KOULA Operations Operating Procedure for HP compressors

suction header tie in

Non-Restricted

HP COMPRESSORS, SUCTION HADER ISOLATION AND

PURGING PROCEDURE FOR TIE IN

Page 1 of 6
 KOULA Operations Operating Procedure for HP compressors
suction header tie in
Non-Restricted

TABLE OF CONTENTS

1.0 OBJECTIVE......................................................................................................................................3
2.0 SCOPE................................................................................................................................................3
3.0 OWNERSHIP STATEMENT..........................................................................................................3
4.0 REFERENCES..................................................................................................................................3
5.0 DEFINITIONS.................................................................ERROR! BOOKMARK NOT DEFINED.
6.0 RESPONSIBILITIES.......................................................................................................................3
7.0 SAFETY & ENVIRONMENTAL...................................................................................................3
8.0 GUIDELINE......................................................................................................................................4
8.1 Introduction.........................................................................................................................................................4
8.2 Guidelines preparation.......................................................................................Error! Bookmark not defined.
8.3 HP.comp and FWKOs mechanical isolation for tie in (cyclone installation)..............................………
8.4 HP.comp header line purging...........................................................................................................................

Page 2 of 6
 KOULA Operations Operating Procedure for HP compressors
suction header tie in
Non-Restricted

1.0 OBJECTIVE
Reference to Koula HP compressors suction header tie in for cyclone installation

This guideline has been developed to establish a uniform method of mechanical isolation, purging header and
Spading.

2.0 SCOPE

The provisions of this Guideline are applicable to Koula Permanent Production Facilities that have direct
involvement in the processes of HP compressors isolation.

3.0 OWNERSHIP STATEMENT

The Koula PPF Operations department maintains ownership of this document and is responsible for
ensuring that this document is necessary and reflects actual practice.

4.0 REFERENCES
-K0100-AGA-PR-PI-00065-001 FWKO-A

- K0100-AGA-PR-PI-00065-001 FWKO-B

- K0100-AGA-PR-PI-00083-001 HP-A Stage 1 suction (1st /3rd & 4th stage P&ID’s also required)

- K0100-AGA-PR-PI-000116-001 HP-B Stage 1 suction (1st /3rd & 4th stage P&ID’s also required)

- K0100-AGA-PR-PI-000123-001 HP-C Stage 1 suction (1st /3rd & 4th stage P&ID’s also required)

-UK100113-01-00-038 LP compressor discharge (LP comp already long term positive isolated).

5.0 RESPONSIBILITIES

Where facilities provide it is the responsibility of ASSALA Operations Quality Representative to ensure
that this guideline is practiced.

6.0 SAFETY & ENVIRONMENTAL

1.0 PRIOR REQUIREMENTS

1.1 Safety requirements

1.1.1 Ensure that all personnel involved in this job are fully conversant with all job details.

Page 3 of 6
 KOULA Operations Operating Procedure for HP compressors
suction header tie in
Non-Restricted

1.1.2 Ensure that a JHA for each of the activities is held and that all precautions are taken to
minimize and control hazards.
1.1.3 Ensure that communication is established between all parties and those roles and
responsibilities are fully recognized. Ensure enough radios and charged batteries are
available.
1.1.4 Ensure that all tools and portable detectors are fit for purpose. Particular note should be
paid to validity of certification.
1.1.5 Ensure that all the work packs, i.e.: PTW, isolation certificates, procedures and method
statements are prepared and discussed prior to shutting down the PPF.
1.1.6 All working personnel must be aware of the hazards and risks related to the below
described sequence of operations.
1.1.7 Required firefighting equipment’s must be made available and ready for use.
1.1.8 Required monitoring and gas freeing equipment should be tested and ready for use.
1.1.9 On site, toolbox meeting to be conducted before starting each phase of operation, Job
Hazards analysis, and required PTW’s.

7.0 GUIDELINE
7.1 Introduction

Production supervisor maintains all responsibility for the enforcement, revision, and updating of the
document. He must ensure all control room operators and operators are trained, competent and authorized
to apply the procedure.

7.2 Major procedures

This procedure will be covering the following:

A. General and important recommendations before isolation
B. Depressurization and draining
C. Isolation
D. Purging with Nitrogen or water
E. Spading
F. Hand-over to Mechanical team (Project).
G. De-spading
H. Purging before line-up
I. Line-up and introduce gas
J. Leak test

During HP compressors draining & purging with natural gas

 Depressurization

1) Ensure all HP compressors are stopped and electrically isolated

2) Drain from the lower section of the lines (pocketed area) using the proper metal pockets (plastic totally
prohibited)
3) Start depressurization FWKO’s/HP comp A/B/C discharge line via BDV’s.

Page 4 of 6
 KOULA Operations Operating Procedure for HP compressors
suction header tie in
Non-Restricted

Isolation (Close following valves):

4) Ensure V-0619 FWKO-A gas outlet (Also turn the 8” spade to close position)
5) Ensure V-0819 FWKO-B gas outlet (Also turn the 8” spade to close position)
6) Ensure V-2455 HP-A 1st stage suction (install spade, 8’’# 150 RF)
7) Ensure V-2401 HP-A 1st stage suction bypass of SDV-2402 ( Turn spade 2”-150# RF )
8) Ensure V-6455 HP-B 1st stage suction (Also one spade in place on, 8”-150# RF )
9) Ensure V-6401 HP-B 1st stage suction bypass of SDV-6402 (Also one spade on V-6401; 2”-150# RF )
10) Ensure V-9455 HP-C 1st stage suction (Also one spade in place on, 8”-150# RF )
11) Ensure V-9401 HP-C 1st stage suction bypass of SDV-9402 open for depressurization to the flare via HP-C
compressor C BDV-9725
12) HP-C close V-9401 after N2 or H2O purging complete.
13) LP compressor discharge line SDV-3921 ensure this valve is 100% closed and install spade

Purging with Nitrogen or Water

14) Connect nitrogen or water hose on suction line V-2455 by V-2453 Open
15) Introduce Nitrogen or water up to 4bars by V-2453 Open
16) HP-C Confirm BDV-9725/V-2843/V-9825 Open [The ventilation zone during flushing] for first purge
cycle only
17) Introduce Nitrogen or water again up to 4 bars and vent and measure the LEL from time to time
18) Introduce Nitrogen or water again and vent and drain form bottom end valves till reach very low LEL
19) Purge the remaining Nitrogen or water from and ensure no liquids and LEL is below 4%

Spading

20) install spade at V-2455 HP-A 1st stage inlet valve 8’’# 150 RF
21) install spade at V-2401 HP-A 1st stage suction bypass of SDV-2402 valve 2’’# 150 RF (Spade in place just to
turn)
22) install spade at V-6455 HP-B 1st stage inlet valve 8’’# 150 RF
23) install spade at V-6401 HP-B 1st stage suction bypass of SDV-6402 valve ( 2’’# 150 RF)
24) install spade at V-9455 HP-C 1st stage inlet valve 8’’# 150 RF
25) install spade at V-9401 HP-C 1st stage suction bypass of SDV-9402 valve 2’’# 150 RF (after purging
completed)
26) LP compressor discharge line SDV-3921 install spade after SDV.
27) FWKO-A V-0619 turn the 8” spade close position
28) FWKO-B V-0819 turn the 8” spade close position

Hand-over the isolated ENGINE and COMPRESSOR to mechanical team (Project team).

De-spading
29) Remove spade at V-2455 HP-A 1st stage inlet valve 8’’
30) Remove spade at V-2401 HP-A 1st stage suction bypass of SDV-2402 valve 2’’# 150 RF (Spade in place
just to turn)
31) Remove spade at V-6455 HP-B 1st stage inlet valve 8’’
32) Remove spade at V-6401 HP-B 1st stage suction bypass of SDV-6402 valve
33) Remove spade at V-9455 HP-C 1st stage inlet valve 8’’
34) Remove spade at V-9401 HP-C 1st stage suction bypass of SDV-9402 valve 2’’ (after purging completed)
35) FWKO-A V-0619 turn the 8” spade close position
36) FWKO-B V-0819 turn the 8” spade close position
37) LP compressor remove spade on discharge line SDV-3921
38) Please ensure new gaskets were install

Page 5 of 6
 KOULA Operations Operating Procedure for HP compressors
suction header tie in
Non-Restricted

Purging before line-up

39) Connect nitrogen Hose inlet scrubber by V-2453 Open
40) Introduce Nitrogen up to 4 bars and vent via HP-C BDV-9725-and measure the LEL
41) Introduce Nitrogen again and vent
42) Test and confirm Oxygen content is below 0.5 %

De-isolation and Line-up and introduce fuel gas

43) Disconnect Nitrogen connections
44) Return all isolation valves to its original positions (FWKO-A/B; HP-A/B/C, etc )
45) Install original blinds with new gaskets on the drain and vent valves
46) Communicate with plant superintendent, all supervisors.
47) Log-in the time and date of completion

Leak test
48) There is a requirement to carry out a leak test after the gaskets replacement, in order to ensure that the
gaskets are not leaking and properly tightened and sealed, Hydro test is not required as per shell advice for
the HP compressors suction header as integrity was not disturbed.
49) Leak testing will be done by N2 or H2O at 4 bar pressure; this will also allow HP compressors gas header
purging at the same time. NB: Drain completely water after leak test.
50) Leak test again with hydrocarbon gas up to header pressure by soapy water as well as gas leak test.
51) Inform Control room that the planned works have been completed.

Validation
Superviseur Production OIM

Page 6 of 6