Diesel Oil Pump (1)

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PT. Brown & Root Indonesia

Doc. No. 350-IOM-PS-1201 Rev. 6B

Project TLNG Author’s Org. KJP

KJP Doc. No. S-350-1283-001 Date 15 Nov, 06

KJP Job Code J-3400-20-0000 Sheet 1 of 26

X Core Non-core Lifecycle Code A

For Information For Review For Approval X Released As-Built

Rev. Date Page Description Prep’d Chk’d App’d BP App’d

5A 20Feb06 all For Approval T.Bessho M.Ditto M.Ditto

6A 20 June 06 All Released T.Bessho Y.Kakutani Y.Kakutani

6B 15 Nov 06 All Released K. Irwan Y.Kakutani Y.Kakutani

3.8 MTPA TRAIN CAPACITY

Operation Manual for GPFSB and Diesel Oil Storage/Transfer System

BPMIGAS

TANGGUH LNG

BP Berau Ltd.

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Doc. No. 350-IOM-PS-1201KJP Doc. No. S-350-1283-001 Rev. 6BSheet No. 2 of 26 Operation Manual for GPFSB and Diesel Oil Storage/Transfer System

BP Berau Ltd. Tangguh LNG Project

CONTENTS

1. Introduction.................................................................................................................................4 2. Basis of Design.............................................................................................................................6

2.1 General.........................................................................................................................................6 2.1.1 EQUIPMENT FOR DIESEL OIL STORAGE/TRANSFER SYSTEM AT GPFSB.................................... 6 2.1.2 EQUIPMENT FOR DIESEL OIL STORAGE/TRANSFER SYSTEM AT COMBO DOCK ....................... 67 2.2 Process Description...................................................................................................................78 2.2.1 DIESEL OIL STORAGE/TRANSFER SYSTEM............................................................................... 78

2.2.1.1 Diesel Oil Unloading Operation.....................................................................................78 2.2.1.2 Diesel Oil Refueling Operation at Combo Dock............................................................ 89 2.2.1.3 Diesel Oil Refueling Operation at GPFSB.....................................................................89 2.2.1.4 Diesel Oil Transfer to 077-TK-1001............................................................................ 9

3. Preparation for initial start-up ..............................................................................................910 4. Initial Start up procedure.......................................................................................................910

4.1 General.....................................................................................................................................910 4.2 Diesel Oil Storage/Transfer System.......................................................................................910

4.2.1 INITIAL FILLING BY TANKER TRUCK (MONTH 17) ............................................................. 910 4.2.2 INITIAL FILLING AFTER INSTALLATION OF THE FACILITIES AT COMBO DOCK AND

PIPELINE (MONTH 47) ..................................................................................................................... 1011 4.2.2.1 Initial Filling by Diesel Oil Unloading Pump (080-P-1001)

1011 4.2.2.2 Initial Filling by Ship Pump

1112 5. Normal Operation.................................................................................................................1213

5.1 Diesel Oil Storage/Transfer System.....................................................................................1213 5.1.1 DIESEL OIL U NLOADING OPERATION................................................................................... 1213 5.1.2 U NLOADING TO DIESEL OIL STORAGE TANK BY DIESEL OIL U NLOADING PUMP................ 1213 5.1.3 U NLOADING TO DIESEL OIL STORAGE TANK BY SHIP PUMP ............................................... 1214

5.1.4 DIESEL OIL R EFUELING OPERATION AT COMBO DOCK ....................................................... 1215 5.1.4.1 Refueling for Large Marine Craft

1215 5.1.4.2 Refueling for Small Marine Craft and Vehicles

1316 5.1.5 DIESEL OIL R EFUELING OPERATION AT GPFSB ................................................................. 1417 5.2 Operating Variables..............................................................................................................1418

6. Quality control ......................................................................................................................1418 7. Normal Shutdown Procedure ..............................................................................................1519

7.1 General...................................................................................................................................1519 7.2 Normal Shutdown.................................................................................................................1519

8. Emergency Shutdown Procedure ........................................................................................1519 8.1 General...................................................................................................................................1519 8.2 Power Failure ........................................................................................................................1620 8.3 Instrument Air Failure.........................................................................................................1620 8.4 Fires/Serious Leakage...........................................................................................................1620 8.5 Equipment Failure................................................................................................................1720 8.5.1 PUMPS .................................................................................................................................. 1720 8.5.2 AUTO SHUT OFF NOZZLE....................................................................................................... 1720

9. Safety Procedure...................................................................................................................1721 9.1 General...................................................................................................................................1721 9.2 Hazardous Material ..............................................................................................................1822 9.3 Emergency Fire Plan ............................................................................................................1822 9.4 Fire Fighting and Protective Equipment ............................................................................1822 9.5 Maintenance of Equipment and Housekeeping..................................................................1923

9.6 Repair Work..........................................................................................................................1923 9.7 Withdrawal of Samples ........................................................................................................2024 9.8 Safe Handling of Volatile and Toxic Materials ..................................................................2024

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9.9 Respiratory Protection .........................................................................................................2024 9.10 Breathing Apparatus (B. A.)................................................................................................2125

10. Isolatiion Procedure for Maintenance.................................................................................2125 10.1 General ..................................................................................................................................2125 10.2 Basic Procedures...................................................................................................................2226

10.2.1 I NDIVIDUAL EQUIPMENT / SYSTEM ISOLATION.................................................................... 2226 10.2.1.1 Tank 2226 10.2.1.2 Pumps

2327 11. Maintenance Procedure........................................................................................................2427

11.1 General ..................................................................................................................................2427 11.1.1 R OUTINE/FIRST LINE/ MAINTENANCE .................................................................................. 2427 11.1.2 BREAKDOWN MAINTENANCE .............................................................................................. 2428 11.1.3 PLANNED PREVENTIVE MAINTENANCE ............................................................................... 2428 11.1.4 PREDICTIVE/CONDITION BASED MONITORING .................................................................... 2428 11.1.5 TURNAROUND /I NSPECTION MAINTENANCE........................................................................ 2428

11.2 Precautions prior to Maintenance.......................................................................................2528 11.3 Preparation for Maintenance ..............................................................................................2529 11.3.1 I NSTALLATION OF BLANK FLANGES OR SPADES ................................................................... 2529 11.3.2 R EPLACEMENT OF NITROGEN WITH AIR .............................................................................. 2529 11.4 Typical isolation method ......................................................................................................2629 11.4.1 TANKS.................................................................................................................................. 2629 11.4.2 CLOSE OUT........................................................................................................................... 2629

12. Attachment List.....................................................................................................................2630

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1. INTRODUCTION

GPFSB consists of the following systems defined in System Definition List 900-PRC-OP-1903

(S-900-1710-004003) and temporary facilities as mentioned in taking over procedure of GPFSB

900-PRC-OP-1910 (S-900-1710-101) and Combo Dock ready for use (S-900-1710-001).

3501-D5 GPFSB Diesel Storage/Transfer System

3502-D5 GPFSB Fire water system

3503-D5 GPFSB Potable water system

9010A-D5 Civil General-GPFSB

9030A-D5 Structure General-GPFSB

9040A-D5 Office Block-GPFSB

9040B-D5 Warehouse-GPFSB

9040C-D5 Palletized Material Storage-GPFSB

9040D-D5 Chemical Storage-GPFSB

9040E-D5 Covered Washdown & Inspection Rack-GPFSB

9040F-D5 Covered Casing Storage-GPFSB

9040G-D5 Toilet Block-GPFSB

9040H-D5 5-Bay Workshop-GPFSB

9040I-D5 Machine Shop-GPFSB

9040J-D5 Vehicle Workshop-GPFSB

9040K-D5 Explosive Storage-GPFSB

9040M-D5 Guard House-GPFSB

9040N-D5 Security Post-2-GPFSB

9040S-D5 Substation-GPFSB

9041X-D5 Watch Tower-GPFSB

9080A-D5 Electrical General-GPFSB

This manual mainly describes the operation of Diesel Storage/Transfer System which are related to

P&IDs. The operation manual for fire water system in GPFSB is described in 82-IOM-HS-1540

(S-082-1241-019) separately. The operation manual for Temporary Potable Water System in GPFSB

is described in 350-IOM-PS-1202 (S-350-1283-002) separately.

The referenced operation manuals for the other systems listed above, which are related to

Infrastructure for building, civil and electricity, are summarized on the table of Manual List for

GPFSB in Attachment-5.

The brief explanation and sketches with overall scheme for the diesel storage/transfer system in

GPFSB are provided below.

There are 2 (two) operations phases, i.e 1st one is Month 17 which is period for taking over of GPFSB

and ready for use of Combo Dock, and 2nd

one is the period after all facilities are completed (plant

acceptance)-which scheduled in Month 47. In Month 17, some of the facilities are not yet available.

In Month 48, the operation will be supported by completion of full facilities.

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DIESEL OIL

In Normal Operation after plant acceptance, diesel oil can be transferred between three units, i.e.,

GPFSB (Unit-350), Combo Dock (Unit-80) and Diesel/Fuel Unit Storage & Transfer (Unit-77).

Please refer to the below sketch for the overall Diesel Oil Storage/Transfer system with complete

facilities.

350-TK-1001

077-TK-1001

080-P-1001

350-P-1001

Unit 080 COMBO DOCKUnit 350 GPFSB

Unit 077

DIESEL OIL PIPELINE

077-P-1001

OFF SHOREON SHORE

SHIP FILLING

UNLOADINGFROM SHIP

Fig 1.1 Overall Diesel Oil Storage/Transfer System with Complete Facilities

The facilities in GPFSB (Unit 350) shall be turned over to Company by schedule Month 17 (early

phase). Available diesel oil operation in GPFSB (Unit 350) is limited between schedule Month 17

and Month 47, because Combo Dock in Unit-80, Diesel/Fuel Oil Unit Storage/Transfer System (Unit

77), and associated diesel oil pipeline are still under construction.

Please refer to the below sketch for Month 17. As temporary transportation from ship at Combodock

to Diesel Tank in GPFSB, truck lorry shall be used.

350-TK-1001

077-TK-1001

350-P-1001

Unit 350 GPFSB

Unit 077

DIESEL OIL PIPELINE

077-P-1001

OFF SHOREON SHORE

Legends:

Not yet available

Completely installed

Battery Limit Boundary

080-P-1001

Unit 080 COMBO DOCK

UNLOADING

FROM SHIP

Fig 1.2. Diesel Oil Storage/Transfer System – Month 17- by Truck Lorry

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2. BASIS OF DESIGN

2.1 General

Diesel oil is supplied from the nearest PERTAMINA UPPDN VII located in Sorong, West Papua.

Ship tankers (Local LCT transporter) are utilized to transport the diesel oil from Sorong to the

Tangguh LNG facility.

Typical diesel oil specification is attached in Attachment 7.

2.1.1 Equipment for Diesel Oil Storage/Transfer System at GPFSB

For details, refer to each equipment data sheet (Attachment 3)

(1) Diesel Oil Storage Tank (350-TK-1001)

Type: Cone Roof Tank

Nominal Capacity: 182.7 m

3

Design Pressure: ATM

Design Temperature: 48degC

(2) Diesel Oil Loading Pump (350-P-1001)

Type: Centrifugal Pump

Rated Capacity: 30 m3/h

Design Differential Head: 72.1m

(3) Auto Shut Off Nozzle (350-V-1005) Size: 1 inch with single swivel

Design Pressure: 3.5kg/cm2G

Hose Length: 5m

(4) Cumulative Flow Meters (350-FQI-9001)Type: positive displacement meter w/ mechanical register

Design Pressure 3.5 kg/cm2g

Flow range Max 4.13 m3/h

2.1.2 Equipment for Diesel Oil Storage/Transfer System at Combo Dock

For details, refer to each equipment data sheet (Attachment 3)

(1) Diesel Oil Unloading Pump (080-P-1001)

Type: Centrifugal Pump

Rated Capacity: 30 m3/h

Design Differential Head: 90.0m

(2) Auto Shut Off Nozzle (080-V-1003)Size: 1 inch with single swivel

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Design Pressure: 3.5kg/cm2G

Hose Length: 15m


Design Pressure: 3.5 kg/cm2G

Flow range Max 4.13 m3/h (3304 kg/h)


Design Pressure: 12 kg/cm2G

Flow range Max 33 m3/h

(5) Cumulative Flow Meters (080-FQI-9003)

Type: positive displacement meter w/ mechanical register

Design Pressure: 12 kg/cm2G

Flow range 30 - 55 m3/h

2.2 Process Description

2.2.1 Diesel Oil Storage/Transfer System

The diesel oil will be utilized by the motorized equipment that is generally associated with the

cargo/supply handling activities at GPFSB and Combo Dock, such as motorized cranes, forklifts,

wheeled and tracked crawlers, and the self propelled multi-wheeled transporter.

In addition, diesel fuel is provided for the marine vessels such as offshore supply vessel (OSV),

tugboats, security boats, pilot boat, crew boats and water taxis.

Normal operation consists of the four operations.

- Diesel Oil Unloading Operation

- Diesel Oil Refueling Operation at Combo Dock

- Diesel Oil Refueling Operation at GPFSB

- Diesel Oil Transfer to Diesel Oil Storage Tank (077-TK-1001)

2.2.1.1 Diesel Oil Unloading Operation

Due to taking over schedule, there are two phases of diesel oil unloading operation.

Phase 1 - Before completion of the unloading facilities at COMBO DOCK and diesel oil pipe line

(Month 17)

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Because, on Month 17, the unloading facilities at COMBO DOCK and diesel oil pipe line between

COMBO DOCK and GPFSB have not yet been installed, diesel oil shall be unloaded to Diesel Oil

Storage Tank (350-TK-1001) by tanker truck.

Phase 2- After completion of the unloading facilities at COMBO DOCK and diesel oil pipe line

Diesel oil is unloaded to Diesel Oil Storage Tank (350-TK-1001) using a Diesel Oil Unloading

Pump (080-P-1001) at COMBO DOCK or ship pump.

The diesel oil is also unloaded to Unit-077 Diesel Oil Storage Tank (077-TK-1001). See Operation

Manual 077-IOM-PS-1201 for further detail.

2.2.1.2 Diesel Oil Refueling Operation at Combo Dock

There are two filling stations at the Combo Dock used for refueling large and small marine craftrespectively.

(1) Refueling for Large Marine Craft

For refueling a large marine craft such as tugs, crew boats and offshore supply vessels, 4” Filling

Connection (080-HC-1001B) and flexible hose are used. Diesel oil is transferred from Diesel Oil

Storage Tank (350-TK-1001) by Diesel Oil Loading Pump (350-P-1001) via 4” pipeline.

A dedicated flow totalizer meter (080-FQI-9002) is installed upstream of the filling connection in

order to measure the total diesel flowrate.

(2) Refueling for Small Marine Craft and Vehicles

For refueling a small marine craft such as pilot boat, security boats, and water taxis, Auto Shut Off

Nozzle (080-V-1003) is used. Diesel oil is transferred from Diesel Oil Storage Tank

(350-TK-1001) by Diesel Oil Loading Pump (350-P-1001) via 4” pipeline.

A dedicated flow totalizer meter (080-FQI-9001) is installed at the inlet of the auto shut off nozzle

in order to measure the total diesel flowrate.

The filling station is also used to refuel the motorized equipment and vehicles in the Combo Dock.

2.2.1.3 Diesel Oil Refueling Operation at GPFSB

For refueling motorized equipment used to support the GPFSB activities, Auto Shut Off Nozzle

(350-V-1005) located at the GPFSB is used.

Diesel oil in Diesel Oil Storage Tank (350-TK-1001) is discharge to Auto Shut Off Nozzle

(350-V-1005) by Diesel Oil Loading Pump (350-P-1001).

A dedicated flow totalizer meter (350-FQI-9001) is installed at the inlet of the auto shut off nozzle in

order to check the amount of diesel transferred to each user.

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2.2.1.4 Diesel Oil Transfer to 077-TK-1001

Design flexibility is made in order to allow transferring diesel from Diesel Oil Storage Tank

(077-TK-1001) to 350-TK-1001.

The operation is enabled by opening block valve located on bypass line around the Diesel OilTransfer Pump (077-P-1001), which is routed to line 077-FD-1001.

3. PREPARATION FOR INITIAL START-UP

Refer to Commissioning Manual for GPFSB (350-PRC-OP-1001) (S-350-1710-001).

4. INITIAL START UP PROCEDURE

4.1 General

After phase-2 (Month 47), Diesel oil for initial filling of the systems is transported by a ship tanker

and introduced by Diesel Oil Unloading Pump (080-P-1001) or Ship Pump.

Before initial filling the pipeline with diesel, the followings shall be confirmed:

(1) PSV inlet/outlet isolation valves are CSO

(2) Pump minimum flow line valves are LO

(3) All instrumentation tapping points are in the open position.

(4) Piping vents and drains are closed.

4.2 Diesel Oil Storage/Transfer System

4.2.1 Initial Filling by Tanker truck (Month 17)

(1) Diesel oil tanker truck shall be ready to unload diesel oil to Diesel Oil Storage Tank(350-TK-1001).

(2) Connect a flexible hose between Diesel oil tanker truck and a 3” nozzle in suction line of

350-P-1001 (line 350-FD-1101-3”-1CS1P-NI).

(3) Establish the unloading line from temporary unloading connection to Diesel Oil Storage Tank

(350-TK-1001) thorugh the pump minimum flow line (350-FD-1710-2”-1CS1P-NI).

Confirm the following valves/spectacles are open:

- 2” Block valve on 2” pump minimum flow line (350-FD-1710-2”-1CS1P-NI)

- 3” Suction valve of Diesel Oil Pump (350-P-1001)

Confirm the following valves are closed

- 4” Block valve just upstream of Unloading Connection in suction line of 350-P-1001 (near

the bottom nozzle of 350-TK-1001)

- 4” Block valve between Diesel Oil Pump (350-P-1001) suction and discharge lines(350-FD-1104-4”-1CS1P-NI)

- 2” Discharge valve of Diesel Oil Pump (350-P-1001)

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(4) Check level gauge (350-LI-1171) indicates Low Liquid Level (LLL) or lower.

(5) Start Diesel Oil Pump (350-P-1001) by the field hand switch (350-HS-1701).

(6) Monitor level gauge 350-LI-1171. Note that maximum tank level is 6000 mm.

(7) Stop Diesel Oil Pump when the level of Diesel Oil Storage Tank reaches HLL.(8) Return to open position from close position for 4” block valve just upstream of unloading

connection in suction line of 350-P-1001 and 2” discharge valve of Diesel Oil Pump

(350-P-1001) in Step 3.

(9) Disconnect the flexible hose at the unloading connection and drain to the suitable basin.

4.2.2 Initial Filling after installation of the facilities at COMBO DOCK and pipeline (Month 47)

4.2.2.1 Initial Filling by Diesel Oil Unloading Pump (080-P-1001)

(1) Berth a ship tanker at the specified location of Combo Dock.

(2) Connect a flexible hose between ship tanker and Unloading Connection (080-HC-1001A).(3) Establish the unloading line from Unloading Connection (080-HC-1001A) to Diesel Oil Storage

Tank (350-TK-1001).

Confirm the following valves are open;

- 4” Block valve just downstream of Unloading Connection (080-HC-1001A)

- 4” Block valve (LO) located at trestle/ shore line battery limit.

- 3” Suction valve of Diesel Oil Unloading Pump (080-P-1001)

- 2” Discharge valve of Diesel Oil Unloading Pump (080-P-1001)

- 4” Bypass valve on the line (350-FD-1104-4”-1CS1P-NI) between suction and discharge

of Diesel Oil Loading Pump (350-P-1001)

- 4” Inlet valve of Diesel Oil Storage Tank (350-TK-1001)


- 4” Block valve just upstream of Filling Connection (080-HC-1001B)

- 4” Bypass valve on the line (080-FD-1701-4”-1CS1P-NI) between suction and dischargeof Diesel Oil Unloading Pump (080-P-1001)

- 3” Suction valve of Diesel Oil Loading Pump (350-P-1001)

- 2” Discharge valve of Diesel Oil Loading g Pump (350-P-1001)

- 3” Block valve and 2” block valve on unloading line to 077-TK-1001 (Line No.

077-FD-1001)


(5) Start Diesel Oil Unloading Pump (080-P-1001) by the field hand switch (080-HS-1701).

Note that Diesel Oil Unloading Pump (080-P-1001) and Ship Pump shall not be used

simultaneously for unloading diesel oil.

(6) Monitor level gauge 350-LI-1171 and flow totalizer meter 080-FQI-9003. Before the tank(350-TK-1001) level reaches HLL, the operators in GPFSB shall inform to the operators in

Combo Dock that unloading operation is about to be completed. Note that maximum tank level is6000 mm.

(7) Stop Diesel Oil Unloading Pump (080-P-1001).

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(8) Close 4” block valve just downstream of Unloading Connection (080-HC-1001A).

(9) Disconnect the flexible hose at the unloading connection (080-HC-1001A) and drain to the ship

tanker by nitrogen.

(10) Open the valves, which were closed in Step-3, except for 4” block valve just upstream of filling

connection (080-HC-1001B) and 3” & 2” block valves in Unit-077.

4.2.2.2 Initial Filling by Ship Pump

(1) Berth a ship tanker at the specified location of Combo Dock.

(2) Connect a flexible hose between ship tanker and Unloading Connection (080-HC-1001A).

(3) Establish unloading line from Unloading Connection (080-HC-1001A) to Diesel Oil Storage

Tank (350-TK-1001).


- 4” Block valve just downstream of Unloading Connection (080-HC-1001A)

- 4” Block valve (LO) located at trestle/ shore line battery limit

- 4”Bypass valve on the line 080-FD-1701-4”-1CS1P-NI between suction and discharge of

Diesel Oil Unloading Pump (080-P-1001)

- 4” Bypass valve on the line 350-FD-1104-4”-1CS1P-NI between suction and discharge of

Diesel Oil Loading Pump (350-P-1001)



- 4” Block valve just upstream of Filling Connection (080-HC-1001B)

- 3” Suction valve of Diesel Oil Unloading Pump (080-P-1001)

- 2” Discharge valve of Diesel Oil Unloading Pump (080-P-1001)


- 2” Discharge valve of Diesel Oil Loading g Pump (350-P-1001)

- 3” Block valve and 2” block valve on unloading line to 077-TK-1001 (Line No.077-FD-1001)


(5) Start Ship Pump.

Note that Diesel Oil Unloading Pump (080-P-1001) and Ship Pump shall not be usedsimultaneously for unloading diesel oil.

(6) Monitor level gauge 350-LI-1171 and flow totalizer meter 080-FQI-9003.Before the tank(350-TK-1001) level reahces HLL, the operators in GPFSB shall inform to the operators in

Combo Dock that unloading operation is about to be completed. Note that maximum tank level is

6000 mm.

(7) Stop Ship Pump when required volume is unloaded.

(8) Close 4” block valve just downstream of Unloading Connection (080-HC-1001A).

(9) Open the valves, which were closed in Step-3, except for 4” block valve just upstream of Filling

Connection (080-HC-1001B) and 3” & 2” block valves in Unit-077.

(10) Disconnect the flexible hose at the unloading connection (080-HC-1001A) and drain to the shiptanker by nitrogen.

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5. NORMAL OPERATION

5.1 Diesel Oil Storage/Transfer System

5.1.1 Diesel Oil Unloading Operation

Diesel Oil is unloaded to Unit 350 Diesel Oil Storage Tank (350-TK-1001) and Unit 077 Diesel Oil

Storage Tank (077-TK-1001). In this document, unloading operation to Unit 350 Diesel Oil Storage

Tank (350-TK-1001) is described.

Unloading operation to Unit 077 Diesel Oil Storage Tank (077-TK-1001) is described in Operation

Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer (Doc No. S-077-1283-001).

5.1.2 Unloading to Diesel Oil Storage Tank by Diesel Oil Unloading Pump

The operation is same as the initial filling operation. See Section 4.2.2.1.

5.1.3 Unloading to Diesel Oil Storage Tank by Ship Pump

The operation is same as the initial filling operation. See Section 4.2.2.2.

5.1.4 Diesel Oil Refueling Operation at Combo Dock

Refueling Operation at Combo Dock consists of two activities.

(1) Refueling for Large Marine Craft

Large Marine Craft is as follows;

- Offshore Supply Vessel (OSV)

- Tug Boat

- Crew Boat

(2) Refueling for Small Marine Craft and Vehicles

Small Marine Craft and Vehicles is as follows;

- Security Boat

- Pilot Boat

- Water Taxi

- Crane

- Forklift

5.1.4.1 Refueling for Large Marine Craft

(1) Berth a marine craft at the specified location of Combo Dock.

(2) Connect a flexible hose between ship tanker and Filling Connection (080-HC-1001B).

(3) Establish loading line from Diesel Oil Storage Tank (350-TK-1001) and Filling Connection(080-HC-1001B) at combo dock.


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- 2” Discharge valve of Diesel Oil Loading Pump (350-P-1001)

- 4” Block valve (LO) located at trestle/ shore line battery limit.




- 4” Block valve installed at the downstream of 080-FQI-9003

- 3” and 2” block valve on unloading line to 077-TK-1001 (Line No. 077-FD-1001)

(4) Check tank level gauge (350-LI-1171) and confirm required volume is stored.

(5) Start Diesel Oil Loading Pump (350-P-1001) by the field hand switch (350-HS-1701)

(6) Monitor flow totalizer meter 080-FQI-9002. When the required volume is supplied to marine

craft, the operators in Combo Dock shall inform to the operators in GPFSB that refuelingoperation is about to be completed.

(7) Close block valve just upstream of Filling Connection (080-HC-1001B) after required volume is

loaded into the marine craft.

(8) Stop Diesel Oil Loading Pump (350-P-1001).

(9) Disconnect the flexible hose and drain to the marine craft by nitrogen.

(10) Return to open position from close position of 4” block valve installed at the downstream of

080-FQI-9003.

5.1.4.2 Refueling for Small Marine Craft and Vehicles

(1) Establish leading line drom Diesel Oil Storage Tank (350-TK-1001) to 080-V-1003.

Confirm the following valves are open:

- 4” Inlet valve Diesel Oil Storage Tank (350-TK-1001)


- 2” Discharge valve of Diesel Oil Loading Pump (350-P-1001)

- 4” Block vavle (LO) loacted at trestle/shore line battery limit

Confirm the following valves are close:



- 4” Block valve installed at the downstream of 080-FQI-9003

- 3” and 2” block valve on unloading line to 077-TK-1001 (Line No. 077-FD-1001)

(2) Set the Auto Shut Off Nozzle (080-V-1003) to the refueling point of marine craft or vehicle.

(3) Pull a lever of Auto Shut Off Nozzle (080-V-1003) and start refueling. Refueling is stopautomatically when liquid level of the marine craft fuel tank or vehicle fuel tank reaches the level

sensor of the Auto Shut Off Nozzle (080-V-1003).(4) Check the total flowrate with the local flow meter (080-FQI-9001).

(5) Put Auto Shut Off Nozzle (080-V-1003) back to the original location.

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080-FQI-9003.

Note:

Operators in GPFSB should check the Diesel Oil Storage Tank level 350-LI-1171 daily.

5.1.5 Diesel Oil Refueling Operation at GPFSB

Auto Shut Off Nozzle (350-V-1005) is used to refuel the vehicles such as truck.

(1) Establish leading line drom Diesel Oil Storage Tank (350-TK-1001) to 080-V-1003. Therequired valves open/close status are same as Step-1 in 5.1.4.3.

(2) Set the Auto Shut Off Nozzle (350-V-1005) to the refueling point of the vehicle.

(3) Pull a lever of Auto Shut Off Nozzle (350-V-1005) and start refueling. Refueling automaticallystops when liquid level of vehicle fuel tank reaches the end of the Auto Shut Off Nozzle(350-V-1005).

(4) Check the total flow rate with the local flow meter (350-FQI-9001).

(5) Put Auto Shut Off Nozzle (350-V-1005) back to the original location.


080-FQI-9003.

5.2 Operating Variables

The facilities are normally manned and operated intermittently.

During unloading to 350-TK-1001, operators monitor tank level (350-LI-1171) at field and in radio

contact with combo dock operators

During using Auto Shut Off Nozzle (350-V-1005) at GPFSB, operators monitor inlet pressure of shutoff nozzle (350-PG-9275) and total flow rate (350-FQI-9001)

When using Auto Shut Off Nozzle (080-V-1003) at Combo Dock, operators monitor inlet pressure ofshut off nozzle (080-PG-9276) and total flow rate (080-FQI-9001).

During diesel refueling through 080-HC-1001B at the Combo Dock, operator needs to monitor total

flow by utilizing 080-FQI-9002.

During diesel unloading operation either from Diesel Oil Unloading Pump (080-P-1001) or ship pump, operator needs to monitor total flow rate by utilizing 080-FQI-9003.

6. QUALITY CONTROL

Operators in this unit have no direct control of the quality of the diesel oil unloaded from the diesel oil

supplier. However water may be contaminated in the diesel oil during transportation from the supplydepot.

To take the following actions for quality control;

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(1) At the end of initial unloading operation, take a sample from the tank bottom drain and do a

visual inspection. If water in pipeline is carried over, water shall be drawn off from the tank bottom.

(2) On weekly basis, water in Diesel Oil Storage Tank (350-TK-1001) shall be drained out, if free

water is found.

7. NORMAL SHUTDOWN PROCEDURE

7.1 General

Shut-downs can be classified into normal shut-down and emergency shut-down.

A normal shut-down is a scheduled shut-down, while an emergency shut-down is an unscheduled

shut-down due to a failure or accident.

The emergency shut-down procedures are shown in Section 8.

When shutting down a unit, it is most important to avoid large and/or rapid fluctuations in flows and

pressures in order to protect the equipment and recover without causing any adverse effects on the

unit.

Further, measures must be considered to avoid hazards to human beings and damage to facilities.

The shut-down schedule must be reviewed and discussed and all operators must be notified of it in

advance.

7.2 Normal Shutdown

Normal shutdown of Unit 350 is represented by the following two activities.

(1) Normal stop of unloading/refueling operations

(2) Regular maintenance of equipment

Note that t diesel oil in Diesel Oil Storage Tank (350-TK-1001) in GPFSB shall be transferred to

Diesel Oil Storage Tank (077-TK-1001) before Diesel Storage Tank (350-TK-1001) undergoes

internal inspection or maintenance.

8. EMERGENCY SHUTDOWN PROCEDURE

8.1 General

(1) An emergency can be caused by the failure of an essential utility supply (power, instrument air,

etc.), mechanical failure, a serious leak or fire. In these cases a partial or complete shut-down

must be carried out quickly without damaging equipment.

(2) A partial failure of a utility may necessitate close monitoring of operating conditions without

enforcing an immediate shut-down.

(3) At all times the safety of personnel is the first priority consideration.

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(4) Operators must judge the conditions of an emergency correctly in order to take the first necessary

action in an actual emergency, and then appropriate action must be taken according to the

changes in the conditions.

(5) If a failure is likely to continue for a considerable time, the unit must be shut-down according to

normal shut-down procedure after taking the initial necessary action.

(6) No Emergency Shutdown System is provided because Unit 350 pumps and valves are operated

manually.

8.2 Power Failure

Power failure will not cause an emergency situation.

Because Diesel Oil Loading Pump (350-P-1001) and Diesel Oil Unloading Pump (080-P-1001) will

stop, stop unloading/refueling activities.

8.3 Instrument Air Failure

Instrument air failure does not cause an emergency situation because all valves for Unit 350 are

opened and closed manually and instrument air is not used for operation.

8.4 Fires/Serious Leakage

The required action will differ depending on the location/extent of the leak fire. In general cases, the

following steps must be taken.

(1) Stop hot work being carried out around the area. Notify the fire safety department about the

situation.

(2) Stop all work and evacuate personnel in the affected area.

(3) Shut-down any related pumps.

(4) Stop Unit 076 HC Condensate Loading if affected area is the combo dock.

(5) Isolate equipment and piping affected by the leak fire, if possible pressure build up should be

taken into consideration.

(6) Switch off power sources if required.

It is of the most importance to detect the source of the fire/leak and to stop the supply of flammable

materials.

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8.5 Equipment Failure

8.5.1 Pumps

When Diesel Oil Loading Pump (350-P-1001) is out of service, a temporary diesel oil loading pump

should be used. Temporary pump connections should be used for refueling operation by

350-V-1005..

8.5.2 Auto shut off nozzle

(1) Auto Shut Off Nozzle at GPFSB area (350-V-1005)

In case of 350-V-1005 failure, the following equipment at another area is available

- Filling station with an auto shut off nozzle (077-V-1002) at Unit 077 area

(2) Auto Shut Off Nozzle at Combo Dock (080-V-1003)

Operators put diesel oil into a small container such as polyethylene tank temporarily and refuel.

9. SAFETY PROCEDURE

9.1 General

To prevent accidents it is of the utmost importance that all personnel be instructed properly of the

following subject:

- The leaks and responsibilities of the operators

- The methods to accomplish this in a safe manner

The following safety regulations cover operations of particular concern to the personnel responsible

for the unit. They are intended to supplement any existing general plant safety regulations which

cover all units; reference should be made to the latter for all points not mentioned below. Mechanical

craftsmen working on their unit will be governed by their own departmental safety regulations, but

the operator should see that none of the following safety regulations are violated by mechanical

workers.

In addition to specifically defined rules and practices, the exercise of good judgment by every person

involved is essential to safe operation. An operator should be alert for any situation which might

present a personnel hazard. It should also be the responsibility of each person familiar with the plant

to warn other workers who enter the plant of possible hazards they could encounter.

All personnel must know the location and use of safety shower, fire extinguisher, plant fire alarm, and

main isolation valves, fire hoses and hydrants, fire blankets, gas masks and respirators, and other

protective equipment such as hard hats, rubber gloves, etc.

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Soda acid or foam type extinguisher must not be used on fire around electrical equipment because the

water solution will conduct electricity and may aggravate the difficulty or result in the electrocution

of personnel.

Carbon dioxide or dry powder extinguisher may be used safety on electrical fires.

Gas masks or breathing apparatus must be worn whenever dangerous fumes are encountered.

Safety hats must be worn when outdoors.

Gloves and goggles or face shields should be worn where dangerous or hot vapor or liquid isencountered, and are recommended for use while samples are being withdrawn and solutions made

up.

Fire extinguishers must be recharged immediately after use. All stream and water hose equipment

must be put back in place after use. Access to such equipment must not be obstructed.

Gas masks must have fresh cartridges installed after use.

9.2 Hazardous Material

Diesel Oil is a complex mixture of hydrocarbons from a variety of chemical processes blended

to meet standardized product specifications. Composition varies greatly and includes C9 to

C20 hydrocarbons.

The major effect of exposure to diesel oil is giddiness, headache, central nervous system

depression; possible irritation of eyes, nose, and lungs; and dermal irritation.

9.3 Emergency Fire Plan

The fire protection system of the plant is designed to prevent fire occurrence, control fire escalation,

or extinguish fire within short period of time, assuming there will be no outside fire fighting

assistance, with only one major fire at a time.

9.4 Fire Fighting and Protective Equipment

Fire hazard status throughout the plant shall be monitored on the Hazard Detection and Monitoring

System (HDMS (F&G)) consoles in the main control room and fire and emergency station.

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Upon fire detection, suitable fire fighting agents such as water, foam, dry chemical and inert gas shall

be used to control and/or extinguish a fire, and cool down equipment exposed by a fire or a heat

radiation.

For the detail, refer to 82-SPEIOM-HS-1540 (S-082-1241-019), “Operation Manual for Fire

Protection System” and the relevant drawings for fire protection system.

9.5 Maintenance of Equipment and Housekeeping

1. Operating equipment should be checked frequently for signs of leakage, overheating, or

corrosion, so that unsafe conditions may be corrected before they result in serious consequences.

Unusual conditions should be reported at once.

2. Guard around moving shafts, coupling belts, etc., which have been removed for repairs of the

equipment must be replaced when repair work is completed.

3. Tools, pieces of pipe etc., should never be left lying on platforms or railings of operation

equipment where they can be knocked off and injure someone below.

4. Access to ladders and fire escapes must be kept clear. Waste material and refuse must be put in

proper locations where they will not offer fire or stumbling hazards.

5. Liquid spills must be cleaned up immediately. Blanket gas leaks with steam and immediately

report leaks for repair.

6. In the event that electrical equipment does not function properly, notify the electrical department

and stay clear of the equipment until the electrician arrives.

7. Gas cylinders should be stored so that they cannot fall over. Guard caps must remain in place

over the valves of cylinders, which are not in use.8. Care should be taken when installing scaffolding to ensure that the wooden boards do not

contact hot equipment and that no part is allowed to impair free access on operational equipment

e.g. ladders, stairways, walkways or valves. Scaffolding should be removed immediately on

completion of the work in hand.

9. Switch pumps regularly when spares are provided. This will assure start the spare pump will be

ready when needed.

9.6 Repair Work

1. Mechanical work around and operating unit must be kept to a minimum, and the minimum

number of men should be used.

2. No mechanical work on the equipment is to be done without a properly authorized work permit.

3. Safety hats must be worn by all personnel in all areas at all times.

4. No burning, welding, open fires, or other hot work shall be allowed in the area unless authorized

by a work permit. Catch basins, manholes, and other sewer connections must be properly sealed

off to prevent the leakage of gases, which may ignite upon contact with an open flame.

5. No personnel shall enter a vessel for any purpose whatsoever until it has been adequately

purged, blanked off, and then tested to ensure freedom from noxious or inflammable gases and

an entry permit issued.

6. Lines operation at a low temperature might fracture if unduly stressed; therefore, do not

physically strike these lines and avoid operation conditions, which would cause a water hammer

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to start.

7. Do not use light distillates such as gasoline or naphtha to clean machinery or for any other

cleaning purposes.

8. Equipment should not be left open overnight. At the end of each day’s work blanks or spades

should be installed to prevent entry of flammable materials due to valve let-by.

9. Welding cylinders should be removed from site to a designate safe area at the end of each

working day.

9.7 Withdrawal of Samples

Samples shall be withdrawn from the unit only by authorized personnel.

Protective equipment, face masks or goggles, and suitable gloves must be worn for sampling. A

container must never be filled to the brim, in order to minimize risk of subsequent spillage.

When sampling any product liquids, gloves and goggles will be worn.

When sampling any material, gas or liquid, the sampling line must be flushed long enough to remove

dormant materials to insure that the sample obtained represents the current stream. Pass enough gas

through the sample vessel to insure the displacement of the purge gas and to adjust the temperature of

the sampler to that the composition is not distorted by condensation or flashing, etc.

When the sample composition is representative of the source material, it shall not be distorted by

flash vaporization. Certain classes of samples may require inert atmospheres , cooling or special

carrying devices. Wear approved personal safety equipment and exercise caution to avoid injuries.

When sample cooling is required, operator shall confirm cooling water is flowing properly before

taking the sample.

9.8 Safe Handling of Volatile and Toxic Materials

The safety rules given below are for the protection of life and limb, and the prevention of property

loss. It is expected that plant people will exercise common sense, alertness, and good judgment in

carrying them out. If ever there is any doubt as to the safety aspect of a particular operation, consult

your supervisor immediately.

9.9 Respiratory Protection

Most plant gases, other than air, are harmful to human beings if inhaled in certain concentration.

Toxic gases may be classified as either asphyxiating or irritating. Asphyxiating gases may cause

death by replacing the air in the lungs or by reaction with the oxygen carried in the blood; examples

are hydrogen sulfide carbon monoxide, and smoke. Irritating gases may cause injury or death not only

by asphyxiating but also by burns internal and external/ examples are chlorine and sulfur dioxide. To

guard against the inhalation of harmful gases:

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Secure a gas test certificate showing the gas condition of the vessel is safe for entry.

Stand on the windward side of an operating from which gases escape.

Provide proper ventilation.

All personnel should become familiar with the accepted method of artificial respiration in order

to render assistance to any one overcome by gas, electric shock, or drowning.

If anyone is overcome by gas, his rescuer should:

Never attempt a rescue unless an assistant is standing by.

Protect himself before attempting a rescue by wearing breathing apparatus.

Get the victim to fresh air as soon as possible.

Give artificial respiration and send his assistant to call for medical aid.

When using a breathing apparatus, be sure that the mask fits the face properly. Test it by the approvedtest method.

Wear the correct type of breathing apparatus, suited to the situation encountered.

9.10 Breathing Apparatus (B. A.)

There are four types of breathing apparatus in general plant service. They are the canister type masks,

the fresh air hose line B. A., the compressed air self-contained B. A. and the compressed air line

trolley B. A.

The compressed air self-contained breathing apparatus has a self-contained air supply carried on the

back of the user.

It is used principally in emergencies.

After use, always notify the proper department so that they can recharge the cylinders as soon as

possible.

10. ISOLATIION PROCEDURE FOR MAINTENANCE

This section describes the isolation procedures to be taken prior to maintenance work based on the

following specification:

Maintainability Philosophy (99-PHI-EM-0005) (S-099-1222-005).

Availability and Sparing Philosophy (99-PHI-PS-0002) (S-099-1222-002).

10.1 General

It is necessary to isolate trains, items of equipment, or groups of equipment, in order to facilitate

shutdown for maintenance, inspection, tie-ins, or loss prevention.

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As the degree of hazard increases, the measure of protection required must be deeply considered. The

degree of hazard is related to the system contents (e.g. flammability, toxicity etc.), pressure and

temperature. There are two main methods of isolation which can be used:

Positive isolation incorporating the use of spades/spectacle blinds or removable spools and blind

flanges, where no leakage can be tolerated for safety and contamination reasons, e.g. for vessel entry

or for creating safe construction areas within a plant.

Valved isolation for less critical duties than those requiring positive isolation, e.g. for control valve

maintenance. Valved isolation will also be required to enable positive isolation to be installed or

removed without the need for a complete plant shutdown.

10.2 Basic Procedures

The basic ideas for method of isolation are shown below. The details will be developed by Owner

when actual isolation work will be required. The selection of type of isolation valve and

blind/removable spools shall be in accordance with the applicable piping and material specifications.

This section considers train or system requiring isolation followed by individual equipment isolation

requirements. Sketches below are provided as an aid to develop actual planning for maintenance

work.

10.2.1 Individual Equipment / System Isolation

10.2.1.1 Tank

All tanks where manned entry may be required are provided with temporary blind arrangements on

every process inlet and outlet nozzles. Relief valve inlet lines from pressure vessels are normally

positively isolated from the vessel by removing the relief valve and blinding the inlet line end. A

typical arrangement is shown on Figure 10.2.1.

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Figure 10.2.1

Tank

10.2.1.2 Pumps

Normally valved isolation method is applied for isolation of pump suction and discharge lines. If

required from the maintenance work nature, blinds will be provided. Refer to Figure 10.2.2.

Figure 10.2.2

Pumps

DRAIN

TANK

OUTLET

LINE

MIN FLOW

LINE

OVERFLOW

INLETLINE

OUTLET LINE

INLET LINE

PUMP‘Y’ or ‘T’ TYPE SUCTION

STRAINER

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11. MAINTENANCE PROCEDURE

11.1 General

INSTRUMENT AIR SYSTEM HAS NITROGEN BACKUP. NEVER USE INSTRUMENT AIR

FOR BREATHING APPARATUS.

Type of maintenance is classified in the following categories.

11.1.1 Routine/First line/ Maintenance

Routine/First Line Maintenance is the daily on-line or off-line visual inspection, lubrication,

calibration or minor adjustment of running and static equipment. In addition to the maintenance

personnel carrying out the above types of checks/adjustments, the operator shall perform thefollowing routine maintenance activities whilst carrying out his daily checks on the Plant, in order to

prevent any minor problems developing into major ones:

• Tightening gland followers on leaking valve packing.

• Checking temperature and pressure gauges for broken glass faces.

• Checking for correct oil levels in compressors, gearboxes, oil reservoirs.

• Topping up low oil levels in the above equipment as required.

• Cleaning pump filters and strainers.

• Keeping equipment clean and tidy.

11.1.2 Breakdown Maintenance

For Breakdown Maintenance, there will be no scheduled checks or servicing. Corrective repairs will

be carried out on failure of the Plant or equipment.

11.1.3 Planned Preventive Maintenance

Planned Preventive Maintenance will be carried out on a calendar or running hours basis. It will be

performed in accordance with the vendors’ recommended frequencies.

11.1.4 Predictive/Condition Based Monitoring

Predictive/Condition based maintenance is the most efficient planning option. It uses direct

observations and instrument readings for the monitoring of the actual condition of the Plant and

equipment, and can trend and forecast when maintenance activities are due to take place.

11.1.5 Turnaround /Inspection Maintenance

Turnaround/Inspection Maintenance will be carried out at approximately 3 yearly intervals, and

usually entails a complete Plant or Train shutdown. It is utilized to perform testing and resetting of

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safety valves, and inspections and repairs of equipment that cannot be shutdown or removed during

Production.

11.2 Precautions prior to Maintenance

This section covers precautions prior to start maintenance work for a whole or a part of the plant.

• All work must be carried out within the requirements of company Safety & Environmental

Policies and Procedures. Prepare all known Work Permits, these must reflect safety issues.

Obtain relevant permit to work before starting work.

• Inform Operations of the work content of this preventive maintenance procedure and how it will

affect them.

• All rotating equipment is to be considered energized until proven isolated.

• All vessels must be isolated, drained and vented.

• Cordon the work area, to prevent unauthorized access.

• Prior to commencement of this work ensure that moving/rotating/power generating/energy

storing equipment has been isolated in accordance with the relevant permit to work and lock-out /

tag-out requirements.

• Physically isolate vessels. Only standard blank flanges and spades should be used. No person

should enter a vessel unless all directly connected sources of utilities fluids have been positively

isolated from the vessel. Entry means total body entry or any part of the body.

• Operations should check for oxygen, taking samples at several representative places, with a

portable analyzer to check for oxygen deficiency.

• Prior to commencement of this work it is recommended that the crew will be briefed on what is

required and what hazards there are. The crew will be reminded of the location of safety showers,

first-aid boxes and telephones.

11.3 Preparation for Maintenance

The outline of the work sequence begins as below.

• Shutdown of the unit operation

• Installation of isolating blank flanges or spades

•

Replacement with air for entry into the equipment, if required

11.3.1 Installation of blank flanges or spades

Isolating blank flanges or spades must be installed at locations as required.

11.3.2 Replacement of Nitrogen with Air

Replacement of nitrogen gas with air and safety test for equipment must be performed prior to

permitting entry.

(1) Connect temporary air hoses at the appropriate location with utility air or instrument air if

required.

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(2) Open the top vent valves and drain off valves to atmosphere of the equipment.

(3) Introduce air to displace/purge nitrogen gas to atmosphere.

(4) Continue to purge until oxygen contents are higher than 20% at all point.

11.4 Typical isolation method

11.4.1 Tanks

• Erect scaffold for access as required.

• Operations to close down the system, depressurize and nitrogen purge.

• Mechanical to spade inlet and outlet nozzles of said equipment.

• Mechanical to open drum.

• Operations to air purge and check for oxygen level.

• Operations to clean.

• One person to enter another to stand by on watch.

11.4.2 Close out

• Ensure the equipment is left in a safe condition.

• Remove all tools and debris, clean local area.

• Note any faults found and comments.

• Raise a work request if any major corrective work is identified or the performance standards are

not met during the above maintenance.• Sign off permit to work and inform area authority of equipment status.

12. ATTACHMENT LIST

Attachment-1 Process Flow Diagram

Attachment-2 P&IDs

Attachment-3 Equipment Data Sheet (List Only)

350-EDS-PSMC-1403 (S-350-1358-001) EDS for 350-P-1001 Diesel Loading Pump

350-EDS-PSVM-1351 (S-350-1354-001) EDS for 350-TK-1001 Diesel Oil Storage Tank

Attachment-4 Laboratory Sampling Schedule

Attachment-5 GPFSB operation manual index

Attachment-6 Available Diesel Oil Operation

Attachment-7 Typical diesel oil specification

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Documents

Diesel Oil Pump (1)