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Commissioning of Tanks & Bullets

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Ensure following Statutory approvals /clearances are available:

OISD clearance

CCE approval (PESO ) for storage of petroleum products

Consent to operate from OPCB

Factory license

Calibration of tanks / bullets done & approved by legal metrologydepartment

CEA approval / clearance

Test certificate of all PSVs & TSVs

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Ensure Power & utilities are available:

Power for MOVs/ DCS operation Instrument air for ROSOVs / control valve operation

Fire water & foam

LP / MP steam

Service water / cooling water /BFW / Drinking water

Nitrogen

Flushing oil

Chemicals & lube oils

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Ensure readiness of following facilities:

All Fire fighting facilities ( Checked & tested by F&S department)

Communication system : Walkie talkies, Telephones, PA/GA system

MCPs/Gas detectors

Area lighting for area illumination

Tank gauging system & TFMS

Control room and DCS

Fire control room & ETP control room

CRWS/OWS system & connectivity with ETP & Storm water pond

Area barricading & round the clock manpower

Tank to tank transfer pump should be made ready and operable prior to

commissioning of any tanks or bullets

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Ensure following pre commissioning activities are complete

Tank/ bullets Box-up in presence of Production (CG)

Flushing, drying & leak testing of all lines

All HPV & LPD valve closed & boxed up with new gasket.

All flanges boxed up with permanent gasket.

Pump no load trial taken Thoroughness of CRWS / OWS channel checked

Earthing of Roof to Ladder & Shell to ladder done

All MOV/control valve operation checked from DCS

All alarms & interlocks checked

All blinding de-blinding job completed

MCPs & gas detection system checked

Protocol format filled & signed by all department/contractor/consultant

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Ensure following major things are checked prior to Box-up

All flanges in roof drain line (floating roof tanks)

All flanges inside tank

Datum plate

Direction of NRV in roof drain line

Emergency roof drain sump water filling

Distance of all internals measured from floor/roof

Inside tank cleaning & roof cleaning

GSFC check complete

Please keep in mind that tank is now in Maintenance leg and during normaloperation tank will be operated in Operational leg.

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Initially receive small quantity of water in tank bottom to avoid statical

electricity generation. Start taking product by gravitation from other tanks or from R/D line in

slow rate.

Vent air from receiving lines by opening HPV in strategic locations.

Check all drain/vents/flanges of receiving line for leakage.

Take manual dip time to time & check the quantity receive.

Check all flanges of tank for leakage.

Check roof condition time to time during floatation.

After complete floatation of roof stop gravitation & isolate the tank.

Reconcile product receive in tanks with mother tanks or unit.

Change legs height from Maintenance leg to operational leg.

Tank commissioning

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De gassing of bullets to be done prior to commissioning.

Ensure PSVs are lined up & connected to flare header

Receive product in slow rate and monitor the level & pressure of bullet.

Check all flanges & vents for leakage.

After commissioning of one bullet, line-up vapour balance line of otherbullets, & commission other bullets.

Bullet Commissioning

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Operation of Tanks & Bullets

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Receiving of products

Preparation of tanks & bullets

Transfer of product

Accounting of product

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Receiving of products :

External source

SPM : Crude

Ship : Crude / Start up fuels

Tank Trucks : Start up fuels

Internal source

Unit R/D directly

Blending Header: MS/HSD/LPG

Tank to tank transfer

SPM

SHIP at NOJ

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Preparation of Tanks:

Water draining Addition of dye & additives

Circulation of tanks

Product blending ( Auto & manual blending)

Charging of steam & heating of products (as & when required)

Sampling of tank for certification

Correction of tank & re certification

Handing over of tank for despatch

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Transfer of product :

Transfer to unit as feed

Transfer to unit as fuel

Transfer from one tank to another tank (as per requirement)

Product despatch through TT loading Product despatch through Ship loading

Finished Product despatch ( Mktg /pipelines)

Do not defloatfloating roof tanks, do not operate floating roof tanks incritical zone.

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Accounting of product :

Total Hydrocarbon Stock

Crude & unit feed stock available

Certified product available

Daily Material Balance Product Despatch quantity

Fuel & Loss accounting

Distillate yield calculation

Payment of Excise & customs duty

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Accounting of product :

Quantity of Crude received in Refinery Quantity of Crude processed in AVU

Quantity of Feed transfer to Unit (Hot Feed & Cold Feed)

Quantity of fuel transfer to power plant & unit

Quantity of product generation from unit

Quantity of slop generation

Quantity of slop processing

Quantity of product despatch from Refinery Total hydrocarbon Stock in refinery

Daily Tank dip, Temp, water cut, density at 7-00hrs to be measured & send to PNC

along with tank operationdata.

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Product transfer through Mass flow meter (CTMS) :

Product transfer to Mktg

Product transfer to Pipeline

Product transfer to Ship

LPG & Propylene loading in TTs

Product accounting by tank dip measurement

Crude receive & feeding to AVU

Product receive from unit Off-spec product transfer to unit

Fuel transfer to CPP / unit

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Thank You