Project Title Document Number

Rental Early Production

Facility (EPF) for RBG
Block I Field

Author’s Organization Date

PT. Guna Tesuma Internasional
– PT. Anton Oil Services Indo

Rental Early Production Facility (EPF) for RBG Block I Field

Standard Operating Procedure SDV AND ESD

Owner
Rev Issue Date By Chk App Issue Purpose
Signature
0 12 September 2023
 Table of Contents

1. GENERAL........................................................................................................................3
1.1 APLICATION.............................................................................................................3
1.2 STANDART IMPLEMENTATION..........................................................................3
1.3 PERFORMANCE PARAMETER..............................................................................3
2. STRUCTURE DESCRIPTION.......................................................................................3
3. DISASSEMBLY & ASSEMBLY....................................................................................3
3.1 DISASSEMBLY SQUENCE.....................................................................................3
3.2 ASSEMBLY SQUENCE............................................................................................4
4. OPERATION....................................................................................................................4
4.1 START-UP.................................................................................................................4
4.2 RUNNING..................................................................................................................4
4.3 SHUTDOWN..............................................................................................................5
5. NOTICES ABOUT MECHANICAL SEAL..................................................................5
7. TROUBLE-SHOOTING FOR PUMP LOADING CONDENSATE...........................6
8. MAINTENANCE.............................................................................................................7

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1. OBJECTIVE

This Standard Operating Procedure (SOP) is used as a guideline or guidance for

operators and technicians to operate and maintenance quickly and correctly.
2. SHUTDOWN VALVE (SDV) :

In the pipeline there is a safety system in the form of a Shutdown Valve (SDV)
which functions to avoid unexpected and sudden accidents occurring in the
system. A shut down valve (also referred to as SDV or Emergency Shutdown
Valve, ESV, ESD, or ESDV) is an actuated valve designed to stop the flow of a
hazardous fluid upon the detection of a dangerous event. This provides protection
against possible harm to people, equipment or the environment. Shutdown valves
form part of a Safety Instrumented System. The process of providing automated
safety protection upon the detection of a hazardous event is called Functional
Safety

2.1 HOW THE SHUTDOWN VALVE (SDV) WORKS:

Shutdown Valve (SDV) functions as a safety measure if a gas leak occurs, the gas
pressure is too high (High Pressure) or the gas pressure is too low (Low Pressure),
etc. SDV will stop fluid (gas) flow if the pressure is too high or too high from the
setting.

3. EMERGENCY SHUTDOWN VALVE (ESD)

Emergency Shutdown Valve is a new high tech product, which has advantages of
energy conservation, environmental protection and convenient and fast operation.
Nowadays, fire protection is applied more frequently in building. In use, there are
some problems with construction or design. A good product not only with high
quality, but also has characters of convenience,simple operation and convenient
maintenance

3.1 Why use Emergency Shutdown Valve

Fire control pipe network and pipe for life always are two different water supply
system, and they supply water respectively. The water of a long distance from

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 the pump house to building is supplied by the second pipe line. Firstly, his
second pipeline construction needs larger workload; piping material cost twice
as much; and it is inconvenient to identify a particular pipe for maintenance;
Second, if the fire pipeline is not used for years, it will be easy to rust, pipe wall
and interface will be thinner due to corrosion. Because of no pressure usually,
once there is a fire, the pipe pressure will increase suddenly, easy to burst,
rendering to the fire protection system can’t supply water. Third, Shanghai has
promoted that they pump water directly from Shanghai municipal pipeline pump
and no longer set the underground pool. This pattern not only has saved the cost
of the pool building, but also has avoided the secondary pollution of water,
which can keep the water clean and healthful. This is the most important item.

3.2 Difference between Shutdown Valve (SDV) and Emergency Shutdown Valve (ESDV)
The construction and accessories of Shutdown Valve (SDV) and
Emergency
Shutdown Valve (ESDV) are similar. What is the basis to
distinguish their name? Their name is distinguished only from their
services. Shutdown Valve referred to actuated valve which is closed
during partial or total process shutdown of system to which the valve
protects. Emergency Shutdown Valve is actuated valve which is
closed when triggered by signal from ESD level signal during
emergency condition occurs.Emergency Shutdown Valves are
commonly located in incoming line and outgoing line of the plant or
platform. Please note that some projects do not use term “ESDV” for
tag numbering, instead Term “SDV” is used for shutdown
valve disregard their services. In this case, shutdown
logic diagram would indicate which actuated valve acts as
Emergency Shutdown Valve.

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3.3 This section describes the ESD shutdown level

1. The entire ESD system is divided into four levels of emergency shutdown, of which level 1 is
the highest shutdown level. A level of turn-off instruction does not cause a higher level of turn-
off, only this level and all related lower levels of turn-off.
2. 1 stage shutdown (ESD-0) is the abandoned station shutdown. This is the highest level of
closure. The trigger cause of this level is irretrievable accidents such as fire or explosion, which
can be manually started. All terminal equipment except emergency support system (delay
shutdown) is shut off and emergency void. Turn off all on-site power supply unrelated to fire
protection, and send sound and light alarm to the whole factory area. The ESD-0 button is
equipped with obvious signs and warning plates, and there are protective devices to prevent
misoperation.
3. 2 stage shutdown (ESD-1) is fire gas shutdown. In case of fire or flammable gas leakage, the
emergency shut-off valve will be triggered and the audible and visual alarm will be sent to the
whole factory. It can also be automatically started after manual confirmation. The ESD-1 button
is equipped with a clear mark and waring plate, and a protective device to prevent misoperation.
4. Level 3 shutdown (PSD) refers to process shutdown shutdown. The shutdown is triggered by an
accident in the main process, which can be started automatically or manually. PSD buttons are
clearly marked and warned, and are protected against misoperation.
5. Level 4 shut-off (USD) is unit shut-off. This stage shutdown is caused by a single process
failure or a single device failure in the production system and can be manually or
automatically started.

4. Cause And Effect SDV

4.1 . ESD -0

Outdor Any Emergency Shutdown Button :

 Hard handle ESD-0 alarm indicator

 HMI Alarm
 Trigger SDV 1
 The welhead gas removal and liquid separation skid line ESOV-0 101 is shut
 The metering valve group outlet line ESDV-0501is shut down
 The metering valve group outlet line ESDV-0502s shut down
 Gas-Iiquid separator Iiquid outlet line ESDV-0201X is shut down
 Emergency opening of BDV-0501 inlet (blowoff line of external metering waive
 Emergency shutdown of gas generator
 Emergency shutdown of diesel generator
 Turn-off heater H-0401X
 Turn-off Condensate heat exchanger E-0601X
 Cut off the domestic power supply other than fire power and emergency power in The process
plant area
 Cut off the non-fire power supply between the integrated equipment

Control Room Hand operator ESD-0 button

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 Hard handle ESD-0 alarm indicator
 HMI Alarm
 Trigger SDV 1
 The welhead gas removal and liquid separation skid line ESOV-0 101 is shut
 The metering valve group outlet line ESDV-0501is shut down
 The metering valve group outlet line ESDV-0502s shut down
 Gas-Iiquid separator Iiquid outlet line ESDV-0201X is shut down
 Emergency opening of BDV-0501 inlet (blowoff line of external metering waive
 Emergency shutdown of gas generator
 Emergency shutdown of diesel generator
 Turn-off heater H-0401X
 Turn-off Condensate heat exchanger E-0601X
 Cut off the domestic power supply other than fire power and emergency power in The process
plant area
 Cut off the non-fire power supply between the integrated equipment

Fire Alarm and Manual Confirmation

 Hard handle ESD-0 alarm indicator
 HMI Alarm
 Trigger SDV 1
 The welhead gas removal and liquid separation skid line ESDV-0 101 is shut down
 The metering valve group outlet line ESDV-0501is shut down
 The metering valve group outlet line ESDV-0502 is shut down
 Gas-Iiquid separator Iiquid outlet line ESDV-0201X is shut down
 Emergency opening of BDV-0501 inlet (blow off line of external metering valve
 Emergency shutdown of gas generator
 Emergency shutdown of diesel generator
 Turn-off heater H-0401X
 Turn-off Condensate heat exchanger E-0601X
 Cut off the domestic power supply other than fire power and emergency power in The process
plant area
 Cut off the non-fire power supply between the integrated equipment

4.2 . ESD - 1

Control Room hand operator ESD-1 button

 Hard handle ESD-0 alarm indicator

 HMI Alarm
 Trigger SDV 1
 The wellhead gas removal and liquid separation skid line ESOV-0 101 is shut
 The metering valve group outlet line ESDV-0501is shut down
 The metering valve group outlet line ESDV-0502 is shut down
 Gas-Iiquid separator Iiquid outlet line ESDV-0201X is shut down
 Emergency opening of BDV-0501 inlet (blow off line of external metering waive
 Emergency shutdown of gas generator
 Emergency shutdown of diesel generator
 Turn-off heater H-0401X
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  Turn-off Condensate heat exchanger E-0601X
 Cut off the domestic power supply other than fire power and emergency power in The process
plant area
 Cut off the non-fire power supply between the integrated equipment

All seal components must be inspected before the mechanical seal is installed. Repair
or replace defective and damaged components. Inspect seal surfaces of stationary seal
rings and rotating seal rings strictly. Defects such as scuffing or breakage are not
allowed. All parts and individual assemblies including the pump casing, the impeller,
the seal chamber etc. should be flushed cleanly. Particularly, surfaces of stationary seal
rings and rotating seal rings should be scrubbed cleanly with soft cloth or cotton yard,
and coated grease or machine oil. Clear out deviation during assembling. Screws should
be fastened uniformly to avoid skew and make seal failure.

7. TROUBLE-SHOOTING FOR PUMP LOADING CONDENSATE

Possible reason of failure Resolution methods

Air in pump or suction pipe ○ ○ ○ Priming liquid, exhausting air
Too high NPSHA or liquid Increase suction pressure
filled is not enough ○ ○ ○

Suction pipe size is too small Increase suction pipe size, clear
or blocked with something ○ ○ ○ odd thing

Submerged Depth of suction Increase submerged depth or

pipe is not enough or air ○ ○ check pipe
leakage
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Speed is too high or too low Inspect speed of driver per
○ ○ ○ requirements

Wrong rotate direction of ○ ○ It is CW view from driver end

pump
Head of system not conforms Reduce resistance of discharge
to head of pump ○ ○ ○ system or height

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Specific gravity and viscosity Recalculate required power or
do not conform to pump ○ ○ ○ replace suitable motor
specification
Abnormal vibration at low Increase flow or supply by-
flow ○ ○ ○ ○ pass circulating pipe

Centerline is different for Readjust centerline until the

pump and motor or shaft ○ ○ ○ ○ ○ same height
is
bent
There is friction between Inspect and repair for pump
rotating parts and stationary ○ ○ ○ ○ parts or improve operating
parts conditions
Bearing has been worn Replace new bearing
away seriously or ○ ○ ○ ○
damaged
Wear ring has been worn badly ○ ○ Replace new bearing
Shaft sleeve or stationary Replace new bearing
and rotating seal ring has ○ ○ ○ ○
been wornbadly

Selected mechanical seal is Reselect or reinstall according

not suitable or install wrongly ○ ○ ○ ○ to requirements

Abnormal vibration duo to Inspect to find reason and

rotor assembly unbalanced ○ ○ ○ ○ ○ eliminate vibration

Oil of oil receiver in bracket is Add oil according to oil level

too much or dirty ○ ○ ○ gauge or replace new oil

Pump and/or pipe is blocked Inspect carefully and clear

by something ○ ○ ○

Barrier liquid pressure on Pressure should be higher 0.5 to

double mechanical seal is not ○ ○ 1.5 MPa than that before
suitable shaft seal
Packing gland is too tight or ○ ○ ○ Adjust suitably
loose

8. MAINTENANCE

- The lubricant model is ISOVG32

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- Check immediately oil level after the pump started and check it every 8 hours. If there

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 is oil in the oil cup, it indicates that oil level in the bearing bracket is normal. It is
suggested that oil should be replaced every three months for outdoor installation
and wet district.
- Rotate the rotor parts of the spare pumps periodically. It is suggested that it be
rotated once a week, for about 180º each, to avoid deformation and keep the
lubricating oil film at the same time.
- For the high temperature spare pumps on the settings, certain temperature shall be
kept for reservation.

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