Work Pack

for

Inspection of TCPP PGC-1
Scrubber internal without vessel entry



0 05.05.2014 Rajesh Rathod
Rev # Date

Prepared

Checked

Approved






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TABLE OF CONTENTS

1.0 Objective
2.0 Abbreviations
3.0 HSSE Considerations
4.0 People and Responsibilities
5.0 General requirements
6.0 Procedure
7.0 Materials List ( Equipment Tools and Tackles)
8.0 Isolations
9.0 Reference documents
10.0 Engineering Documents































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1) Objective
The objective is to inspect PGC 1 suction scrubber internally for any debris or
muck. Also clean the internals with out confined space entry.
2) Abbreviations
LOTO: Lockout Tag out
QA: Quality Assurance
QC: Quality Control
AM: Assistant Manager
OIM: Offshore Installation Manager
TRA: Task Risk Assessment
HSSE: Health Safety Security and Environment
AFC: Approved For Construction
SDV: Shut down Valve.

3) HSSE Considerations
a) Personnel protective equipment to be used at all times during the work.
b) All offshore activities shall be risk assessed and controlled through
permit to work (PTW) system.
c) Job specific TRA should be available before commencement of job.

4) People and Responsibilities

a) OIM
i) Ensure that offshore jobs managed through PTW system.
ii) Overall coordination and general administration

b) AM
i) Issue related Work permits after review.
ii) Review the work pack and recommend for approval
iii) Overall coordination and general administration.

c) Process Engineer:
i) Assist crew in the preparation of Permit.
ii) Prepare the necessary work pack.
iii) Arrange the required spares and resources to execute the job
iv) Prepare the detailed job specific TRA
v) Ensure appropriate RAs are in place for all the overrides required during
the job


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vi) Onsite supervision.

d) Performing crew
i) Follow safe working practices throughout the job.
ii) Task Risk Assessment.
iii) Toolbox Talk.
iv) Apply LOTO as applicable.
v) Use proper tools / equipments necessary for completion of job.
vi) Clean up area after task completion

5) General requirements
i) A permit to work system will be in operation, issued and controlled by
Offshore Installation Manager.
ii) Tool box talks will be carried out before start of the job.
iii) Ballymore for accessing man way should be ready for use and inspected
before start of the job. Competent Authority to operate Ballymore must
be identified before starting job.
iv) Only competent and qualified people will be involved in the work.
v) Good communication between the crew will be ensured.
vi) All precautions stated in the PTW and associated risk assessment will be
adhered to.
vii) Flange management will be carried out by competent personal.
viii) Approved Rigging Plan by Mechanical Engineer to open man way to be
discussed and in place. Ensure MPI of Man way davit is done.

6) Procedure
Prerequisites:
i) Approved Task Risk Assessment.
ii) permit to work issued
iii) Inspect, bag and tag and arrange all the required material at the work site
iv) Ballymore to access manhole in place and is inspected and approved and
fit for use.
v) All the temporary equipment checks done and certified.
vi) All the contractors involved in the job are properly briefed on their tasks
and their risks and mitigations
vii) Discuss TRA and TBT with the crew going to perform job.
viii) Discuss Approved Rigging Plan.
ix) PGC 1 shutdown
x) Obtain the clearance from the Issuing Authority, after shutting down the
Unit.


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xi) Carry out isolations as per authorized Process Isolation Check List and
LOTO. (Section 8)
xii) Suction & Discharge Valves integrity proved
Depressurization of the section:

xiii) Ensure Isolation valves upstream of PGC 1 suction side SDV and
downstream of PGC discharge SDV are isolated
xiv) Keep suction and discharge SDVs of PGC 1 force open. SDVs will be
forced open from engineering station by E&I engineer.
xv) Force open the BDVs to depressurize PGC casing and the suction &
discharge lines. BDVs will be forced open from engineering station by
E&I Engineer.
a) After depressurization ensure that all the BDVs and their bypass
isolation valves are closed. All the suction, discharge SDVs are closed
(air supply tubing to be disconnected for keeping the SDVs positively
closed.). Monitor PTG3005, PTG3535 to zero pressure to ensure
complete depressurization.
xvi) Check for any pressure build up for 30 mins.
xvii) Depressurize the trapped pressure between isolation valve on both
suction and discharge side by connecting hoses open to atmosphere.
If any slight passing of isolation valves is suspected on
suction/discharge side, connect hose to drain port and leave the
other end of the hose away from the platform. Secure the hose ends
to a rigid structure or pipe to avoid swing motion. Ensure wind
direction is away from platform. Ensure there are no gas detectors
near by the loose end of the hose.
xviii) Drain all liquid from Suction scrubber by opening the drain line LCV as
well as with LTG3513 bottom drain line tubing.
xix) Connect water connection to suction scrubber utility point and fill scrubber
with water and drain the liquid again to flush out the hydrocarbons in
the vessel. Repeat this step again.
xx) The sections between PGC suction SDV to Discharge SDV to be purged
with Nitrogen. Connect hose from nearest utility point and start
pressurizing the section with N2.Once pressurized up to 10 psig vent
the Nitrogen from Suction scrubber vent line & BDV bypass on
discharge line.
xxi) Check for Hydrocarbon presence in the suction scrubber by opening LG
bottom tapping. Ensure Vessel is HC free. If required again purge the
section with Nitrogen until the Vessel becomes HC free. Also check
LEL by opening 1/2 tapping at PSV G4550A/B upstream being the
highest point in the loop.
xxii) Take Permission from Person In charge to open Man way.
xxiii) Ensure Man way is secured with Appropriate Chain pulley as a back up
incase man way Davit fails.
xxiv) Remove the manhole cover flange with Flange management tools and
then inspect the internals with out any vessel entry. Ensure to keep
Airway clear from the confined space.


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(A Confined Space is defined as any space of an enclosed nature where there is
a risk of death or serious injury from hazardous substances or dangerous
conditions (e.g. lack of oxygen).)
xxv) Clean any debris if observed in suction scrubber with water jets. Spray
water jets on all internal to clean out the internals. Try to remove debris
from manhole as much as possible.
xxvi) Drain all liquid from Scrubber. Inspect if the debris are cleared. If not
again spray water jets and try to clear the debris. Keep Bottom tapping
open to monitor any liquid coming out if vessel get de choked.
xxvii) Once confirmed that the debris or muck is clear, close the manhole.
xxviii) Tighten the studs as per flange management procedure
xxix) Once Vessel inspection/cleaning is done.SDVG 3515 downstream line to
slop also should be flushed properly by connecting hose with ported
flange to the section upstream of LCV. Keep LCV force open while de
choking or flushing the line.
xxx) Reinstate all flanges disturbed while flushing the line. Tighten the same as
per flange management procedure.
xxxi) Fill PGC#1 scrubber with 9 of water in LT, so as to keep minimum liquid
seal in vessel.
xxxii) Normalize all isolations as per Isolation list and sign off the same with
Issuing Authority.
xxxiii) Purge Scrubber & associated pipeline with N2.
xxxiv) Clean up area after completion of job.
xxxv) Leak test Once isolations are normalized, give start command to PGC
and while loading valve is pressurizing the suction to discharge
section carry out leak checks. If any leak is observed immediately
inform LER & CCR to stop PGC & blow down the inventory. If no leaks
are found, pressurize PGC and keep it in idle mode for 20 mins.
xxxvi) Stop PGC if everything is found Normal.

Disturbed flanges List:-
24 Manway of Suction scrubber
SDVG3515 D/s Flange 2 900#
LCVG3514 U/s isolation valve
LCVG3514 D/s isolation valve u/s flange
LCVG3514 bypass RO flange.










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7) Materials list
1) Gasket R-78, Oval 01 Nos
2) Stud bolt 2-1/2IN X 19-3/4IN LG 10 Nos
3) Hydraulic Torque wrench 01 Nos
4) high pressure hose 03 Nos and fittings
5) Chain Pulley & Web belts as per Rigging Plan
6) Nylon Ropes 01 Bundle
7) Ballymore
8) tubing bent at both ends
9) Ex proof torch
10) Cotton rags
11) Zip locks bags to collect debris.
12) LEL Meter 01 with extra battery


8) Isolations checklist
Sr.
No Valve Descriptions
ISOLATED
STATUS
CURRENT
STATUS
ISOLATED
BY
NORMALIZ
ED BY
1 Inlet Manual Isolation valve 1 CLOSED
OPEN
2 Inlet Manual Isolation valve 2 CLOSED
OPEN
3
Scrubber inlet SDVG3001 - Impulse
tubing to Inlet SDV
CLOSED
removed
and blinded
OPEN
4
Scrubber inlet SDVG3002 - Impulse
Tubing to Inlet Loading SDV
removed
and blinded
CLOSE
5
Discharge SDV G3561- Impulse
tubing to outlet SDV
removed
and blinded
OPEN
6 Discharge SDV - Outlet Loading Valve CLOSED
CLOSE
7 Discharge Manual Isolation Valve 1 CLOSED
OPEN
8 Discharge Manual Isolation Valve 2 CLOSED
OPEN
9 HP BDVG-3545 D/S isolation valve CLOSED
OPEN
10
HP BDVG-3545 bypass isolation valve
1 CLOSED
OPEN
11 LP BDVG-3547 D/S isolation valve CLOSED
OPEN
12
LP BDVG-3547 Bypass Isolation Valve
1 CLOSED
CLOSED
13
Suction Scrubber PSV bypass line
valve 1 CLOSED
CLOSED
14
Suction Scrubber LCV U/S isolation
valve CLOSED
OPEN
15
Suction Scrubber LCV D/S isolation
valve CLOSED
OPEN
16 Suction Scrubber LCV Bypass valve 1 CLOSED
CLOSED
17 Bleed Valve B/W 2 suction isolations OPEN
CLOSED


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valve
18
Bleed Valve B/W 2 discharge
isolations valve OPEN
CLOSED
19 Fuel Gas Inlet Isolation valve 1 CLOSED
OPEN
20 Fuel Gas Inlet Isolation valve 2 CLOSED
OPEN
21 PGC#1 start button from LER Tagged

22 PGC#1 starter Motor Locked




9) Reference Documents:
Permit to Work Procedure : BGEPIL-HSSE-MS-WHM-406-001
Lockout / Tag out Procedure : BGEPIL-HSSE-MS-WHM-406-002
BG flange management procedure: BGEPIL-BGOP-M000-GEN-PI-12-00-01
BG Procedure for Safe plant & Equipment isolation
10) Engineering Documents:
Marked up P&IDs
Rigging Plan