
5 done along with the IOCL representative, assess the provisional SI/OI
receipt quantity.
Completion Procedure
1 Record the completion time of the receipt to the first bullet. SI/OI
Ensure fully close of the inlet valve which is opened for above
2 FO/OI
operation.
receipt quantity.
4 Close the vapour balancing line of the first Bullet.
All timing and provisional bullet receipt figures noted in receipt log
5 FO/OI
book.
Batch formation, water draining and sampling will be done as per
6 SOPs given in Bullet Operations Manual and then final out turn is FO/SI/OI
prepared.
10.8 SAFETY PRECAUTIONS:

1 Ensure positive receipt lineup. FO/OI
Pressures in the pipe lines and bullets should not be more than
2 FO/SI/OI
design pressure.
If bullet is empty (first time commissioning or after maintenance
3 FO/SI/OI
activity) LPG to be received at minimum flow rate (velocity 1 m/s).
4 Ensure all ESD, GDS, FDAS are in place and in working condition. SI/OI
5 Ensure all PSVs are in line and their outlets are open to LT Flare. FO/OI
6 Ensure LT Flare is in order. SI/OI
7 Ensure proper illumination while carrying out operations. FO/SI/OI
Ensure all first aid fire fighting equipments are in place and in
8 SI/OI
working condition.
Ensure agreed flow rates and pressures (between IOC and IOT) are
9 FO/SI/OI
maintained during receipt operation.
Positive line up and positive flow rates to be ensured during receipt
10 FO/SI/OI
operation.
Ensure that the receipt bullet was lined up to vapour balancing
11 FO/OI
bullet during operation.
12 Monitor rise in levels of the bullets other than receipt bullet. SI/OI
At a time only one operation (receipt or dispatch or batch
13 SI/OI
formation or water draining or sampling) to be carried out on bullets.
Storage bullet should not be filled up above safe level. A high-level
alarm is set below safe level to warn the Control room officers. The
14 High-high alarm is set at maximum safe fill level which will FO/SI/OI
automatically close the receiving SDV of bullet once it is actuated.
In the event that the level to be raised above safe level, a
41 | P a g e
Management of Change (MOC) must be raised prior to conducting
the task with authorization from IOC.
15 Monitor required Mercaptan dosing quantity on hourly basis. FO/SI/OI
Ensure that rundown lines of refinery shut down units are isolated
16 FO/OI
from the blending unit.
10.9 PFD FOR LPG RECEIPT FROM REFINERY
42 | P a g e
CHAPTER-11
MERCAPTAN DOSING DURING RECEIPT OF LPG
11.1 OBJECTIVE:
The objective of the SOP is to define the general procedure for Ethyl Mercaptan dosing
to LPG as an odouriser.
11.2 SCOPE:
The SOP is applicable for dosing of Ethyl Mercaptan to LPG during receipt operation
from IOCL refinery division run down lines to LPG storage bullets through Blending Unit
within LPG terminal and during batch formation.
11.3 DESCRIPTION:
1. LPG is an odorless gas, heavier than air. Any leakage developed from a source of
LPG can go undetected, thereby creating a grave safety hazard. Therefore, if LPG is
to be distributed as a utility gas to the consumers, it shall be odorised by addition of a
warning agent of such characteristics that it is detectable by a distinct odour down
to a concentration in air of not over one fifth of the lower limit of flammability.
2. Ethyl Mercaptan is commonly used as the odorant for LPG because of its distinctive
smell. The assessment of odour level and the amount of ethyl Mercaptan to be
dosed are determined as per the guidelines given in IS :1448 - 1968 (P : 75) or
instructed by IOCL.
3. Ethyl Mercaptan dosing will be done at the downstream inline static mixer during LPG
receipt to Bullets. If not, having provision at pumps suction during batch formation.
4. System has been designed with 1 running and 1 stand by pump.
1. Ethyl Mercaptan dosing to LPG, plan shall be developed by IOT in accordance with
the IOCL refinery requirements.
2. This plan is verified by the Operations–in-charge and executed by Shift Manager.
Control Room to ensure the Field Officer is fully aware of all operations associated
with Mercaptan charging to storage vessel and dosing, P&IDs, field piping network,
product characteristic, operation facility and troubleshooting.
3. Ensure that the Ethyl Mercaptan storage vessel is having sufficient quantity, if not
Mercaptan charging to be done as per the procedure.
4. Communication- For effective communication between Refinery storage, IOCL
refinery Control room and IOT, VHF base station along with handheld radios and
telephones are provided. Before commencement of operation, ensure effectiveness
of communication system.
5. Continuous, short, precise and clear communication is maintained between Control
Room Officer and Field Officers during Receipt Operation.
 Planning of LPG dispatch and ppm of Mercaptan dosing.

43 | P a g e
 Supply required quantity of Ethyl Mercaptan.
 Ensure communication is proper between Refinery and IOT and overall co-ordination
for the smooth operations.
IOT’S ROLE:
 Coordinate with IOCL officers for receipt operations and ensure ppm level of ethyl
Mercaptan to be dosed.
 Calculation of ethyl Mercaptan quantity to be dosed as per the receipt plan and
ppm given by IOCL.
 Ethyl Mercaptan charging and dosing.
 Reconciliation of the quantity and raising indent for ethyl Mercaptan in advance.
 Documentation.
Instruction.
ETHYL MERCAPTAN DOSING CALCULATION
Formula for determining the quantity of Mercaptan to be dozed:

Nomenclature:
Quantity of LPG pre-determined to be received in the Bullet per hour: X MT
Required Mercaptan level in the product: Y ppm
Specific gravity of Mercaptan: Z
Calculations:
1 ppm means 1 part per every million parts
1 MT of LPG = 1 MT*1000 Kgs.*1000 grams = 1,000,000 grams or 1,000,000 parts.
Thus if required Mercaptan dosage is Y ppm it means Y grams for 1,000,000 grams of LPG
(i.e. 1 MT)
Therefore for X MT of LPG the quantity of Mercaptan required for dozing = Y*X grams.
Since specific gravity of Mercaptan is Z, quantity of Mercaptan required = (Y*X)/Z cc =
((Y*X)/Z)/1000 litres = A litres
Each centimeter level of the Mercaptan storage tank is equal to 5litres of Mercaptan.
Therefore the level drop required for X MT of LPG to be dozed with Y ppm of Mercaptan
= A/5 centimeters
Sample calculation
Say X = 1000 MT, Y = 25 ppm and Z = 0.847
Qty. of Mercaptan required = (25*1000)/0.847 = 29515.938 cc

= 17709.56/1000
= 29.52litres
Required level drop in the storage tank = 17.70/5cms.
= 5.9cms.
11.6 PREPARATION

1 LPG receipt plan developed in the control room and verified. SI/OI
44 | P a g e
2 The required order prepared for the receipt operation and work
SI/OI
instructions printed accordingly.
3 Ethyl Mercaptan dosing calculation as above in line with the receipt
SI/OI
plan.
4 Ensure sufficient quantity of Mercaptan is available in the Ethyl
Mercaptan storage vessel, and the system is in working condition. If
FO/OI
quantity of Mercaptan is not sufficient then charging to be done as
per the procedure.
5 Establish proper communication between field and control room. FO/SI/OI
6 Open 2” out let of the Ethyl Mercaptan storage vessel and line up to
FO/OI
any one of the pump (205-P-043 A or 205-P-043 B).
7 Open 2” valve on pump delivery line and ensure no leaks. FO/OI
8 Open 2” valve at Mound II connected with inlet header after
FO/OI
ensuring receipt of LPG.
11.7 PROCEDURE:

1 Record initial level of the Mercaptan storage vessel. SI/OI
2 Start ethyl Mercaptan dosing pump. FO/OI
4 Physically check for leakages if any through the system. Stop the
FO/OI
operation in case leakages observed and rectify.
5 Monitor the level of the Ethyl Mercaptan storage vessel. FO/SI/OI
6 Reconciliation to be done on hourly basis between LPG receipt and
SI/OI
Mercaptan dosing. Accordingly adjust the pump delivery.
7 All operational timings/ operational activities should be logged in
FO/SI/OI
Mercaptan dosing log book as per the format.
8 After completion of the operation, stop the pump, close the
Mercaptan dosing point valve provided on LPG inlet stream, and FO/OI
pump delivery, suction valves which are opened for operation.
9 Record final level of the Mercaptan storage vessel. FO/OI
10 Prepare the reconciliation report and log. SI/OI

Pressures in the pipe lines and storage vessel should not be more
1 FO/SI/OI
than design pressure.
6 SI/OI
working condition.
Positive line up and positive flow rates to be ensured during the
7 FOOI
operation.
8 Monitor level of the storage vessel and hourly dosing rate. FO/SI/OI
9 Ensure no leaks. FO/OI
11.9 ANNEXUR-4.2
45 | P a g e
46 | P a g e
CHAPTER-12
OFF-SPEC RECEIPT
12.1 OBJECTIVE:
The objective of the SOP is to define the general procedure for LPG Off-Spec receipt
from IOCL refinery division to LPG storage bullets via rundown lines.
12.2 SCOPE:
The SOP is applicable for all LPG Off-Spec receipt operation from IOCL refinery division to
LPG storage bullets within LPG terminal.
12.3 DESCRIPTION:
The LPG Off-Spec rundowns streams from the process units shall be received directly in
the offsite LPG storage Bullets.
LPG Off-Spec Product is routed to normally one of pressurised storage bullets (205-V-
3/4/5/7/8/9/12/13/14) lined up for receiving.
1. If receipt is being done to a newly constructed bullet ensures that vapour purging
was completed prior to liquid receipt.
2. Operations in-charge should ensure that the field officers are fully aware of their roles
and responsibilities as required and are fully understood the SOP.
3. Field officer should have full awareness of LPG product characteristic, operation
facility and troubleshooting.
4. Operating personnel should be thorough with LPG Mounded P&IDs, field piping
network and operating procedure prior to be involved in mounded bullet operation.
5. Control room to ensure that the field officer are fully aware of all operation within the
LPG bullet area.
6. Officer has to ensure the status of HOV‟s.
7. Ensure bullet Off-Spec receipt line up as per the diagram and position of valves.
8. Vapour balancing line up to other bullet if required.
9. Ensure no deliveries from the receipt bullet.
10. Ensure next bullet is ready prior to first bullet top up.
 Production planning and dispatch to BOOT storage facility.

 Maintaining flow rates during initial start up.
 Overall co-ordination for the receipt operation.
IOT’S ROLE:
 Coordinate with IOCL officers for off-spec receipt operations.

 Preparation of LPG bullet for off-spec receipt.
 Line ups from the BOOT-3 battery limit to bullet for the receipt of off-spec receipt.
47 | P a g e
 Joint reconciliation of the off-spec receipt operations with IOCL/ IOCL representative.
 Documentation and preparation of outturn reports.
Instruction.
12.6 PREPARATION

1 A Receipt plan developed in the control room and verified. SI/OI
2 The required order prepared for the Receipt operation and work
SI/OI
instructions are printed accordingly.
3 IOCL/ IOCL representative available at terminal prior to receipt
SI/OI
4 Discharging nominations, initial rates and max rates agreed with
SI/OI
IOCL and documented in the receipt Logbook.
5 Close all the inlet and outlet valves of the receipt bullets (off-spec).
Note down the opening level, temperatures, pressures and densities FO/OI
and prepare joint initial out turn report.
6 Ensure next bullets (for the receipt of off-spec) are ready and the out
FO/SI/OI
turn report was prepared.
7 Ensure the proper communication between refinery, field and
FO/SI/OI
control room.
8 Ensure that the instruments and equipment‟s are inline and having
FO/SI/OI
proper communication.
9 Ensure bullet vapour balancing was done to other bullet. FO/OI
10 Ensure all HOV in off-spec receipt line are in working condition. FO/OI
11 Open the off-spec LPG receipt line 4” valve in battery limit. FO/OI
12 Open the 4” valve in between unit-204&&205. FO/OI
13 Close all other valves in that bullet. FO/OI
14 Close 4”off-spec valves in remaining bullets. FO/OI
15 Check that bullet inlet and vapour line XZV is open. FO/OI
12.7 PROCEDURE:

Inform Refinery about the terminal readiness for the off-spec receipt
1 SI/OI
of LPG.
Once refinery confirms the delivery, Open 4” off-spec inlet valve of
2 FO/OI
LPG receipt bullet and ensure no leaks.
Once the receipt starts, note the time of starting of discharge as
3 SI/OI
conveyed by the IOCL refinery.
Field officer/ control room officer confirms the receipt of product,
field officer observes and clears the area for any leak, intimate the
4 FO/SI
same, if found, to Control Room and do the necessary course of
action.
Once LPG (off-spec) starts filling the bullet, check the bullet level is
5 SI/OI
increasing and pumping rate and pressure of receipt.
6 TFMS report screen in the Officer Engineering station is checked for SI/OI
48 | P a g e
any movement in the non-operational bullets.
During the receipt operation, regular monitoring of the following
items are required:-
Flow rate, pressure, temperature (lines and bullets)
7 Leaking of the System SI/OI
LT Flare system
Observance of safety rules and regulations
Verification of product receipt with IOCL refinery dispatch on

8 SI/OI
random basis to be done.
For any abnormal variation between the discharge qty and receipt
qty, investigate the reason. If the difference is more than 5%,
9 SI/OI
intimate the same, to concerned IOCL official for further course of
action.
Switching over of receipt bullet
It is required to change the receipt of the LPG from one bullet to
1 another, this procedure can be carried out without stopping the FO/SI/OI
receipt operation.
As soon as the receiving bullet attains High Level, the next bullet for
receiving of LPG from should be lined up as under:
First open the valves (Body and header) of the Bullet which will be
lined up for receipt and then close the valve of the Bullet currently
under receipt.
2 FO/OI
Before closing, ensure that the valves of receipt bullet are open.

of the previous bullet is done after ensuring rise of level and steady
pressure of the pipe lines.
The same is done for the bullets to be lined up next, after receipt
3 FO/SI/OI
operation of the bullet under receipt.
On filling of the first bullet, close the line-up of first bullet. Now make
4 the third bullet ready for receipt and so on for the next bullets to be FO/SI/OI
filled.
receipt quantity.
1 Record the completion time of the receipt to the first bullet. SI/OI
Ensure fully close of the inlet valve which is opened for above
2 FO/OI
operation.
receipt quantity.
All timing and provisional bullet receipt figures noted in receipt log
4 SI/OI
book.
Close the vapour balancing line of the first bullet after ensuring that
5 FO/OI
there is no pressure rise in the bullet from normal.
49 | P a g e
Before lining up bullet, check and calculate the ullage availability.
1 Lining up of receiving bullet should be done carefully to avoid FO/OI
pressure surges, overfilling etc.
Check from processing units the flow rate of Off-Spec LPG and cross
check this quantity with the rate of Off-Spec receipt. Also calculate
2 SI/OI
the time when change over is likely to come. This must be checked
in each shift should the figures differ, investigate at both the ends.
Before changing over Off-Spec receipt from one storage bullet to
3 SI/OI
another; inform concerned processing units.
While changing over Off-Spec receipt from one bullet to another first
4 open the vessel which is to receive and establish the flow of LPG FO/OI
fluid before closing the other vessel, which was receiving earlier.
Ensure proper illumination while carrying out operations after day
6 FO/SI/OI
light hours.
Ensure first aid firefighting systems and safety systems are in place
7 SI/OI
and in working condition.
12.9 PFD FOR OFF-SPEC RECEIPT
50 | P a g e
CHAPTER-13
RE - CIRCULATION OF LPG BULLET
13.1 OBJECTIVE:
The objective of the SOP is to define step by step approach to perform recirculation of
LPG in a mounded bullet for batch formation.
13.2 SCOPE:
The SOP is applicable for all operational requirements and procedures in relation to
recirculation of individual bullets for LPG batch formation prior to sampling for lab
analysis.
13.3 DESCRIPTION:
1. Re-Circulation of LPG in any mounded bullet is a must to ensure homogeneity before

offering the bullet for sampling and lab certification/dispatch.
2. The circulation of any mounded bullet is done using LPG transfer pumps 205-P-
001A/B/C (PH-05) for Mound I bullets and 205-P-001D/E/F (PH-06) for Mound II bullets.
1. Recirculation to be carried out for minimum 4 hours to ensure homogeneity of the

product for sampling.
2. If Mercaptan dosing was not done during receipt, then it will be done from provision
made at pump suctions as per the procedure.
3. Dispatch plan shall be developed by IOT in accordance with the IOCL refinery
requirements.
5. Control Room to ensure the Field Officer is fully aware of all operations within the
facility, LPG product characteristic, troubleshooting and lineup.
6. Continuous, short, precise and clear communication should be maintained between
Control Room Officer and Field Officers during Pumping Operation.
7. Ensure effectiveness of communication between control room and field before
commencement of operation.
8. All the recirculation activities in the facility shall be carried out as per the Work
Instructions and instructions from Control Room. Field Officer should notify the Control
Room upon completion of all tasks.
 Overall co-ordination for the smooth operation.
IOT’S ROLE:
 Coordinate with IOCL officers for re-circulation operations.

 Preparation of LPG bullet for re-circulation.
 Line up bullets for re-circulation.
51 | P a g e
Instruction.
13.6 PREPARATION

1 A batch formation plan developed in the control room and verified. SI/OI
2 The required order prepared for the batch formation operation and
SI/OI
work instructions are printed accordingly.
3 Take the provisional out turn report after receipt operation from
SI/OI
refinery as given in SOP as opening for recirculation.
5 Ensure all Hand Operated Valves in batch formation line are in
FO/OI
working condition and no leaks.
6 Open the 6” Inter Bullet Transfer valve in the batch formation bullet. FO/OI
7 Close all the 6” Inter Bullet Transfer valves in the other bullets. FO/OI
8 Open the 10” Inter Bullet Transfer suction valve in the batch
FO/OI
formation bullet outlet.
9 Ensure all the XZV's in the batch formation bullet are open. FO/OI
10 Open 10” valve in the pump Inter Bullet Transfer suction and close
FO/OI
the 10” main dispatch suction in the pump used for batch formation.
11 Open 6” valve in the pump Inter Bullet Transfer delivery and close
FO/OI
the 8” main dispatch delivery.
12 Close the 6” double ball valve placed in Inter Bullet Transfer hook up
FO/OI
line with other mound.
13 Open the 6” valves in upstream and downstream of HV-0012 and
FO/OI
close its bypass valve.
14 Check the pump for lubrication oil, coolant, cooling water, direction
FO/OI
of rotation etc.
13.7 PROCEDURE:

1 Inform the IOCL about the Batch formation operation. SI/OI
Start the pump and ensure that there is a positive differential
2 pressure at the pump discharge. Slowly open the pump delivery FO/OI
valve.
Observe the pump condition for any abnormal vibration, sound etc.
3 FO/OI
Keep watch on running pump.
4 Physically ensure for no leakages in the system. FO/OI
Continue recirculation for minimum 4 hours, after getting clearance
5 FO/OI
from the control room, stop the operation.
6 Close the entire valves lined up for recirculation. FO/OI
All operational timings/ operational activities should be logged in
7 FO/SI/OI
dispatch log book as per the format.
Give one hour settlement time for the recirculation bullet, check for
8 water presence and if found water draining to be done as per the FO/OI
procedure.
52 | P a g e
After water draining, LPG sampling is done for lab analysis in
9 FO/SI/OI
presence of IOCL/ IOCL representative.
S.No Description FPR

1 Do not perform the operation while leakages are observed. FO/OI
2 Pressures in the pipe lines should not be more than design pressure. FO/OI
7 SI/OI
working condition.
8 Ensure no other operations on the bullet except recirculation. FO/SI/OI
Clear communication should be there between field and control
9 FO/SI/OI
room.
Ensure that the bullet was lined up to vapour balancing bullet
10 FO/OI
during operation.
Ensure all the instrument and equipment used for the batch
11 formation operation are in working condition and has proper FO/SI/OI
communication with automation system.
13.9PFD FOR RE - CIRCULATION OF LPG BULLET
53 | P a g e
CHAPTER-14
INTER BULLET TRANSFER
14.1 OBJECTIVE:
The purpose of the SOP is to define a general procedure for LPG transfer from one
storage bullet to other within the same mound or between two mounds.
14.2 SCOPE:
The SOP is applicable for all Inter Bullet Transfer operations of LPG bullets within the
storage facility.
14.3 DESCRIPTION:
Inter Bullet Transfer of LPG is required for the following reasons:

a. If required to create ullage in a bullet.
b. To offer bullet for maintenance.
Inter Bullet Transfer is done using LPG transfer pumps, 205-P-001A/B/C (PH-05) for Mound I
bullets and 205-P-001D/E/F (PH-06) for Mound II bullets.
1. If bullet has to be emptied out, then take necessary clearances and follow the bullet
decommissioning procedure SOP. If not, then minimum dead stock to be
maintained in the bullet so that pump will not get affected by cavitation etc.
2. Ensure that there is sufficient ullage available in the receiving bullet to
accommodate the quantity from source bullet.
3. Control Room to ensure the Field Officer is fully aware of all operations within the LPG
storage facility.
Control Room Officer and Field Officers during Inter Bullet Transfer Operation.
5. All the activities in the facility shall be carried out as per the Work Instructions and
instructions from Control Room. Field Officer should notify the Control Room upon
completion of all tasks.
facility, troubleshooting and line ups.
7. Bullet Level Alarm Set point screen in Control Room shall be used to give alarm prior
to low level in the discharge bullet and high level in the receipt bullet.

 Communicate IOT upon requirement and quantity to be transferred between the
bullets. Overall co-ordination for the smooth operation.
 Product quality assessment and samples retention after Inter Bullet Transfer.
 Joint reconciliation of the Inter Bullet Transfer operations with IOT.
IOT’S ROLE:
54 | P a g e
 Coordinate with IOCL officers for Inter Bullet Transfer operations.
 Preparation of LPG bullets for Inter Bullet Transfer.
 Line up and all operational activities for Inter Bullet Transfer.
 Joint reconciliation of the INTER BULLET TRANSFER operations with IOCL/ IOCL
representative.
Instruction.
14.6 PREPARATION

An Inter Bullet Transfer plan developed in the control room and
1 SI/OI
verified.
The required order prepared for the Inter Bullet Transfer operation
2 SI/OI
and work instructions are printed accordingly.
Close all the inlet and outlet valves of the Inter Bullet Transfer bullets.
3 Note down the opening level, temperatures, pressures and densities SI/OI
5 Ensure vapour balancing to be done between these bullets. FO/OI
Ensure all Hand Operated Valves in Inter Bullet Transfer line are in
6 FO/OI
working condition and no leaks.
Close all the 6” Inter Bullet Transfer receipt line valves in the other
7 FO/OI
bullets.
Open the 6” Inter Bullet Transfer receipt line valve in the receipt
8 FO/OI
bullet.
9 Open the 10” Inter Bullet Transfer suction valve in the dispatch bullet. FO/OI
10 Ensure all the XZV's in the Inter Bullet Transfer bullet are open. FO/OI
Ensure all other valves are closed except 10” Inter Bullet Pump
11 FO/OI
suction valve of the respective pump.
Ensure 6” ball valve (two no‟s) fully closed, placed in Inter Bullet
Transfer pump delivery line. (a hook up between Mound I and
12 FO/OI
Mound II required if Inter Bullet Transfer to be done between two
mounds)
Check the pump for lubrication oil, coolant, cooling water, direction
13 FO/OI
of rotation etc.
14.7 PROCEDURE:

1 Inform the IOCL officer about the Inter Bullet Transfer operation. SI/OI
Check the line up of the entire system to transfer LPG from delivery
2 FO/OI
Bullet to receipt bullet.
valve.
Observe the pump condition for any abnormal vibration, sound etc.
5 FO/OI
Keep watch on running pump.
55 | P a g e
Monitor the levels/ pressures of the both bullets and line pressures
6 FO/OI/OI
throughout the operation./OI
Ensure that there is no abnormal variation in transfer operation
7 FO
between the bullets (dispatch and receipt).
8 Record hourly dispatch figures (receipt and dispatch). SI/OI
9 Physically ensure for no leakages in the system. FO
Stop the operation as soon as the nominated quantity was
10 FO/OI
transferred.
11 Close the entire delivery line up. FO
Record final readings of the both bullets level, temperature and
12 OI/SI
pressures and prepare joint final out turn report.
13 SI/OI
S. No Description FPR
1 Do not perform the operation while leakages are observed. OI/FO
Hourly recheck quantity delivered and received between the
2 bullets. Do not perform the operation while discrepancy in OI/SI
discharge and receipt figures is observed.
Ensure pump minimum flow recycle lined up to dispatch bullet and
4 FO
flow control valve is in operation if required.
5 Ensure all ESD, GDS, FDAS are in place and in working condition. OI/SI
6 Ensure all PSVs are in line and their outlets are open to LT Flare. FO
8 Ensure proper illumination while carrying out operations. FO
9 SI/OI
working condition.
Positive line up and positive flow rates to be ensured during dispatch
10 OI
operation.
11 Ensure no other operations carried out on these two bullets. FO/OI
Clear communication should be there between field and control
12 FO/SI/OI
room.
14.9. INTER BULLET TRANSFER
56 | P a g e
CHAPTER-15
LPG DESPATCH TO MARKETING TERMINAL
15.1 OBJECTIVE:
The objective of the SOP is to define a step-by-step approach for

performing the Pumping of LPG to the Marketing Terminal.
15.2 SCOPE:
The SOP is applicable for all Pumping Operations from LPG storage bullets to Marketing
Terminal.
15.3 DESCRIPTION:
1. LPG from storage bullets is dispatched to Marketing Terminal using LPG transfer
pumps, 205-P-001A/B/C (PH-05) for Mound I bullets and 205-P-001D/E/F (PH-06) for
Mound II bullets.
2. Accounting of product transferred to Marketing Terminal is done by CTMS 205-A-035.

1. A written confirmation should be received from IOCL regarding product transfer to
Marketing Terminal.
requirements for LPG transfer to marketing terminal.
facility, LPG product characteristic, troubleshooting and line up.
6. Ensure effectiveness of communication between IOT, IOCL refinery, IOCL Marketing
Terminal and IOT field before commencement of operation
7. All the transfer activities in the facility shall be carried out as per the Work Instructions
and instructions from Control Room. Field Officer should notify the Control Room
upon completion of all tasks.
to low level in the tank.
9. Bullet level, temperature and pressure are used for reconciliation between bullet and
Metering Skid (205-A-035). Actual quantity delivered to marketing terminal is based
on flow meter only.
 Communicate to IOT the quantity to be transferred to Marketing Terminal pipe line.

 Nominating IOCL representative for the out turn finalisation prepared by IOT.
 Excise and Custom related formalities
 Ensure effectiveness of communication between IOT and IOC Marketing Terminal
and overall co-ordination for the smooth delivery operation.
 Provide LPG lab analysis report (bullet nominated for product transfer) to IOT and
IOCL Marketing Terminal.
57 | P a g e
 Ensure effectiveness of communication between IOCL Refinery, Marketing Terminal
and IOT and overall co-ordination for the smooth product transfer operations
IOT’S ROLE:
 Preparation of LPG bullet for transfer.

 Coordinating with the IOC refinery and Marketing Terminal during LPG transfer
operation.
 Joint witness of readings of Metering Skid, LPG Bullet (level, temperature and
pressure) with IOCL nominated representative before and after dispatch.
 Product reconciliation, preparation of outturn and documentation.
 The Operations-in-charge is overall responsible for maintaining the quality of this SOP.
 The Shift Manager is responsible for overall implementation of this SOP
 The Planning and Co-ordination department is overall responsible for preparation of
pumping plan.
 The Control room Officer and Field officers are responsible for conducting the work
specified within this SOP.
15.5 PREPARATION

Ensure bullet free of water, lab analysis of the product completed
1 SI/OI
and product passed the test. Collect quality test report from IOC.
Confirm from IOC refinery quantity to be dispatched to Marketing
2 SI/OI
Terminal.
IOCL/ IOCL representative/ Marketing Terminal representative/
3 surveyor available at terminal prior to delivery operation for initial SI/OI
out turn preparation.
4 IOCL Marketing Terminal and documented in the dispatch log SI/OI
book.
Close all the inlet and outlet valves of the dispatch bullet. Note
5 down the opening level, temperature and pressure. Use lab density SI/OI
Note the initial reading of the flow meter in the Metering Skid (205-
6 SI/OI
A-035.
If more than one bullet required for the dispatch then ensure that
7 SI/OI
the out turn report was prepared for the other bullet also.
Establish proper communication between refinery, Marketing
8 FO/SI/OI
Terminal, field and control room.
Ensure all Hand Operated Valves in delivery line are in working
9 FO/OI
Ensure calibration validity and working condition of Mass Flow Meter
10 (205-A-035) installed in line to product transfer between Boot-3 SI/OI
Terminal to Marketing Terminal as per CTMS operating manual.
11 Ensure LPG transfer pumps are in good working condition. FO/OI
Check the pump for lubrication oil, cooling water, direction of
12 FO/OI
rotation etc.
13 Ensure 18” main out let valves of other bullets are in closed position. FO/OI
Ensure 18” common header isolation between Mound I and Mound
14 FO/OI
II is fully closed.
58 | P a g e
15 Open 18” out let valve for the dispatch bullet and ensure no leaks. FO/OI
Ensure 4” LPG product transfer pump minimum flow recycle receipt
16 FO/OI
valve of other bullets in closed position.
Open 4” LPG product transfer pump minimum flow recycle for the
17 FO/OI
dispatch bullet.
Ensure 10” and 6” Inter Bullet Transfer suction and delivery
18 FO/OI
respectively of the product transfer pump are closed.
19 Open 10” Product Transfer pump main suction valve. FO/OI
Open upstream and downstream valves of 4” pump minimum flow
20 FO/OI
recycle flow control valve.
Close 6”, 3”&12” valve of alkylation unit, DCU & marketing terminal
21 FO/OI
lines respectively.
Ensure 10” tank truck loading gantry Metering Skid upstream valve is
22 FO/OI
closed.
23 Open 12” marketing terminal header valve. FO/OI
24 Open Metering Skid (205-A-035) upstream and downstream valves. FO/OI
25 Ensure XZV 0179 is open. FO/OI
After confirmation from IOCL marketing terminal for their readiness
26 FO/OI
to receive the product open 12” valve at downstream of XZV 0179.
15.7 PROCEDURE:

valve.
2 Observe the pump condition for any abnormal vibration, sound etc. FO/OI
Keep watch on running pump. Monitor the flow rate, if stabilized
3 FO/OI
then start second pump.
4 SI/OI
throughout the operation.
5 FO/OI
between the bullet and Metering Skid quantities.
6 Record hourly dispatch figures (both bullet and Metering Skid). SI/OI
Switch over of dispatch bullet
It is required to change the dispatch of LPG from one bullet to
another, this procedure can be carried out without stopping the
1 FO/SI/OI
operation and informing to IOCL refinery/ IOCL Marketing Terminal
about the switch over.
As soon as dispatch bullet about attain Low level, the next bullet for
dispatch of LPG should be lined up as under:
First open the valves (Body and header) of the bullet which will be
lined up for dispatch and then close the valve of the bullet currently
2 FO/OI
under dispatch.
Before closing, ensure that the valves of the dispatch bullet are
open.
59 | P a g e
of the previous bullet is done after ensuring decrease of level of
second bullet and steady pressure of the pipe lines.
The same is done for the bullets to be lined up next, after dispatch
3 FO/SI/OI
operation of the bullet.
On completing the first bullet, close the line up of the first bullet.
4 Now make the third bullet ready for dispatch and so on for the next FO/OI
bullet to be dispatched.
Record level, temperature and pressures of the first bullet to be
5 done along with IOCL refinery/ IOCL marketing terminal SI/OI
representative, and finalise the out turn report.
8 Record the completion time of the dispatch from the first bullet. SI/OI
Ensure fully close of the valves which are opened for the above
9 FO/OI
operation.
Record final readings of bullet level, temperature and pressures and
10 SI/OI
prepare joint final out turn report.
11 Confirm quantity received by IOCL marketing terminal. SI/OI
12 SI/OI
Special Note:
1. Actual quantity transferred to Marketing Terminal is based on accounting from CTMS

(205-A-035).
2. Individual bullets outturn is prepared and reconciliation is done between bullets and
Metering Skid.
Product Transfer Operation through Duty Meter

Ensure upstream and downstream MOVs of Stand by meter and
1 FO/OI
master meter are closed.
Ensure calibration MOVs of duty meter and stand by meter are
2 FO/OI
closed.
3 Open upstream and downstream MOVs of Duty meter. FO/OI
Product Transfer Operation through Standby Meter

Ensure upstream and downstream MOVs of Duty meter and master
1 FO/OI
meter are closed.
Ensure calibration MOVs of Duty meter and stand by meter are
2 FO/OI
closed.
3 Open upstream and downstream MOVs of Standby meter. FO/OI
Calibration of Duty meter during Product Transfer Operation

1 Ensure upstream and downstream MOVs of Standby meter closed. FO/OI
60 | P a g e
2 Ensure calibration MOV of standby meter is closed. FO/OI
Close downstream MOV of Duty meter and open downstream MOV
3 FO/OI
of Master meter.
4 Open calibration MOV and upstream MOV of Duty meter FO/OI
Above procedure is repeated with respect to line up as required to
5 FO/OI
calibrate Standby meter.

Hourly recheck quantity delivered from storage and receipt by
2 marketing terminal. Do not perform the operation while SI/OI
discrepancy in discharge and receipt figures is observed.
4 FO/OI
flow control valve is in operation.
Ensure all instrumentation and automation system provided in LPG
5 SI/OI
dispatch lines in working condition.
10 SI/OI
working condition.
Ensure agreed flow rates and pressures (between IOC marketing
11 FO/SI/OI
terminal and IOT) are maintained during dispatch operation.
Positive line up and positive flow rates to be ensured during
12 FO/OI
dispatch operation.
13 Ensure no other operations on the bullet except dispatch. FO/SI/OI
Clear communication should be there between the IOT field and
14 FO/SI/OI
control room, IOT and marketing terminal about the operation.
15.9 LPG DESPATCH TO MARKETING TERMINAL FROM MOUND-01
15.11 LINE-UP AS PER APPENDIX-18
61 | P a g e
CHAPTER-16
LPG TANK TRUCK LOADING
16.1 OBJECTIVE:
The objective of this SOP is to define the general procedure for product dispatch to Tank
Truck taking all safety precautions.
16.2 SCOPE:
This SOP is applicable for all operational requirements and procedures in relation to
product transfer from bullets to tank trucks.
16.3 DESCRIPTION:
LPG from the Bullets is transferred to tank trucks at LPG Tank Truck Loading Gantry using
pumps.
7 bay loading gantry is provided for loading of Tank Trucks. LPG from the bullets V-003/
004/005/007/ 008/ 009 of Mound-I or from V-012/ 013/ 014 of Mound-II is transferred to
TTLG using PH – 05 (205-P-001A/B/C) or PH-06 (205-P-001D/E/F).
Accounting of LPG transferred to LPG tanker is done by Flow Meter provided at the
metering package (205-A-053).
1. Quality certificate of the product in the mounded bullet used for TT loading.
2. LPG Tank Truck loading should be done only after written confirmation from IOCL.
Confirm the quantity to be dispatched and planning for the TT loading on daily basis.
3. Ensure that there is sufficient quantity of LPG available in the nominated bullet for
Truck loading leaving the dead stock.
4. If sufficient quantity is not available in the bullet, then change over to another bullet
may be required during; hence, next bullet to be made ready prior to first bullet
completion.
5. Ensure calibration validity and working condition of Metering Skid installed in line to
product transfer Tank Truck Loading.
6. Operations in charge should ensure that the field officers are fully aware of their roles
and responsibilities as required and are fully understood the SOP.
facility, troubleshooting and line ups.
8. Ensure no other operations except TT loading from the bullet.
9. Establish proper communication between field and control room.
10. Tank Trucks being placed for the loading should confirm to safety check list as
mentioned in Annexure prior to entry into the Terminal premises.
62 | P a g e
IOCL ROLE:
 Planning of LPG dispatch through TT loading.

 Intimating IOT about the TT schedule, quantity to be loaded.
 Generating FAN, Invoice against IOT‟s TAS invoice in MT/ Kg.
 Ensure safety confirmation of tank truck being placed for loading.
 Joint reconciliation and finalisation of out turn prepared by IOT before and after Tank
Truck loading.
IOT’S ROLE:
 Preparation of LPG bullet for dispatch.

 Joint reconciliation and out turn preparation, documentation before and after Tank
Truck loading.
 Security has to check the safety check list for all the TT's as per the Tank Truck Safety
Check List attached in APPENDIX: 16.
 Line up and loading of LPG Tank trucks as per IOCL requirement.
 Ensure all safety rules and regulations follow up by the personnel entering the LPG
premises and working in the area.
Instruction.
16.6 PREPARATION

1 Ensure quantity to be loaded in Tank Truck from IOCL. SI/OI
Ensure product quality test report obtained from IOCL for the product
2 SI/OI
being dispatched to tank trucks.
Note the opening reading of Metering Skid installed for Tank Truck
3 SI/OI
loading and check the communication of the Metering Skid.
Ensure pump being used is in working condition (check as per the
4 FO/OI
pumps operating manual).
Record Initial Level, Temp, Density and Pressure of the bullet used for
5 SI/OI
Tank Truck Loading.
If change over required in between the TT loading, then make the
6 SI/OI
next bullet ready.
7 Calculate the total quantity, and the quantity to be transferred. SI/OI
8 Ensure out let XZV of dispatch bullet is in open position. FO/OI
Ensure all hand operated valves of inlet and out let on the dispatch
9 FO/OI
bullet are closed.
Ensure other bullets 2 numbers 18” HOVs connecting bullet out let to
10 FO/OI
pump suction header are closed.
Open 2 numbers 18” hand operated valves connecting dispatch
11 FO/OI
bullet and pump suction header.
Open 4” hand operated pump minimum flow inlet valve to the
12 FO/OI
dispatch bullet.
63 | P a g e
13 Close 10” IBT pump suction and Open 10” pump main suction. FO/OI
14 Ensure other pumps 8” delivery valves are in closed position. FO/OI
Close 6” IBT delivery valve and open 8” pump main delivery of the
15 FO/OI
operating pump.
Close pump delivery line 3” & 6” valves connected to Alkylation and
16 FO/OI
DCU at battery limit.
Close Pump delivery header 3” & 6” valves near Pump House – 5 inter
17 connected with Pump House – 6 delivery header (Alkylation and FO/OI
DCU).
Isolate 12” hand operated valves on pump delivery line connected
18 FO/OI
with Pipe Line off-take and Marketing Terminal.
Ensure 205-A-035 upstream 12” hand operated valve is in closed
19 FO/OI
position.
Open the 12” valve in pump common delivery header and line up to
20 FO/OI
Tank Truck loading gantry metering skid.
21 Close all the MOV's inside the Metering Skid for calibration. FO/OI
Close the all Master Meter and stand-by meter hook ups connected
22 FO/OI
to duty meter.
23 Open the 10” valve in upstream of Metering Skid (205-A-053). FO/OI
24 Open inlet/outlet of the Duty Meter MOV's. FO/OI
25 Ensure XZVs of liquid lines in open condition for all loading bays. FO/OI
Ensure Tank Truck unloading and FLT lines are positively isolated with
26 FO/OI
spectacle blind.
27 Open 3” valve in downstream of sight glass in liquid loading line. FO/OI
28 Open 3” valve in upstream of liquid loading arm. FO/OI
Open 2 numbers 3” vapour balancing valves at the downstream of
29 FO/OI
vapour loading arm.
Open the 3”, 2 no. ball valve in bullet loading vapour balancing line
and ensure that spectacle blind between them is through & open
30 FO/OI
the 3” ball valve in TT vapour balancing line joining with bullet
common vapour header.
Close 4” and 3”, Total 6 no of ball valve which are joined with
31 FO/OI
spectacle blinds provided for TT unloading.
Open the vapour balancing of the dispatch bullet by opening the 8”
32 valve in the bullet vapour line and ensure that the vapour XZV's is in FO/OI
open position.
After carrying out the safety checks for the Tank Truck at the entry
33 gate, allow the Tank Truck to weighbridge for tare weight FO/OI
measurement after weighment TT will proceed to Gantry.
After TT reaching the gantry, fix the male coupling in the TT and
34 ensure no leak checked by opening the liquid inlet/ outlet manifold FO/OI
valve.
Ensure there is a positive LPG vapour pressure inside the Tank Truck
35 FO/OI
prior to loading.
Ensure that Filling Advice Note (FAN) from S & D (sales and dispatch)
has been signed by concern officer and field officer has to cross
36 FO/OI
check that all entries are corrected, if any variation observed, then
clarify with S&D officer.
Place the TT inside the allocated bay in proper position and place
37 the wooden blocks under front and rear tyres and instruct driver to FO/OI
switch off the master switch and confirm.
64 | P a g e
38 Place the DCP extinguisher in front of the TT. FO/OI
39 Connect earthing clamp to the tank truck at designated place. FO/OI
Connect the liquid loading and vapour balancing arms to the TT
40 FO/OI
respective manifolds.
41 Open the 3” liquid and vapour line valves of the Tank Truck manifold. FO/OI
Show the proximate card and generate the loading details in BCU to
42 authourise the Tank Truck loading in the designated bay. After FO/OI
authorization (TT number, Loading quantity and Bay) start TT loading.
Positive earthing/bonding circuit will allow start of loading by
43
communicating through LRCS/PLC as safety interlock.
16.7 PROCEDURE:
Loading Operation by Duty Meter

Once again re-check the line up and safety precautions to be
1 FO/OI
followed while Tank Truck loading.
2 Slowly Open the liquid and vapour line ball valves at loading arm. FO/OI
Ensure flow of liquid to the Tank Truck and monitor the loading
3 FO/OI
operation continuously.
After completion of loading close the liquid and vapour line valves of
4 tank truck and lines. Blow down the product entrapped in the FO/OI
loading arms to FLT.
After completion of blow down close valves and disengage loading
5 FO/OI
arms.
Ensure that wheel chokes are removed & instruct driver to remove the
6 FO/OI
TT from the bay and go to assigned place.
Remove the male coupling and fix blind or flange with mechanical
7 FO/OI
gasket.
After completion of the TT loading again TT will be allowed to pass
8 FO/OI
through the weigh bridge for gross weight measurement.
9 TT can be passed out with proper clearance of S&D FO/OI
SPECIAL NOTE:
Loading Operation by Stand- by Meter:
All the loading procedure will be same as mentioned above, only the Metering Skid
arrangement and requirement will change as mentioned below

1 Close the inlet/outlet MOV of the duty to be isolated. FO/OI
2 Open the inlet/outlet MOV of the standby meter to be lined up. FO/OI
3 Open the HOV in hook up between standby and duty meter to be
FO/OI
lined up.
Loading Operation by Duty/Stand- by with Master Meter for Calibration:

All the loading procedure will be same as mentioned above, only the Metering Skid
arrangement and requirement will change as mentioned below
65 | P a g e
1 Close the outlet of the MOV of the duty/ standby meter to
FO/OI
Calibrated.
2 Close the inlet MOV of the Master meter and open the MOV of
FO/OI
duty/standby calibrating line.
3 Open the outlet MOV of Master Meter and HOV of the line hooked
FO/OI
up with the duty/standby to be calibrated.

The driver observes the Green lamp flashing and presses the „START‟
1
pushbutton on the RIT. He observes that loading begins
Upon detection of „Start‟ push button press, the system issues a
2 remote command to the Batch Controller. The Green lamp is set to
glow steadily.
The Batch Controller activates the pump demand output to the DCS.
Depending on the number of batch controllers demanding the
pump, the DCS executes the auto pump sequencing logic (as
3
defined in the DCS logic) and turns ON a pump if it is not already
ON. Loading begins with the help of electronic flow control unit and
multistage set stop valve.
While loading, the Batch Controller handles all primary loading
functions and the LRC monitors the loading operation. The Batch
4
Controller continuously monitors the Earth safety interlock and stops
the loading upon negative input
In the normal loading sequence, the load status to “LOADING”
indicating that the load is in progress. During Loading Operation
5
Batch controller monitors the FlowMeter and flowrate of the Loading
arm.
LOADING COMPLETION PROCEDURE
Loading stops after equivalent amount of product is delivered by
6
flow meter, it sends signal to Batch controller to stop loading.
After loading is complete, the Batch Controller displays a message
7 to „Disconnect earth‟. The Green lamp turns OFF and Red lamp turns
ON. The Red lamp is turned OFF when earth is disconnected
The driver observes that the Red lamp is ON, realizes that the truck
8 has been loaded and disconnects earth. He then drives out of the
loading bay.
The loading bay is now free to receive the next tank truck. The bay is
9 free from loading operation. Next TT in queue can be placed in bay
and start loading. Batch control sends signal to LRC.
The driver is instructed to proceed to the exit gate. Shows the
10 proximity card, the gate is fully open and drives out of the loading
area.
The driver after exiting approaches the operator at the S&D Room
and hands over the respective card. The card must be shown to
11
reader for load completion and automatic IOT Exit pass generation
through software.
The driver then receives the IOT TAS invoice and exits the terminal
12
gate.
66 | P a g e
Loading Interrupt Handling
Interruptions at the loading bay may occur in one of the following forms:
1. Safety interlocks failure.
2. Alarm raised by Batch Controller.
3. Stop Command at the bay.
4. Stop command from the control room.
5. Emergency shutdown.
Though loading stops on occurrence of any of the above interruptions, the method of
recovery of the batch and the lamp indication on the LCP differ in each case and
hence needs elaboration.
a. Interruption due to Safety Interlock Failure
Loading at the bay stops immediately. The Batch Controller
Action on Interlock failure
displays the earth loss alarm.
Lamp status on Interlock
Red lamp is set to flashing
failure
Action on recovery of The Batch Controller displays a message : Press START when ready
interlock or STOP to cancel” Sequence continues.
Lamp status on recovery
The green lamp is set to flashing
of Interlock
Available with Batch Controller and hence will not be
Batch status
downloaded again from LRCS
b. Interruption due to Alarm by Batch controller

Action on Alarm Loading at that Batch Controller stops immediately. The Batch
detection by Batch Controller displays the alarm condition and then a request to
Controller present supervisor card.
Lamp status on detection Yellow lamp is set to flashing
of alarm
Action on supervisor card Load is PART LOADED. Batch Controller displays a message to
present card and the sequence continues.
c. Interruption due to Stop press on RIT

Action on Stop Loading at that Batch Controller stops immediately. The Batch Controller
press on RIT displays a message to “Press Start when ready or Stop to cancel”.
Lamp status on Red lamp turns ON.
Stop Press
Action on Start is Green lamp turn ON and loading continues from where it was Left off .
pressed
Batch status if Start Available with Batch Controller and hence will not be downloaded
is pressed again from LRCS.
Action on Stop Load is PART LOADED and Batch Controller displays a message to
press again disconnect earth. On detection of removal of earth, TT is released from
bay.
Batch status if Stop Batch is released and batch is PART LOADED.
is pressed second
time
d. Interruption due to Stop command from control room
67 | P a g e
Action on Stop Loading of that batch stops immediately. The Batch Controller display
command from an error message.
OIC in control
room
Lamp status on Yellow lamp is set to flashing
Stop command
from control room
Action on resume Batch Controller(s) displays a message “Press START when ready or STOP
command from to cancel”. Sequence continues
control room
Lamp status on Green lamp starts flashing
resume command
from control room
Batch status Batch shall be downloaded again
e. Emergency Shut Down

Action on Loading at all bays stops immediately. The Batch Controller(s) display
Emergency Shut “PerTT Loading Automation Softwaresive loss” alarm
down pushbutton
press
Lamp status on Red lamp is turned ON
Stop command
from control room
Batch status Batch(es) shall be downloaded again.

1 Ensure proper illumination while carrying out operations. FO/OI
2 Ensure first aid fire fighting systems and safety systems are in place
SI/OI
3 Clear communication should be there between the field and
FO/SI/OI
control room.
4 Line up should be done carefully and must be ensured to avoid
FO/OI
wrong line up.
6 Ensure all instrumentation and automation is in place and working. SI/OI
7 Ensure that Tank Truck safety check list was ful-filled at the security. FO/OI
16.9 PFD FOR LPG TANK TRUCK LOADING FROM MOUND-1
PFD FOR LPG TANK TRUCK LOADING FROM MOUND-2
16.10 PFD FOR LPG TANK TRUCK LOADING
16.12 LOADING LINE-UP AS PER APPENDIX-18
68 | P a g e
CHAPTER-17
LPG DESPATCH TO PIPE LINE OFFTAKE
17.1 OBJECTIVE:
The objective of the SOP is to define a step-by-step approach for performing the
Pumping of LPG to the Pipe Line off take.
17.2 SCOPE:
The SOP is applicable for all Pumping Operations from LPG storage bullets to Pipe Line off
take.
17.3 DESCRIPTION:
1. LPG from storage bullets is dispatched to Pipe Line off take using LPG transfer pumps,
205-P-001A/B/C (PH-05) for Mound I bullets and 205-P-001D/E/F (PH-06) for Mound II
bullets.
2. Accounting of product transferred to Marketing Terminal is done by CTMS 205-A-035.

pipeline off take.
requirements for LPG transfer to Pipe Line off take.
6. Ensure effectiveness of communication between IOT, IOCL refinery, IOCL Pipe Line
off take and IOT field before commencement of operation
9. Bullet level, temperature and pressure are used for reconciliation between bullet and
Metering Skid (205-A-051). Actual quantity delivered to marketing terminal is based
on flow meter only.
 Communicate to IOT the quantity to be transferred to Pipe line division.

 Nominating IOCL representative for the out turn finalisation prepared by IOT.
 Excise and Custom related formalities
 Ensure effectiveness of communication between IOT and IOCL Pipe line division and
overall co-ordination for the smooth delivery operation.
 Provide LPG lab analysis report (bullet nominated for product transfer) to IOT and
IOCL Pipe line division.
69 | P a g e
 Ensure effectiveness of communication between IOCL Refinery, Pipe line division and
IOT and overall co-ordination for the smooth product transfer operations
IOT’S ROLE:

 Coordinating with the IOC refinery and Pipe Line off take during LPG transfer
operation.
 Joint witness of readings of Metering Skid, LPG Bullet (level, temperature and
pressure) with IOCL nominated representative before and after dispatch.
 Product reconciliation, preparation of outturn reports and documentation.
pumping plan.
17.5 PREPARATION

Ensure bullet free of water, lab analysis of the product completed
1 FO/SI/OI
and product passed the test. Collect quality test report from IOC.
Confirm from IOC refinery quantity to be dispatched to pipeline off
2 SI/OI
take division.
IOCL/ IOCL representative/ Marketing Terminal representative/
3 surveyor available at terminal prior to delivery operation for initial SI/OI
out turn preparation.
4 IOCL pipeline off take Terminal and documented in the dispatch SI/OI
log book.
5 down the opening level, temperature and pressure. Use lab density FO/SI/OI
Note the initial reading of the flow meter in the Metering Skid (205-
6 FO/SI/OI
A-051.
If more than one bullet required for the dispatch then ensure that
7 FO/SI/OI
the out turn report was prepared for the other bullet also.
Establish proper communication between, pipeline off take
8 FO/SI/OI
Terminals, field and control room.
9 FO/OI
Ensure calibration validity and working condition of Mass Flow
Meter (205-A-051) installed in line to product transfer between Boot-
10 FO/SI/OI
3 Terminal to pipeline off take Terminals as per CTMS operating
manual.
12 FO/OI
rotation etc.
14 Ensure 18” common header isolation between Mound I and Mound FO/OI
70 | P a g e
II is fully closed.
16 FO/OI
17 FO/OI
dispatch bullet.
Close 6”, 3”&12” valve of alkylation unit, DCU & marketing terminal
18 FO/OI
lines respectively.
19 FO/OI
22 FO/OI
23 Open 12” valve in pump delivery common header valve. FO/OI
24 Open Metering Skid (205-A-051) upstream and downstream valves. FO/OI
25 Ensure XZV 3002 is open. FO/OI
After confirmation from IOCL pipeline off take terminals for their
26 readiness to receive the product open 12” valve at downstream of FO/OI/SI
XZV 3002.
17.6PROCEDURE:

valve.
Observe the pump condition for any abnormal vibration, sound
2 FO/OI
etc.
3 FO
4 FO/SI
5 SI
6 Record hourly dispatch figures (both bullet and Metering Skid). SI
7 Physically ensure for no leakages in the system. FO
Switch over of dispatch Bullet
1 SI/OI
operation and informing to IOCL refinery/ IOCL Marketing Terminal
about the switch over.
2 under dispatch. FO/OI
open, generally after 10-15% of opening of the valve in new bullet,
closing of the previous bullet is done after ensuring decrease of
level in the second bullet and steady pressure of the pipe lines.
71 | P a g e
3 SI/OI
4 Now make the third bullet ready for dispatch and so on for the next FO/SI
5 done along with IOCL refinery/ IOCL marketing terminal SI/OI
8 Record the completion time of the dispatch from the first bullet. SI
9 FO/OI
operation.
10 SI/OI
11 Confirm quantity received by IOCL marketing terminal. SI
12 FO/SI
Special Note:
1. Actual quantity transferred to Marketing Terminal is based on accounting from CTMS

(205-A-051).
2. Individual bullets out turn is prepared and reconciliation is done between bullets and
Metering Skid.
Product Transfer Operation through Duty Meter

Ensure upstream and downstream MOVs of Stand by meter and
1 FO/OI
master meter are closed.
Ensure calibration MOVs of duty meter and stand by meter are
2 FO/OI
closed.
3 Open upstream and downstream MOVs of Duty meter. FO/OI
Product Transfer Operation through Standby Meter
S.No Description FPR

Ensure upstream and downstream MOVs of Duty meter and master
1 FO/OI
meter are closed.
Ensure calibration MOVs of Duty meter and stand by meter are
2 FO/OI
closed.
3 Open upstream and downstream MOVs of Standby meter. FO/OI
Calibration of Duty meter during Product Transfer Operation

1 Ensure upstream and downstream MOVs of Standby meter closed. FO/OI
2 Ensure calibration MOV of standby meter is closed. FO/OI
3 Close downstream MOV of Duty meter and open downstream FO/OI
72 | P a g e
MOV of Master meter.
4 Open calibration MOV and upstream MOV of Duty meter FO/OI
Above procedure is repeated with respect to line up as required to
5 FO/OI
calibrate Standby meter.
1 Do not perform the operation while leakages are observed. FO/SI/OI
Hourly recheck quantity delivered from storage and pipeline off
2 take CTMS. Do not perform the operation while discrepancy in SI/OI
discharges figures is observed.
3 Pressures in the pipe lines should not be more than design pressure. FO/SI/OI
4 FO/OI
Ensure all instrumentation and automation system provided in LPG
5 FO/SI/OI
dispatch lines in working condition.
10 SI/OI
working condition.
Ensure agreed flow rates and pressures (between IOC pipeline off
11 FO/SI/OI
take terminal and IOT) are maintained during dispatch operation.
12 FO/SI/OI
dispatch operation.
14 FO/SI/OI
control room, IOT and marketing terminal about the operation.
17.9 PFD FOR LPG DESPATCH TO PIPE LINE OFFTAKE FROM MOUND-1
17.10 PFD FOR LPG DESPATCH TO PIPE LINE OFFTAKE FROM MOUND-2
73 | P a g e
CHAPTER-18
LPG TANK TRUCK UNLOADING/SICK TT HANDLING
18.1 OBJECTIVE:
The objective of this SOP is to define the general procedure for LPG TT unloading and
SICK Truck unloading taking all safety precautions.
18.2 SCOPE:
This SOP is applicable for all operational requirements and procedures in relation to
product transfer from Tank Trucks to bullets.
18.3 DESCRIPTION:
In the 7 bay loading gantry, all bays are provided with Tank Truck unloading facility
where in loading needs to be suspended during unloading of Tank Trucks at bay no 2 to
7. Bay no 1 is having separate unloading line up for handling sick trucks/ tank trucks
unloading while loading operation is in progress at other bays.
Unloading of Tank trucks is done by differential pressure using Vapour Compressor 205-A-
006-V-01.
Accounting of LPG transferred to bullet from sick TT is done by joint outturn report
prepared in presence of IOCL representative.
1. Unloading of LPG tank trucks should be done after written confirmation from IOCL
representative.
2. Ensure minimum 0.5 kg/cm 2 pressure of LPG vapour left in the tank truck after
unloading.
3. Control Room to ensure the Field Officers is fully aware of all operations within the
facility.
4. Continuous, short, precise and clear communication should be maintained
between Control Room Officer & Field Officers during unloading operation.
5. All the activities in the facility shall be carried out as per the Work Instructions and
instructions from Control Room.
6. Field Officer should notify the Control Room upon completion of all tasks.
facility, troubleshooting and line ups for loading and unloading of TT.
8. Ensure no other operations except TT unloading from bay no-1 or all bays to
designated bullet.
9. Tank Trucks being placed for the unloading should confirm to safety check list as
mentioned in Annexure prior to entry into the Terminal premises.
IOCL ROLE:
 Planning of LPG Receipt through TT unloading.

 Intimating IOT about the TT schedule, quantity to be unloaded.
74 | P a g e
 Generating Tank Truck invoice as per the unloading details given by IOT.
 Ensure safety confirmation of tank truck being placed for unloading.
 Joint reconciliation and finalisation of out turn prepared by IOT before and after Tank
Truck unloading.
IOT’S ROLE:
 Preparation of LPG bullet for Tank Truck unloading.

 Joint reconciliation and out turn preparation with IOCL before and after Tank Truck
unloading.
 Documentation of Out- Turn report.
 Security has to check the safety check list for all the TT's as per the list attached in the
APPENDIX:
 Line up and unloading of LPG Tank trucks as per IOCL requirement.
 Ensure all safety rules and regulations follow up by the personnel entering the LPG
premises and working in the area.
Instruction.
18.6 PREPARATION

1 Ensure quantity to be unloaded from Tank Truck as per IOCL
SI/OI
instruction.
2 Ensure product quality test report obtained from IOCL for the
FO/OI
product being unloaded from tank trucks to bullets.
3 Ensure inlet and out let HOVs of the nominated bullet are closed. FO/OI
4 Record Initial Level, Temp, Density and Pressure of the bullet used
SI/OI
for Tank Truck unloading and prepare initial out turn report.
6 Ensure LPG compressor being used is in working condition (check as
FO/SI/OI
per the compressor operating manual).
If change over required in between the TT unloading then make
SI/OI
the next bullet ready and its out turn prepared.
7 Calculate the total quantity, and the quantity to be unloaded from
Tank Trucks by measuring weighment as per weighbridge SOP FO/SI/OI
XXXX.
8 Ensure Inlet and Vapour line XZV of nominated bullet is in open
FO/SI/OI
position.
9 Ensure 6” Tank Truck unloading line inlet HOV to non-operating
FO/OI
bullets is closed.
10 Open 6” Tank Truck unloading line inlet HOV to nominated bullet. FO/OI
11 Ensure that Propylene Tank Truck vapour balancing is stopped and
FO/OI
3” HOV in TT loading gantry and 10” double ball valves are isolated.
12 Ensure that 8” vapour balancing HOV in nominated bullet is open. FO/OI
13 Open 8” LPG compressor suction HOV. FO/OI
14 Open 3 nos. of 10” common (for LPG & Propylene) compressor
FO/OI
suction valves.
75 | P a g e
15 Ensure 3” vapour recovery valves in TT gantry for LPG and
FO/OI
Propylene are closed.
16 Open 4” compressor delivery valve. FO/OI
17 In TT gantry 2 set of double ball valves of 4” are provided for Sick TT
unloading and whole TT unloading, open any one set of valves as FO/OI
per the operation.
18 Ensure 3” blow down valves in all the bays are closed. FO/OI
19 In case of sick TT unloading at Bay-01 close the 3” upstream HOV in
FO/OI
Vapour line and open 3” downstream HOV in vapour line.
20 Close the 3” HOV adjacent to sight glass and open the 3” HOV
FO/OI
adjacent to Check valve in liquid line.
21 Open the 3” unloading double ball valve tapped between sight
FO/OI
glass and check valve.
18.7 PROCEDURE:

1 Recheck the unloading line up and open Tank Truck vapour loading
FO/OI
line valve.
2 Start the compressor and check for vibrations, discharge pressure. FO/OI
3 After getting positive pressure in compressor open the 3” valve of
FO/OI
vapour arm.
4 After TT reaching positive pressure than bullet, open the 3” liquid arm
FO/OI
valve.
5 Conform the flow of liquid and keep continuous monitoring on
FO/SI/OI
unloading operation.
6 Once it conform that the TT is fully unloaded then stop the
FO/OI
compressor.
7 Change the lineup for vapour recovery by closing 4” TT unloading
FO/OI
valve and open 3” sick TT evacuation valve.
8 In compressor suction close the 10” (two nos.) sick TT evacuation
FO/OI
valve and open the 4” bypass valve.
9 And then start the compressor and make vapour recovery. FO/OI
10 After getting the required pressure in TT stop the compressor and
close the valves in liquid and vapour arm and blow down the FO/OI
vapour in spool piece between TT and arms.
11 Disengage the loading arm and remove the TT from the bay. FO/OI
12 Place the TT out of the bay and remove the male coupling and fix
FO/OI
blind.
13 After getting the proper clearance from the S&D send the TT out. FO/OI
14 Note all the operational activities and timings in log book and the
FO/SI/OI
log sheets as per the formats.

2 Ensure first aid fire fighting systems and safety systems are in place
SI/OI
3 Clear communication should be there between the field and
FO/SI/OI
control room.
76 | P a g e
4 Line up should be done carefully and must be ensured to avoid
FO/OI
wrong line up.
8 Ensure all PSVs are in line and their outlets are open to LT Flare. SI/OI
18.9 PDF FOR LPG TANK TRUCK UNLOADING
77 | P a g e
CHAPTER-19
OFF-SPEC LPG PUMPING TO ALKYLATION UNIT/ DCU UNIT
19.1 OBJECTIVE:
Pumping of Off-LPG to the Alkylation Unit/ DCU Unit.
19.2 SCOPE:
The SOP is applicable for all Pumping Operations from off-spec LPG storage bullets to
Alkylation Unit/ DCU Unit.
19.3 DESCRIPTION:
1. Off-spec LPG from storage bullets is dispatched to Alkylation Unit/ DCU Unit using LPG
transfer pumps, 205-P-001A/B/C (PH-05) for Mound I bullets and 205-P-001D/E/F (PH-
06) for Mound II bullets.
2. Accounting of product transferred to fuel gas pool is to done by the bullet initial and
final parameters.

pipeline off take.
requirements for off-spec LPG transfer to alkylation and DCU.
6. Ensure effectiveness of communication between IOT, IOCL refinery and IOT field
before commencement of operation.
9. Bullet level, temperature and pressure are used for reconciliation as there is no
Metering Skid.
 Communicate to IOT the quantity to be transferred to alkylation unit and DCU.

 Excise and custom related formalities if any.
 Ensure effectiveness of communication between IOT and overall co-ordination for
the smooth delivery operation.
 Joint witness with IOT official for LPG storage bullet (level, temperature and pressure)
nominated for dispatch.
 Finalise the outturn prepared by IOT (initial and after).
78 | P a g e
IOT’S ROLE:

 Coordinating with the IOC refinery during off-spec LPG transfer operation to
alkylation and DCU.
 Joint witness of readings of LPG Bullet (level, temperature and pressure) with IOC
refinery before and after dispatch.
 Reconciliation.
pumping plan.
19.6 PREPARATION

Confirm from IOC refinery quantity to be dispatched to alkylation
1 SI/OI
unit or DCU.
IOCL/ IOCL representative/ surveyor available at terminal prior to
2 SI/OI
delivery operation for initial out turn preparation.
3 IOCL alkylation unit or DCU and documented in the dispatch log SI/OI
book.
If more than one bullet is there for the dispatch then ensure that the
5 FO/SI
out turn report was prepared for the other bullet also.
Establish proper communication between refinery, alkylation unit or
7 SI/OI
DCU, field and control room.
8 FO/OI
11 FO/OI
rotation etc.
Ensure 18” common header isolation between Mound I and Mound
13 FO/OI
II is fully closed.
15 FO/OI
16 FO/OI
dispatch bullet.
17 FO/OI
79 | P a g e
19 FO/OI
Close the 6” and 3” valve of alkylation unit and DCU respectively in
20 FO/OI
hook up line with other mound pumphouse.
21 Close 12” valve in pipeline off take tapping. FO/OI
22 Close 12” marketing terminal header valve. FO/OI
Open the 6” alkylation valve in BOOY-3 battery limit if the product is
transferring to alkylation unit, if the product is transferred to DCU
23 FO/OI
close the alkylation valve and open the 3” DCU BOOT-3 battery limit
valve.
19.7 PROCEDURE:
valve.
3 FO
4 FO/SI
5 FO/SI
6 Record hourly dispatch figures. SI
1 SI/OI
operation and informing to IOCL refinery/ IOCL alkylation unit or
DCU about the switch over.
second bullet level and steady pressure of the pipe lines.
3 FO/SI/OI
4 Now make the third bullet ready for dispatch and so on for the next FO/SI/OI
5 done along with IOCL refinery/ IOCL alkylation unit or DCU SI/OI
1 Record the completion time of the dispatch from the first bullet. SI
2 FO/OI
operation.
80 | P a g e
3 SI/OI
4 Confirm quantity received by IOCL alkylation unit or DCU. SI
5 FO/SI/OI

3 FO/OI
7 Ensure proper illumination while carrying out operations. FO/OI/SI
8 SI/OI
working condition.
Ensure agreed flow rates and pressures (between IOC refinery and
9 FO/SI/OI
IOT) are maintained during dispatch operation.
Positive line up and positive flow rates to be ensured during dispatch
10 FO/SI/OI
operation.
12 FO/SI/OI
control room, IOT and IOCL refinery about the operation.
81 | P a g e
CHAPTER-20
OFF-SPEC LPG PUMPING TO REFINERY FUEL GAS POOL
20.1 OBJECTIVE:
Pumping of Off-LPG to the Fuel Gas Pool.
20.2 SCOPE:
The SOP is applicable for all Pumping Operations from off-spec LPG storage bullets to
Fuel Gas Pool.
20.3 DESCRIPTION:
1. Off-spec LPG from storage bullets is dispatched to Fuel Gas Pool using off-spec LPG
transfer pumps, 205-P-027A/B/C for all 9 bullets located in Mound I & Mound II.
2. Accounting of product transferred to fuel gas pool is to done by the bullet initial and
final parameters.

pipeline off take.
requirements for off-spec LPG transfer to fuel gas pool.
6. Ensure effectiveness of communication between IOT, IOCL refinery and IOT field
before commencement of operation.
9. Bullet level, temperature and pressure are used for reconciliation as there is no
Metering Skid.
 Communicate to IOT the quantity to be transferred to Fuel Gas Pool.

 Excise and custom related formalities if any.
 Ensure effectiveness of communication between IOT and overall co-ordination
for the smooth delivery operation.
 Joint witness with IOT official for LPG storage bullet (level, temperature and
pressure) nominated for dispatch.
 Finalise the outturn prepared by IOT (initial and after).
82 | P a g e
IOT’S ROLE:

 Coordinating with the IOC refinery during off-spec LPG transfer operation.
 Joint witness of readings of LPG Bullet (level, temperature and pressure) with IOC
refinery before and after dispatch.
 Reconciliation.
 The Operations-in-charge is overall responsible for maintaining the quality of this
SOP.
 The Planning and Co-ordination department is overall responsible for preparation
of pumping plan.
 The Control room Officer and Field officers are responsible for conducting the
work specified within this SOP.
20.6 PREPARATION

Confirm from IOC refinery quantity to be dispatched to Fuel Gas
1 SI/OI
Pool.
IOCL/ IOCL representative available at terminal prior to delivery
2 SI/OI
3 SI/OI
IOCL refinery and documented in the dispatch log book.
Establish proper communication between refinery, field and control
5 FO/SI/OI
room.
6 FO/OI
7 Ensure off-spec LPG transfer pumps are in good working condition. FO/OI
8 FO/OI
rotation etc.
9 Ensure 6” valve for off-spec pump suction outlet in bullet are close. FO/OI
Open 6” valve for off-spec pump suction outlet in the bullet to be
10 FO/OI
dispatched and ensure no leak.
Ensure 3” off-spec pump minimum flow recirculation valve in all
11 FO/OI
bullet are closed
Open 3‟ off-spec pump minimum flow recirculation valve in the
12 FO/OI
bullet to be dispatched and ensure no leak.
Make the vapour balancing for the bullet by opening 8” valve in
13 FO/OI
bullet vapour line.
14 Ensure all the XZV‟s are open. FO/OI
15 Open the 6” valve in pump suction. FO/OI
16 FO/OI
20.7 PROCEDURE:
83 | P a g e
1 pressure at the pump discharge. Slowly open the pump delivery 4” FO/OI
valve.
3 FO
4 SI/OI
5 FO/SI/OI
6 Record hourly dispatch figures of Bullet. SI/OI
It is required to change the dispatch of LPG from one Bullet to
1 another Bullet; this procedure can be carried out without stopping FO/SI/OI
the operation and informing to IOCL refinery about the switch over.
level in the second bullet and steady pressure of the pipe lines.
3 FO/SI/OI
4 Now make the third bullet ready for dispatch and so on for the next FO/SI/OI
5 done along with IOCL refinery representative, and finalise the out SI/OI
turn report.
1 Record the completion time of the dispatch from the first bullet. SI/OI
2 FO/OI
operation.
3 SI/OI
4 Confirm quantity received by IOCL fuel gas pool in refinery. SI/OI
5 FO/SI/OI

1 Do not perform the operation while leakages are observed. FO/SI/OI
Verification of product dispatch from Bullet and receipt by refinery
2 SI/OI
on random basis with IOCL to be done. Do not perform the
84 | P a g e
operation while discrepancy in discharge and receipt figures is
observed.
4 FO/OI
9 SI/OI
working condition.
Ensure agreed flow rates and pressures (between IOC refinery and
10 FO/SI/OI
IOT) are maintained during dispatch operation.
11 FO/SI/OI
dispatch operation.
13 FO/SI/OI
control room, IOT and IOCL refinery about the operation.
85 | P a g e
PART-III
APPENDICES
86 | P a g e
APPENDIX-1.0: BULLET DETAILS:
NOMINAL Safe
Liquid Inlet Inside
Bullet LENGTH( CAPACITY HH H L LL Filling
S. No. ID(M) The Bullet Distance
No. M) (M3 (mm) (mm) (mm) (mm) Capacity
From Bottom (M)
WATER) (M3)
1 V-003 6.4 93.45 3130 1.235

2 V-004 6.4 93.45 3130 1.235
3 V-005 6.4 93.45 3130 1.235
4 V-007 6.4 93.45 3130 1.235
5 V-008 6.4 93.45 3130 1.235
6 V-009 6.4 93.45 3130 1.235
7 V-012 6.4 93.45 3130 1.235
8 V-013 6.4 93.45 3130 1.235
9 V-014 6.4 93.45 3130 1.235
APPENDIX-2.0: NOZZLES AND ASSOCIATE FITTINGS FOR EACH BULLET
DESCRIPTION PIPE FLANGE

NAME QTY SERVICE NB SCH/THK RATING
N1 1 Liquid outlet 500 SCH.80 300#
N2 1 Vapour inlet/outlet 250 SCH.80 300#
N3 1 LIQUID INLET 350 SCH.80 300#
N4 1 SAFETY RELIEF VALVE 200 SCH.80 300#
N5 1 SPARE 100 SCH.80 300#
K1 1 PRESSURE TRANSMITTER 80 SCH.160 300#
K2 1 LEVEL TRANSMITTER(SERVO) 200 SCH.160 300#
K3 1 LEVEL TRANSMITTER(GWR) 100 SCH.160 300#
K4 1 TEMERATURE TRANSMITTER 80 SCH.160 300#
K5 1 LEVEL SWITCH 100 SCH.160 300#
M1 1 MANHOLE 600 28THK 300#
M2 1 MANHOLE 600 28THK 300#
D1 1 DOME 1500I.D 28THK --
D1 1 DOME 1500I.D 28THK --
87 | P a g e
2.1 BULLET MANIFOLD CONNECTIONS:
CONNECTIONS SIZE
PROPYLENE IBT 6”
TT UNLOADING 6”
STARTUP 3”
BLENDING SPILLAGE 10”
LPG RECEIPT 12”
OFF SPEC RECEIPT 4”
PUMP MINIMUM FLOW 6”
IBT 6”
OFF SPEC PUMP MINIMUM FLOW 3”
INLET HEADER 12”
VAPOUR BALANCE 8”
DISPATCH SUCTION 18”
IBT SUCTION 10”
OFF SPEC PUMP SUCTION 6”
WATER DRAINING 3”
APPENDIX-3.0: RECEIPT DETAILS
REFINERY UNIT DESIGN PRESSURE (Kg/ cm2) DESIGN TEMPERATURE (0C) LINE SIZE (in) FLOWRATE
FCC 39.2 98 10
CCR 39.2 98 3
AVU – C3 39.2 98 3
PROPANE-
39.2 98 3
ALKYLATION
AVU-BUTANE 39.2 98 4
C4 39.2 98 6
LPG- ALKYLATION 39.2 98 8
PROPANE – PRU 39.2 98 4
3.1DISPATCH DETAILS
FUEL GAS
PARAMETER MARKETING TERMINAL PIPE LINE OFF-TAKE TANK TRUCK LOADING
POOL
Design Pressure 39 (Kg/ cm 2) 39 (Kg/ cm 2) 32.3 (Kg/ cm 2) 22.3 (Kg/ cm 2)
Design Temp -45 to 65 (0C) -45 to 65 (0C) -45 to 65 (0C) -45 to 65 (0C)
Line Size 12” 12” 12” 4”
Pump Flow rate 190 m3/hr 190 m3/hr 190 m3/hr 20 m3/hr
Pump Tag No. 205-P-001 205-P-001 205-P-001 205-P-001 205-P-001 205-P-001 205-P-027
A,B,C, D,E,F A,B,C D,E,F A,B,C D,E,F A,B,C
Connected V- V- V- V-012, V- V-012, 013, V-
Bullet 003,004,005 012,013,014 003,004,005 013, 014 003,004,0 014 003,004,005,00
88 | P a g e
,007,008,00 ,007,008,00 05,007,00 7,008,009,012,0
9 9 8,009 13,014
89 | P a g e
APPENDIX-4.0: PUMP & MOTOR DETAILS
Pump No.
205-P-001 A,B,C 205-P-001D,E,F 205-P-027 A,B,C
DISPATCH TO
MARKETING VIA PIPELINE OFF TAKE VIA OFF SPEC PUMPING
Service
PIPELINE TRANSFER & TT PIPELINE TRANSFER TO FUEL GAS POOL
LOADING
Rated
190 m 3/hr 190 m 3/hr 20 m 3/hr
Capacity(m³/hr)
Discharge
24.07 kg/cm²g 24.07 kg/cm²g 16.7 kg/cm²g
Pressure(kg/cm²g)
Discharge Pressure
Shut Off(kg/cm²g)
CAN TYPE CENTRIFUGAL CAN TYPE
Type CAN TYPE CENTRIFUGAL CENTRIFUGAL
Flow Control loop FV-0002 FV- 9802 FV-0092

Suction Header Size 10'' 10'' 4''
Discharge Header
8'' 8'' 3''
Size
Rating of Motor(kw) 132 132 7.5
Motor Current
1493 1493 14
(amp)
Motor RPM 216 216 1460
4.1 WATER DRAIN POT DETAILS:
205-VT-110
WATER DRAIN POT
ID 1900 mm
HEIGHT 4300 mm
DESIGN PRESSURE 3.5 Kg/cm 2g
DESIGN TEMPERATURE -450C/ 650C
4.2 ETHYL MARCAPTAN PUMP AND VESSEL FACILITY:
205-P-105
ETHYL MERCAPTAN TRANSFER PUMP
CAPACITY @ suction cond. 0.40 m 3/hr
205-VT-105
ETHYL MERCAPTAN STORAGE VESSEL
ID 750 mm
HEIGHT 1500 mm
DESIGN PRESSURE 3.5 Kg/ cm 2g
90 | P a g e
DESIGN TEMPERATURE 650C
205-P-043 A/B
ETHYL MERCAPTAN DOSING PUMP
CAPACITY @ suction cond. 15 LPH
APPENDIX-4.3 VAPOUR COMPRESSOR DETAILS

205-A-006
Motor KW 90
RPM 1480
Drive V-Belt
Stage Single
APPENDIX-5.0: UTILITY SYSTEM
S. No Parameter Minimum Normal Maximum Mech. Design

SERVICE WATER (WS)
Pressure (Kg/cm2 g) 4 6 8 10.5
Temperature (°C) Ambient Ambient Ambient 65
PLANT AIR (AP)

Pressure (Kg/cm2 g) 4 7 8 10.5
Temperature (°C) 40 40 50 65
INSTRUMENT AIR
Pressure(Kg/cm2 g) 4.5 7 8 10.5
Temperature (°C) Ambient 40 50 65
N –NITROGEN
Pressure(Kg/cm2 g) 3 8 8.3 10.5
Temperature (°C) 20 Ambient Ambient 65
POTABLE WATER
Pressure (Kg/cm2 g) - 6 9 -
Temperature (°C) - - 65 -
FIRE WATER
Pressure(Kg/cm2 g) 7 7 11.5 16
Temperature (°C) Ambient Ambient Ambient 65
91 | P a g e
APPENDIX-6.0: XZV DETAILS:
INSTRUMENT AIR PRESSURE

TAG NO. SIZE FULL OPENING/CLOSING TIME (SEC) SERVICE
(Kg/cm2)
XZV- 0001 14” 90 LPG 4.5
XZV- 0002 18'' 90 LPG 4.5
XZV- 0023 8” 90 LPG 4.5
XZV-0003 14” 90 LPG 4.5
XZV- 0004 18'' 90 LPG 4.5
XZV- 0024 8” 90 LPG 4.5
XZV- 0005 14” 90 LPG 4.5
XZV- 0006 18'' 90 LPG 4.5
XZV-0025 8” 90 LPG 4.5
XZV-0188 14” 90 LPG 4.5
XZV- 0190 18'' 90 LPG 4.5
XZV- 0189 8” 90 LPG 4.5
XZV- 8603 14” 90 LPG 4.5
XZV- 0192 18'' 90 LPG 4.5
XZV- 0191 8” 90 LPG 4.5
XZV-0193 14” 90 LPG 4.5
XZV- 0195 18'' 90 LPG 4.5
XZV- 0194 8” 90 LPG 4.5
XZV-1188 14” 90 LPG 4.5
XZV-1190 18'' 90 LPG 4.5
XZV- 1189 8” 90 LPG 4.5
XZV-1003 14” 90 LPG 4.5
XZV- 1192 18'' 90 LPG 4.5
XZV- 1191 8” 90 LPG 4.5
92 | P a g e
XZV- 1193 14” 90 LPG 4.5
XZV- 1195 18'' 90 LPG 4.5
XZV- 1194 8” 90 LPG 4.5

APPENDIX-7.0: MOV AND HOV DETAILS
TAG NO. SIZE FULL OPENING/CLOSING TIME (SEC) SERVICE LOCATION

BOOT-3 BATTERY LIMIT
MOV-0724 12” 90 LPG
MARKETING PIPELINE TRANSFER
BOOT-3 BATTERY LIMIT
MOV-0279 12” 90 LPG
MARKETING PIPELINE TRANSFER
LPG PUMPHOUSE HOV DETAILS
LPG Marketing
LOCATION 250-P-001 A 250-P-001 B 250-P-001 C
Pump Main Suction HO Valve P-001A-S-001 P-001B-S-001 P-001C-S-001
Pump IBT Suction HO Valve P-001A-S-002 P-001B-S-002 P-001C-S-002
Pump Main Delivery HO Valve P-001A-D-001 P-001B-D-001 P-001C-D-001
Pump IBT delivery HO Valve P-001A-D-002 P-001B-D-002 P-001C-D-002
LPG Pipeline Off Take
LOCATION 250-P-001 D 250-P-001 E 250-P-001 F
Pump Main Suction HO Valve P-001D-S-001 P-001E-S-001 P-001F-S-001
Pump IBT Suction HO Valve P-001D-S-002 P-001E-S-002 P-001F-S-002
Pump Main Delivery HO Valve P-001D-D-001 P-001E-D-001 P-001F-D-001
Pump IBT delivery HO Valve P-001D-D-002 P-001E-D-002 P-001F-D-002
LPG Off-Spec
LOCATION 250-P-027 A 250-P-027 B 250-P-027 C
Pump Main Suction HO Valve P-027A-S-001 P-027B-S-001 P-027C-S-001
Pump Main Delivery HO Valve P-027A-D-001 P-027B-D-001 P-027C-D-001
93 | P a g e
LPG TT GANTRY HOV DETAILS
LPG LOADING GANTRY

LOCATION BAY-01 BAY-02 BAY-03 BAY-04 BAY-05 BAY-06 BAY-07
LLG- LLG-
LLG-B1- LLG-B2- LLG-B3- LLG-B5-
Liquid Loading Upstream B4-L- B6-L- LLG-B7-L-001
L-001 L-001 L-001 L-001
3"HO Valve 001 001
LLG- LLG-
Liquid Loading B4-L- B6-L- LLG-B7-L-002
L-002 L-002 L-002 L-002
Downstream 3"HO Valve 002 002
LLG- LLG-
Liquid Unloading B4-L- B6-L- LLG-B7-L-003
L-003 L-003 L-003 L-003
Upstream 3"HO Valve 003 003
LLG- LLG-
Liquid Unloading B4-L- B6-L- LLG-B7-L-004
L-004 L-004 L-004 L-004
LLG- LLG-
Liquid Blowdown B4-L- B6-L- LLG-B7-L-005
L-005 L-005 L-005 L-005
LLG- LLG-
Liquid Blowdown B4-L- B6-L- LLG-B7-L-006
L-006 L-006 L-006 L-006
LLG- LLG-
Vapour upstream 3"HO B4-V- B6-V- LLG-B7-V-001
V-001 V-001 V-001 V-001
Valve 001 001
LLG- LLG-
Vapour Downstream B4-V- B6-V- LLG-B7-V-002
V-002 V-002 V-002 V-002
3"HO Valve 002 002
LLG- LLG-
Vapour Blowdown B4-V- B6-V- LLG-B7-V-003
V-003 V-003 V-003 V-003
LLG- LLG-
Vapour Blowdown B4-V- B6-V- LLG-B7-V-004
V-004 V-004 V-004 V-004
LPG TT METERING SKID HOV DETAILS
LPG Metering Skid

Duty Duty Duty Duty Duty Duty Duty
Meter- Meter- Meter- Meter- Meter- Meter- Meter-
01 02 03 04 05 06 07
Master Meter HO LMS-M- LMS-M- LMS-M- LMS- LMS-M- LMS- LMS-
Valve D1 D2 D3 M-D4 D5 M-D6 M-D7
Stand-by Meter-01 HO LMS-S1- LMS- LMS-S1- LMS- LMS-S1- LMS- LMS-
Valve D1 S1-D2 D3 S1-D4 D5 S1-D6 S1-D7
94 | P a g e
LPG BULLETS HOV DETAILS

LPG Bullets
LOCATION V-003 V-004 V-005 V-007 V-008 V-009 V-012 V-013 V-014
Off-Spec Receipt 4" V-003- V-004- V-005- V-007- V-008-I- V-009- V-012-I- V-013-I- V-014-I-
HO Valve I-001 I-001 I-001 I-001 001 I-001 001 001 001
Blending Spillage 10" V-003- V-004- V-005- V-007- V-008-I- V-009- V-012-I- V-013-I- V-014-I-
HO Valve I-002 I-002 I-002 I-002 002 I-002 002 002 002
Blended LPG Receipt V-003- V-004- V-005- V-007- V-008-I- V-009- V-012-I- V-013-I- V-014-I-
12"HO Valve I-003 I-003 I-003 I-003 003 I-003 003 003 003
Intter Bullet Transfer V-003- V-004- V-005- V-007- V-008-I- V-009- V-012-I- V-013-I- V-014-I-
6"HO Valve I-004 I-004 I-004 I-004 004 I-004 004 004 004
Pump minimum Flow V-003- V-004- V-005- V-007- V-008-I- V-009- V-012-I- V-013-I- V-014-I-
4"Line I-005 I-005 I-005 I-005 005 I-005 005 005 005
Inter Mound
Transfer From V-003- V-004- V-005- V-007- V-008-I- V-009- V-012-I- V-013-I- V-014-I-
Propylene 6"HO I-006 I-006 I-006 I-006 006 I-006 006 006 006
Valve
Off-Spec Minimum V-003- V-004- V-005- V-007- V-008-I- V-009- V-012-I- V-013-I- V-014-I-
Flow 3"HO Valve I-007 I-007 I-007 I-007 007 I-007 007 007 007
Receipt Start-up V-003- V-004- V-005- V-007- V-008-I- V-009- V-012-I- V-013-I- V-014-I-
3"HO Valve I-008 I-008 I-008 I-008 008 I-008 008 008 008
TT Unloading 6"HO V-003- V-004- V-005- V-007- V-008-I- V-009- V-012-I- V-013-I- V-014-I-
Valve I-009 I-009 I-009 I-009 009 I-009 009 009 009
Pump Main Suction
V-003- V-004- V-005- V-007- V-008- V-009- V-012- V-013- V-014-
Upstream 18"HO
O-001 O-001 O-001 O-001 O-001 O-001 O-001 O-001 O-001
Valve
Pump Main Suction
V-003- V-004- V-005- V-007- V-008- V-009- V-012- V-013- V-014-
down Stream 18"HO
O-002 O-002 O-002 O-002 O-002 O-002 O-002 O-002 O-002
Valve
Intter Bullet Transfer
Suction V-003- V-004- V-005- V-007- V-008- V-009- V-012- V-013- V-014-
Upstream10"HO O-003 O-003 O-003 O-003 O-003 O-003 O-003 O-003 O-003
Valve
Intter Bullet Transfer
V-003- V-004- V-005- V-007- V-008- V-009- V-012- V-013- V-014-
Suction Down
O-004 O-004 O-004 O-004 O-004 O-004 O-004 O-004 O-004
stream10"HO Valve
Off-Spec Pump
V-003- V-004- V-005- V-007- V-008- V-009- V-012- V-013- V-014-
Suction Upstream
O-005 O-005 O-005 O-005 O-005 O-005 O-005 O-005 O-005
6"HO Valve
Off-Spec Pump
V-003- V-004- V-005- V-007- V-008- V-009- V-012- V-013- V-014-
Suction Down
O-006 O-006 O-006 O-006 O-006 O-006 O-006 O-006 O-006
Stream 6"HO Valve
Water Draining
V-003- V-004- V-005- V-007- V-008- V-009- V-012- V-013- V-014-
Upstream 3"HO
O-007 O-007 O-007 O-007 O-007 O-007 O-007 O-007 O-007
Valve
Water Draining
V-003- V-004- V-005- V-007- V-008- V-009- V-012- V-013- V-014-
Down Stream 3"HO
O-008 O-008 O-008 O-008 O-008 O-008 O-008 O-008 O-008
Valve
95 | P a g e
Vapour Line 8"HO V-003- V-004- V-005- V-007- V-008- V-009- V-012- V-013- V-014-
Valve V-001 V-001 V-001 V-001 V-001 V-001 V-001 V-001 V-001
96 | P a g e
APPENDIX-8.0: RELIEF VALVE SETTINGS
OUTLET
PRESSURE SET INLET SIZE
S.NO TAG NO SERVICE SIZE RATING
POINT (Kg/cm2g) (INCH)
(INCH)
V-003 LPG
1 PSV-0003 18.5 8 18 300
storage bullet
V-003 LPG
2 PSV-2222 18.5
storage bullet
V-004 storage
3 PSV-0082 18.5 8 18 300
bullet
V-004 storage
4 PSV-0083 18.5
bullet
V-005 storage
5 PSV-0084 18.5 8 18 300
bullet
V-005 storage
6 PSV-0089 18.5
bullet
V-007 storage
7 PSV-0426 18.5 8 18 300
bullet
V-007 storage
8 PSV-0427 18.5
bullet
V-008 storage
9 PSV-0431 18.5 8 18 300
bullet
V-008 storage
10 PSV-0430 18.5
bullet
V-009 storage
11 PSV-0434 18.5 8 18 300
bullet
V-009 storage
12 PSV-0435 18.5
bullet
V-012 storage
13 PSV-1426 18.5 8 18 300
bullet
V-012 storage
14 PSV-1427 18.5
bullet
V-013 storage
15 PSV-1431 18.5 8 18 300
bullet
V-013 storage
16 PSV-1430 18.5
bullet
V-014 storage
17 PSV-1434 18.5 8 18 300
bullet
V-014 storage
18 PSV-1435 18.5
bullet
205-P-027
SUCTION
19 PSV-0392 39 2 2 300
COMMON
HEADER
205-P-001 A,B,C
PUMP IBT
20 PSV-0001 39 2 2 300
COMMON
SUCTION HEADER
205-P-001 A,B,C
PUMP DISPATCH
21 PSV-0004 39 2 2 300
COMMON
SUCTION HEADER
205-P-001 A,B,C
MINIMUM FLOW
22 PSV-0005 39 2 2 300
COMMON
HEADER
23 PSV-0391 205-P-027 A,B,C 39 2 2 300
97 | P a g e
MINIMUM FLOW
COMMON
HEADER
205-P-0001 A,B,C
IBT DELIVERY
24 PSV-0002 39 2 2 300
COMMON
HEADER
BETWEEN 205-P-
027 A,B,C
MINMUM FLOW
COMMON
25 PCV-0390 3 3 300
HEADER AND
SUCTION
COMMON
HEADER.
BETWEEN 205-P-
001 A,B,C
MINMUM FLOW
COMMON
26 PCV-0016 3 3 300
HEADER AND
SUCTION
COMMON
HEADER.
STARTUP RECEIPT
27 PSV-5026 COMMON 39 2 2 300
HEADER
inter bullet
28 PSV-5027 39 2 2 300
suction header
29 PSV-5028 OFF SPEC RECIPT 39 2 2 300
TT UNLOADING
30 PSV-5029 39 2 2 300
HEADER
BETWEEN 205-P-
001 A, B, C
MINMUM FLOW
COMMON
31 PCV-1116 2 2 300
HEADER AND
SUCTION
COMMON
HEADER.
PUMP COMMON
32 PSV-0393 39 2 2 300
DELIVERY
PUMP COMMON
33 PSV-5024 39 2 2 300
SUCTION
PUMP COMMON
34 PSV-5021 39 2 2 300
SUCTION
PUMP IBT
35 PSV-5022 COMMON 39 2 2 300
SUCTION
NOTE: All PSV outlets are connected to LT Flare.
98 | P a g e
APPENDIX-9.0: INTEGRATION BETWEEN REFINERY AND LPG STORAGE FACILITY
RESPECTIVE BOOT-3 BATTERY LIMIT

STREAM OPERATING DESIGN
PRESSURE (kg/cm²) TEMP ( C) PRESSURE (kg/cm²)
0 TEMP (0C)
FCC 15.5 40 39.2 98
CCR 16.4 40 39.2 98
AVU – C3 15.5 40 39.2 98
PROPANE – ALKYLATION 15.5 40 39.2 98
AVU-BUTANE 15.5 40 39.2 98
C4 15.5 40 39.2 98
LPG- ALKYLATION 16 40 39.2 98
PROPANE – PRU 15.6 40 39.2 98
SERVICE WATER (WS) 6 Ambient 10.5 65
PLANT AIR (AP) 7 40 10.5 65
INSTRUMENT AIR 7 40 10.5 65
N –NITROGEN 8 Ambient 10.5 65
POTABLE WATER 6 Ambient 10.5 65
FIRE WATER 7 Ambient 16 65
APPENDIX-10.0: BULLETS INSTRUMENTATION DETAILS:
NAME TAGE NO. LOCATION

Servo gauge LT-0001
Radar gauge LT-0002
Pressure transmitter PT-0002 V-003
Temperature transmitter TT-0001
Level switch LZT-2001
Servo gauge LT-0004
Radar gauge LT-0005
Servo gauge LT-0007
Radar gauge LT-0008
Servo gauge LT-0206
Radar gauge LT-0207
Servo gauge LT-0206
Radar gauge LT-0209
V-008
Pressure transmitter PT-0429
99 | P a g e
Servo gauge LT-0210
Radar gauge LT-0211
Servo gauge LT-1206
Radar gauge LT-1207
Servo gauge LT-1206
Radar gauge LT-1209
Servo gauge LT-1210
Radar gauge LT-1211
100 | P a g e
APPENDIX-11.0: ALARMS
LEVEL (mm)
SL.NO BULLET NO. SERVICE/ Low Low Low High High High
AREA ALARM, ALARM, ALARM, ALARM,
mm mm mm mm
1 V-003 LPG
2 V-004 LPG
3 V-005 LPG
4 V-007 LPG
5 V-008 LPG
6 V-009 LPG
7 V-012 LPG
8 V-013 LPG
9 V-014 LPG
PRESSURE (Kg/cm2 g)
SNO TAG SERVICE/ LOW LOW LOW HIGH HIGH HIGH
AREA ALARM ALARM ALARM ALARM
1 V-003 LPG 5.63 6.2 14 17
2 V-004 LPG 5.63 6.2 14 17
3 V-005 LPG 5.63 6.2 14 17
4 V-007 LPG 5.63 6.2 14 17
5 V-008 LPG 5.63 6.2 14 17
6 V-009 LPG 5.63 6.2 14 17
7 V-012 LPG 5.63 6.2 14 17
8 V-013 LPG 5.63 6.2 14 17
9 V-014 LPG 5.63 6.2 14 17
LPG TRANSFER PUMPS DELIVERY
10 205-P- LPG 23.2 -- -- 31.767
001
A/B/C
11 205-P- LPG 23.2 -- -- 31.767
001
D/E/F
12 205-B- LPG – OFF 15.5 -- -- 22.3
027 SPEC
A/B/C
APPENDIX-12.0: SAFETY INTERLOCKS
EQUIPMENT/LOCA SAFETY
CAUSE EFFECT REMARK
TION INTERLOCKS
Level>510
High level Alarm
0mm
Level>520 2 out of 3 logic.
High High ESD valve at the inlet and
0mm LI-0001,LI-
V- level Alarm
0002,LZT-2001
003/004/007/008/
Low level Alarm.
009/012/013/014
Close ESD valve at the
Low Low outlet XZV
level Shutdown LPG transfer
pump.p-001A/B/C.
101 | P a g e
Shutdown off-spec LPG
transfer pump.p-027A/B/C.
Close ESD valve at LPG
marketing line. (XZV-0179).
pipeline-off-take .(XZV-3002).
Alarm
Close inlet XZV.

High High
Alarm.
pressure
High
Alarm
pressure
Low pressure Alarm
Close ESD valve at the
outletXZV.
Shutdown LPG transfer
pump.p-001a/b/c.
Shutdown offspec LPG
transfer pump.p-027a/b/c.
Low Low marketing line.(XZV-0179).
pressure Close ESD valve at LPG
pipeline .(XZV-3002).
Alarm.
Close ESD valve at
vapour balancing line(XZV-
0023).
Alarm.
On LPG High line

transfer pressure. Shutdown LPG transfer
pump pump(p-0001a/b/c/d/e/f/).
common alarm
disc.
Header.
On LPG Low
transfer pressure
pump
alarm.
common
disc.
Header.
ESD Shutdown LPG transfer
actuation pumps(p-001a/b/c/d/e/f).
at LPG shutdown propylene
tanker vapour compressor
loading Close ESD valves at LPG
bays(refin transfer bays (XZV-6001, 6002,
ery end) 6003, 6004, 6006, 6007 6051).
vapour balancing line(XZV-
102 | P a g e
6005)
Alarm.
ESD Shutdown LPG transfer ESD system

actuation pumps(p-0001a/b/c/d/e/f). should stop the
at LPG close ESD valve at LPG transfer pump
pipeline transfer pipeline(XZV-3002). first before ESD
offtake.(at ESD signal to pipeline. valve
refinery Alarm. completely
end). closed.
ESD Shutdown LPG transfer
actuation pumps(p-0001a/b/c/d/e/f).
at LPG close ESD valve at LPG
marketing marketing line(XZV-0179).
terminal.( Close ESD valve at LPG
at refinery marketing line(XZV-0104).
end) ESD signal to marketing
line.
Alarm.
Common disc.
High flow alarm
Header of p-
rate
001a/b/c.
Common disc.
Low flow Alarm.
Header of p-
indication.
001a/b/c.
Individual Disc. Of Shutdown particular LPG
p- High High transfer pumps.
001A/B/C/D/E/F/. pressure. alarm
Individual Disc. Of Shutdown particular LPG

p- Low Low transfer pumps.
001A/B/C/D/E/F/. pressure. Alarm
Ethyl Mercaptan Alarm

High level
storage vessel
Ethyl Mercaptan Alarm
Low level
storage vessel
Ethyl Mercaptan Shutdown ethyl
storage vessel Mercaptan dosing pump(p-
Low Low
43a/b).
level
Alrm
On bullet 205-V- Pump trip

003/004/005/007/ action in case
008/009/012/013/ Shutdown LPG transfer of High High
14. High High pump(p-001a/b/c/d/e/f). level in the
level. alarm bullet has to
take place
only if that
perticular bullet
103 | P a g e
is getting filled
under IBT not
normal receipt
mode.
On off-spec. LPG Shutdown off spec LPG
transfer pump High transfer pump(p-027a/b/c).
disharge header. pressure. alarm.
On off spec. LPG

Low Alarm
transfer pump
pressure.
disharge header.
Off spec LPG
transfer pump Alarm
High flow
discharge
header.
Off spec LPG
transfer pump Alarm
Low flow
discharge
header.
At pump 205-p- shutdown off spec LPG
027A/B/C. High High pump 205-P-027a.
pressure alarm
At pump 205-p- Shutdown off spec LPG

027A/B/C Low Low pump 205-P-027a.
pressure alarm
104 | P a g e
APPENDIX-13.0: FIRE PROTECTION DETAILS
EQUIPMENTS QUANTITY
DOUBLE HYDRANT 27
HOSE BOX 15
WATER MONITOR 15
DELUGE 6
APPENDIX-14.0: FIRST AID FIRE FIGHTING DETAILS

EQUIPMENTS LOCATION QUANTITY
10KG DCP TT GANTRY 4
75KG DCP TT GANTRY 1
10KG DCP PUMPHOUSE-5 4
25KG DCP PUMPHOUSE-6 2
APPENDIX-15.0: AGDC (ALARM AND GAS DETECTORS COMBUSTIBLE)
TAG NO LOCATION REMARKS

205-AGDC-0807 V-003 DOME-1
205-AGDC-0810 V-004 DOME-1
205-AGDC-0814 V-005 DOME-1
205-AGDC-0817 V-007 DOME-1
205-AGDC-0821 V-008 DOME-1
205-AGDC-0825 V-009 DOME-1
205-AGDC-0806 V-003 DOME-2
205-AGDC-0813 V-004 DOME-2
205-AGDC-0816 V-005 DOME-2
205-AGDC-0820 V-007 DOME-2
205-ADGC-0824 V-008 DOME-2
205-AGDC-0827 V-009 DOME-2
205-AGDC-0809 V-003 OUTLET
205- AGDC-0812 V-004 OUTLET
205- AGDC-0804 V-003 MANIFOLD
205- AGDC-0801 205-P-001A MANIFOLD
205- AGDC-0802 205-P-001B MANIFOLD
205- AGDC-0803 205-P-001C MANIFOLD
205- AGDC-0844 V-012 DOME-1
105 | P a g e
205- AGDC-0845 V-013 DOME-1
205- AGDC-0846 V-014 DOME-1
205- AGDC-0839 V-012 DOME-2
205- AGDC-0841 V-013 DOME-2
205- AGDC-0843 V-014 DOME-2
205- AGDC-0829 205-P-001D MANIFOLD
205- AGDC-0830 205-P-001E MANIFOLD
205- AGDC-0831 205-P-001F MANIFOLD
205- AGDC-0832 205-P-027A MANIFOLD
205- AGDC-0833 205-P-027B MANIFOLD
205- AGDC-0834 205-P-001-C MANIFOLD
205- AGDC-0733 TT gantry Bay-1
205- AGDC-0734 TT Gantry Bay-2
15.1 FDAS (FLAME DETECTOR AND ALARM SYSTEM)

205-AFDF-0803 V-003 DOME-2
205-AFDF-0804 V-004 DOME-2
205-AFDF-0805 V-005 DOME-2
205-AFDF-0806 V-007 DOME -2
205-AFDF-0807 V-008 DOME-2
205-AFDF-0808 V-009 DOME-2
205-AFDF-0801 205-P-001A MANIFOLD
205-AFDF-0802 205-P-001C MANIFOLD
205-AFDF-0812 V-012 DOME-2
205-AFDF-0813 V-013 DOME-2
205-AFDF-0814 V-014 DOME-2
205-AFDF-0809 205-P-001D MANIFOLD
205-AFDF-0810 205-P-001F MANIFOLD
205-AFDF-0811 205-P-027C MANIFOLD
205-AFDF-0707 TT gantry Bay-1
205-AFDF-0708 TT Gantry Bay-2
106 | P a g e
15.2 GAS ALARM BEACON WITH HOOTER-AGB
205-AGB-0803 PUMPHOUSE-6
205-AGB-0802 SOUTH SDIE OF MOUND-1
205-AGB-0801 PUMP HOUSE-5
205-AGB-0702 WEST SIDE OF TT GANTRY
15.3 MANUAL CALL POINT-MCP

205-AFMCP-0803 ENTRY OF PUMPHOUSE-6
205-AFMCP-0807 SOUTH SIDE OF PUMPHOUSE-6
205-AFMCP-0802 EAST SIDE MOUND-1
205-AFMCP-0801 NORTH SDIE OF MOUND-1
205-AFMCP-0804 ENTRY OF PUMPHOUSE-5
205-AFMCP-0806 SOUTHSIDE OF PUMPHOUSE-5
205-AFMCP-0805 EAST SIDE OF MOUND-2
205-AFMCP-0707 WEST SIDE OF TT GANTRY
15.4 GAS ALARM SIREN-AGS

205-AGS-0803 NORTH SIDE OF PUMPHOUSE-6
205-AGS-0802 SOUTH SIDE OF MOUND-1
205-AGS-0801 SOUTH SIDE OF PUMPHOUSE-5
205-AGS-0702 WEST SIDE OF TT GANTRY
15.5 FIRE ALARM BEACON-AFB

205-AFB-0801 NORTH SIDE OF MOUND-1 MANIFOLD
205-AFB-0804 SOUTH SIDE MOUND-1
205-AFB-0802 SOUTH SIDE OF PUMPHOUSE-5
205-AFB-0803 SOUTH SIDE OF MOUND-2
205-AFB-0702 WEST SIDE OF TT GANTRY
15.6 FIRE ALARM SIREN-AFS

205-AFS-0801 NORTH SIDE OF MOUND-1 MANIFOLD
205-AFS-0804 SOUTH SIDE MOUND-1
205-AFS-0803 SOUTH SIDE OF MOUND-2
205-AFS-0802 SOUTH SIDE OF PUMP HOUSE-5
205-AFS-0702 WEST SIDE OF TT GANTRY
107 | P a g e
APPENDIX-16
SAFETY CHECK LIST FOR LPG ROAD TANKERS
Customer:
Tank Truck No. Date
Oil Company’s Name. _________Carriers

____________
S. No Check points OK Not OK

1 VALID LICENCE FROM CCOE
2 VALID CERTIFICATE FROM „RTO‟ (R.C. AND F.C)
3 RLW-ULW Licenced capacity.
VALID DRIVING LICENCE & HAZARDOUS CHEMICAL
4
DRIVING CERTIFICATE
Has suitable spark arrestor of make and design
5
approved by CCOE, Nagpur, properly fixed to exhaust.
6 CONDITION OF EXHAUST PIPE
BATTERY CUT-OFF SWITCH/BATTERY
7
ENCLOSURE/INDICATION LIGHTS
8 „U‟ CLAMPS & FOUNDATION BOLTS
9 NO EXPOSED / LOOSE WIRING
Carries 2 nos. 10 Kg. DCP extinguishers in easily
accessible and removable position with Truck No. date
10
of checking and charging painted on it and 1 no. of 2
Kg CO2 extinguisher in the driver cabin.
11 ENGINE STARTER AND STARTER COVER
12 ANY FLAMMABLE LIQUID / MATERIAL
13 PROPER BONDING FOR CHASSIS, CABIN AND BULLET
ROTOGUAGE & PRESSURE GAUGE AND TEMPERATURE
14
GAUGE
BONDING / EARTHING WIRE AT LIQUID & VAPOUR
15
CONNECTION
PROTECTION AT ROTOGUAGE, LIQUID & VAPOUR VALVES
16
(STOPPER PIN) SAFETY VALVE, DIESEL TANK PROTECTION
17 Height barrier provided as per specifications.
18 ANY OTHER TEMPORARY PLUGGING
19 SPARE WHEEL
GENERAL CONDITION OF TANKER AND PROPER
20
HAZCHEM SIGN
21 NO VISIBLE DENT OR CORROSION ON THE BULLET
22 Paint of bullet is not peeling off.
TREMCARD INSTRUCTION BOOKLET DETAILING
23
INSTRUCTION ON HANDLING EMERGENCIES ENROUTE
24 STATUTORY TEST CERTIFICATE 43,44,2,18&19
25 HAND BRAKE OR WOODEN CHOKE
26 Quick closing manifold valve with lever indicating close
108 | P a g e
and open status.
Fuel tank is protected by means of stout guard and fuel
27
tank cap is locked.
28 First aid kit is available.
Hazchem sign, name of contractor with address and
29
telephone No. displayed prominently.
Vessel identification code includes
Radiography
PWHT
Design Pressure
30
Design Temperature
Hydrostatic test pressure
First test date and subsequent test dates
Water capacity in litres
Liquid/vapour lines are adequately anchored and are

31
well protected by means of stout steel guard.
Tool box containing Leather hand gloves and heat
resistant hand gloves, Safety Goggles , 2 nos. red flags
32
non-metallic tools, wooden plugs of appropriate size
and sealing compound.
33 CHECK LIST FROM UNLOADING POINTS
Remarks: VEHICLE GROSS WEIGHT I here by declare that there is no accident of bullet
LOADING CAPACITY occurred during my period
FORM ‘F’ VALIDITY
TANKER: LOADING APPROVED / NOT APPROVED / HOLD

Reference OISD- 159.
Driver Signature
109 | P a g e

005 LPG Om & Sop PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

005 LPG Om & Sop PDF

Загружено:

Авторское право:

Доступные форматы

Operating Manual and Standard Operating

Procedures for LPG

2.0 Design Basis

3.0 Process Description

3.2 Integration between Refinery and LPG facility

4.0 Facilities for LPG Handling

5.0 Operating Philosophy

5.1 LPG Receipt

6.0 Control Philosophy

9.0 Modes of Operation and Operating Procedure

10. LPG (ON-SPEC/ BLENDING SPILLAGE) RECEIPT

This facility is constructed as state-of-art technology which is fully automated. It meets

LPG at ambient temperature is in gaseous state, but it is liquefied under pressure.

1.1 OVERVIEW OF PARADIP BOOT LPG FACILITY

A) Activities of the LPG facility:

The principal activities of the LPG handling facility are -

There is no manufacturing process involved in this facility and it is only an intermediate

B) FACILITIES FOR HANDLING LPG:

1.3 SCOPE AND APPLICABILITY

2.0 DESIGN BASIS:

Mound I: Six bullets (205-V-003/004/005/007/008/009) located together.

Mound II: Three bullets (205-V-012/013/014) located together

The off-spec LPG from bullets (205-V003/4/5/7/8/9/12/13/14) is pumped through 3 no of

All PSV outlets are connected to LT Flare.

2.2 RECEIPT DETAILS

DESIGN PRESSURE DESIGN TEMPERATURE LINE SIZE

2.3 DISPATCH DETAILS

MARKETING PIPE LINE OFF- TANK TRUCK FUEL GAS

The off-spec LPG from bullets (205-V003/4/5/7/8/9/12/13/14) is pumped by 3x50% Off-

Instrument details for each bullet is furnished in Appendix-10

3.2 INTEGRATION BETWEEN REFINERY AND LPG STORAGE FACILITY:

The process streams are:

1. Receipt from refinery is from the following rundowns

For detailed parameters of the above streams refer APPENDIX-5

The facilities/systems are as under:

4.1 MOUNDED STORAGE BULLET

Bullets details are given in APPENDIX-1

4.3 PIPELINE DETAILS

4.4 BLENDING SYSTEM:

The Blending System comprises of:

(Refer Equipment Operating Manual for details).

4.5 ETHYL MERCAPTAN DOSING:

4.6 INSTRUMENTATION AND AUTOMATION

Fully Automated Tank Gauging System (TGS).

Refer Manual on Automation for details.

4.6.2 Detailed list of XZVs Furnished in APPENDIX-6

4.6.3 PRESSURE RELIEF / BLOW DOWN SYSTEM

4.6.4 GAS DETECTION

GAS DETECTORS & FLAME DETECTORS

4.6.5 HEAT DETECTORS & QUARTZ BULB DETECTORS:

1. All ROVs will be closed

4.6.6 SAFETY INTERLOCKS, TRIPS AND ALARMS.

4.6.7 METERING SKIDS

(Refer Equipment Operating Manual for details).

4.7 Tank Truck Loading/ Unloading Facility.

All the PSV outlets are connected with LT Flare.

4.10 WATER DRAIN POT

(Refer bullet water draining procedure for details).

Details of the Water drain pot is as under:

4.11 ELECTRICAL SYSTEM

The electrical set-up in the Product side is as follows:

Power Transformers (312N-205-TR-301/302)

Distribution Transformers (312N-205-TR-401/402/403/404)