Cap HSE

MANUAL
CLIENT:
JOB:
HALDOR
TOPSOE
I-MA-9525.05-5124-000-TPI-001
UFN - V
1500 MTPD AMMONIA PLANT
AREA:
5124
TITLE:
OPERATING INSTRUCTION MANUAL

COOLING WATER SYSTEM
SHEET
C.C.
1 of
55
9525.05
GE-PGI/IETQ/IEUFN-V
INDEX OF REVISIONS
REV.
DESCRIPTION AND/OR REVISED SHEETS
FIRST ISSUE
FINAL ISSUE
HTAS Doc. No.
REV. 0
REV. A
REV. B
REV. C
REV. D
REV. E
REV. F
REV. G
REV. H
DATE
16/11/11 20/01/12
DESIGN
UNF V
UNF V
EXECUTION A.D.M.
M.C
CHECK
A.A.
A.A
APPROVAL
A.M.
A.M.
THE INFORMATION CONTAINED IN THIS DOCUMENT IS PETROBRAS PROPERTY AND MAY NOT BE
PETROBRAS DOC. NUMBER:
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Serial N
Rev.
Page
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I-MA-9525.05-5124-000-TPI-001
PETROBRAS
1500 MTPD AMMONIA PLANT UFN-V
UBERABA (BRAZIL)
THIS FORM IS PART OF STANDARD PETROBRAS N-381 REV. J ENGLISH ANNEX A SHEET 01/08
TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68
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I-MA-9525.05-5124-000-TPI-001
PETROBRAS
UBERABA (BRAZIL)
OPERATING INSTRUCTION MANUAL

UNIT 5124
COOLING WATER SYSTEM
20/01/2012
ISSUE FOR BASIC DESIGN
16/11/2011
ISSUE FOR REVIEW
REV.
DATE
STATUS
M. CARINCI
A.ALTAMURA
A.MAGARINI(L.DE GAETANO
A.DE MICHELE
A.ALTAMURA
A.MAGARINI(L.DE GAETANO
WRITTEN BY
(name & visa)
CHECKED BY
(name & visa)
APPROV./AUTHOR. BY
(name & visa)
DOCUMENT REVISIONS
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UBERABA (BRAZIL)
INDEX
1
INTRODUCTION...................................................................................................5
1.1
1.2
List of Process Equipment....................................................................................5

Process Theory.....................................................................................................5
PROCESS DESCRIPTION...................................................................................8
2.1
2.2
2.3
Design Condition................................................................................................10
Cooling Water System........................................................................................10
Control and Interlock Description........................................................................12
PREPARATION FOR INITIAL START-UP...........................................................14
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.4
3.4.1
3.4.2
3.4.3
General............................................................................................................... 14
General plant inspection.....................................................................................14
Equipment inspection and cleaning....................................................................15
Piping Inspection................................................................................................19
Electrical Equipment Inspection.........................................................................20
Instrumentation Preparation...............................................................................21
Heating, Ventilation Air Conditioning Equipment................................................21
Telecommunications...........................................................................................22
Cleaning of Piping and Equipment.....................................................................22
General............................................................................................................... 22
Water Flushing...................................................................................................23
Air Blowing..........................................................................................................24
Steam Blowing....................................................................................................25
Chemical Cleaning.............................................................................................25
Lubrication Systems Flushing.............................................................................25
Leak Test............................................................................................................ 25
General Procedure.............................................................................................25
Tightness Test.....................................................................................................26
Leak Repairs / Tightening...................................................................................26
NORMAL START-UP..........................................................................................27
4.1
4.2
4.2.1
4.2.2
4.2.3
Start Up Preparation...........................................................................................27
Start Up Sequence.............................................................................................27
Main operation:...................................................................................................27
Operating description.........................................................................................28
Start-up of cooling water system........................................................................29
NORMAL OPERATION AND PROCESS VARIABLES.......................................31
5.1
5.2
5.3
5.4
5.5
General............................................................................................................... 31
Feedstock...........................................................................................................31
Products............................................................................................................. 31
Process Variables...............................................................................................31
Analytical procedures for sampling.....................................................................32
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NORMAL SHUT DOWN......................................................................................33
6.1
6.2
6.2.1
6.2.2
Shutdown Preparation........................................................................................33
Shutdown Sequence (cold shutdown)................................................................33
Main operation:...................................................................................................33
Operating Description:........................................................................................33
EMERGENCY SHUT DOWN..............................................................................35
7.1
7.2
7.3
7.4
7.5
Power failure.......................................................................................................35
Instrument Air Failure..........................................................................................36
Presence of Hydrocarbons.................................................................................36
Presence of Ammonia........................................................................................36
Excess of Chemical............................................................................................36
PLANT SAFETY.................................................................................................38
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.2
8.2.1
8.2.2
8.3
8.3.1
8.4
Introduction to Hazardous Material.....................................................................38

Physical and Chemical Properties of Ammonia..................................................38
Hazards Identification.........................................................................................39
First Aid Measures..............................................................................................40
Fire Fighting Measures.......................................................................................41
General safe working procedure........................................................................41
Personal protective equipment...........................................................................41
Fire prevention, protection and Fire Fighting......................................................43
FIRE AND GAS DETECTION & ALARM SIGNALLING PHILOSOPHY..............48
Fire Detection and Alarm....................................................................................48
Fire and Gas Monitoring System........................................................................51
REFERENCE DOCUMENTATION......................................................................53
9.1
9.2
9.3
9.4
9.5
9.6
9.7
PFD.................................................................................................................... 53
PID...................................................................................................................... 53
Basis of Design...................................................................................................53
Data Sheets........................................................................................................54
Cause and effect Diagrams................................................................................55
Interlock Narrative...............................................................................................55
Fire and gas Layout............................................................................................55
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UBERABA (BRAZIL)
INTRODUCTION
This operating instruction manual outlines the principles of operating the Cooling
Water System (UNIT 5124 OSBL) for the 1,500 MTPD ammonia plant UFN-V of
Petrobras, in Uberaba, Brazil.
Special attention has been paid to the principles of start-up, normal operation and
shutdown (normal as well as emergency shutdowns).
This manual should be used as the basis for the establishment of detailed operating
instructions, which should be prepared as part of the detailed engineering.
The Cooling Water System includes all the equipment required to produce and
distribute cooling water to the users of Nitrogen Fertilizer UNIT V (UFN V). This
system consists of an Open Circuit
Cooling Water System through which the hot cooling water return from the users is
cooled by a induced draft Cooling Tower.
The objective of this system is to provide the Plant with an uninterruptible supply of
cooling water to cool streams in the process, utilities & offsite units.
List of Process Equipment.

Equipments in this system:
Equipment No.
B-5124001 A/B/C/D
Equipment description
Cooling Water Pump
B-5124002 A/B
Emergency Cooling Water Pump
BBC-5124001
Cooling Tower Basin
TR-5124001
Cooling Tower
UQ-5124001
Corrosion Inhibitor and Dispersant Treatment Package
UQ-5124002
Corrosion Inhibitor and Anti-scale Treatment Package
UQ-5124003
Non-Oxidant Biocide Treatment Package
UQ-5124004
Sodium Hypochlorite Dosing Package
UQ-5124005
UT-5124001
Sulphuric Acid Treatment Package

Side Stream Filter
Process Theory
The objective of this system is to provide the Plant with an uninterruptible supply of
cooling water to cool streams in the process, utilities & offsite units.
The Cooling Water System is normally fed by filtered water coming from Dual Media
Filtration Package (UT-5121002) via Cooling Water make-up Pump (B-51210013A/B)
as make-up of Cooling Water Circuit
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Cooling Water System

Cooling Tower (TR-5124001)
The design of the Cooling Tower (TR-5124001) will be based on a Design Ambient
Wet Bulb Temperature of 26.9C. A minimum additional of 0.5 C, as overdesign
factor, will be added to take into account the wet air recirculation effect (Recirculation
Factor to be applied shall be verified and confirmed by CT Vendor).
The design capacity of the Cooling Water System shall be calculated with a design
margin of 30% to the maximum operating flow rate. The cooling water circuit is
designed for 26100 m3/h: this figure has been calculated considering a differential
temperature of 10C.
The Cooling Tower is composed by ten (10) cells with one fan for each cell.
The Cooling Tower drift eliminator will be designed to limit drift load to a maximum of
0.005% of the design cooling water flow rate to limit impact on surrounding
equipment.
Side Stream Filter (UT-5124001)
The Cooling Water Side-stream Filter (UT-5124001) is designed for treating 1300 m 3/h
(5% maximum of the cooling tower design flow circulating): six (6) self-cleaning
syphon type filters shall be provided.
Cooling Water Pump (B-5124001 A/B/C/D)
Four (4) horizontal centrifugal pumps (B-5124001 A/B/C/D) with a design flow rate of
8700 m3/h (9000 m3/h is the maximum allowed design flow rate as per Petrobras
Doc.I-MD-9525.05-5124-PEI-001 rev.0) are foreseen to supply cooling water to
distribution: the normal configuration is three (3) pumps operating and one (1) spare;
all pumps are electrical motor driven.
A by-pass line is accomplished by operator through hand operated valve to allow startup operation and additional circulation in case of low cooling water requirement.
Emergency Cooling Water Pump (B-5124002A/B)
An independent circuit pertaining to the same Cooling Tower (TR-5124001) has its
own supply/return header. It is fed by Emergency Cooling Water Pump (B-5124002
A/B), one (1) operating and one (1) spare which has the purpose to ensure the
cooling of the equipment that must run even in case of power failure:
These equipment are:
Inst/Plant Air Compressor (Unit 5136)
Ammonia Refrigeration Package (Unit 6351)
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Emergency Diesel Generator will supply power to Emergency Cooling Water Pump in
case of power failure.
Cooling Tower Basin (BBC-5124001)
The Cooling Tower Basin (BBC-5124001) is divided into three main sections:
the first one is located below the cells and it has the function of receiving the
water dripping from the cell packing. It is provided with partitions for independent
operation of the cells (a sluice gate allows the isolation of each cell for
maintenance during the operation of the remaining ones);
the second one collects the water coming from all the cells, routing it to the
suction bay of the pumps;
the third section represents the suction bay of the Cooling Water Pump
(B5124001A/B/C/D) and Emergency Cooling Water Pump (B-5124002A/B)
The suction bay is deeper than the rest of the basin to guarantee optimal
hydraulics of the pumps; a pair of suction screens will be provided at each
entrance of the pumping bay to prevent access of suspended material into the
system.
The Cooling Tower make-up will be sent to Cooling Tower Basin (BBC-5124001)
and the flow is automatically adjusted to maintain a constant water level inside
basin.
The design of the pump suction basin shall be in accordance with the
recommendations of Hydraulic Institute Standards (HIS).
Chemical Dosing Packages (UQ-5124001/5124002/5124003/5124004/5124005)
The Cooling Water will be chemically treated to protect the equipment from scale and
corrosion and to avoid bacteriological growth: chemical treatment will be performed
and optimized by Chemical Supplier based on cooling water characteristics.
The chemicals receiving, storage and handling area will be located on a paved area
provided with a shelter and partial walls for direct sunlight protection. The paving shall
be foreseen with anti-acid covering and curb: curbs dimension shall be adeguate to
contain the largest chemical storage inventory.
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PROCESS DESCRIPTION
The Cooling Water System is an Open Evaporative Circuit: the cooling tower is
induced draft counter flow type. The cells are installed on top of the common Cooling
Tower Basin in-line configuration.
The Cooling Tower is used to reduce the temperature of the cooling water return by
the mechanism of evaporating cooling and the exchange of sensible heat. Return
water will be distributed in the cooling tower where it will fall through the fill and cool
by evaporation.
Induced draft will be achieved by fans, which will move air through water to promote
evaporation.
The discharge air exits the top of the cell.
Drift eliminators will be provided to minimize liquid water carry over and prevent from
fallout around the tower itself. The Cooling Tower drift eliminator will be designed to
limit drift load to a maximum of 0.005% of the design cooling water flow rate to limit
water losses.
Cooled water is collected under the tower in a concrete basin (BBC-5124001) which
collect the water from all the cells and routes it to the suction buy of the pumps. Each
pump has an independent suction pit interconnected to the common, which has an
opening provided with two (2) screens. The screens, in series arrangement, will allow
the first screen to be cleaned while the other one will be in line. Suitable access
facilities and manual lifting device will be provided to enable the screens to be
cleaned outside the cooling water pumps basin.
Normally the Cooling Water Basin is drained to Rainy Sewer; in case of NH 3
contamination the basin draining shall be diverted to Oily Sewer.
Make-up water, replacing system losses (evaporation, drift losses and blow down), is
composed of filtered water coming from Cooling Water Make-up Pump (B-5121013
A/B),boiler blow down coming from Unit 5131, condensate from CO2 Compressor and
Air Compressor Inter stage from Unit 3211. The minimum liquid level (LL) in the
cooling towers basin will be sufficient to provide cooling water pumps flooded in all
conditions.
As evaporation occurs, dissolved solids build up in the water. By removing blow down
and adding filtered water as make-up water, the dissolved solids level in the water can
be maintained and the cycles of concentration can be controlled.
Blow down flow depends on conductivity level in the circulating cooling water and is
controlled with
Blow down control valves. Blow downstream is normally sent to Rainy Sewer.
Four (4) horizontal centrifugal (three main, one spare) Cooling Water Pump (B5124001 A/B/C/D) allow water circulation in the Cooling Water Supply circuit; while the
Emergency Cooling Water
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Pump (B-5124002A/B) guarantee the cooling water supply to the critical machines
inside the Plant during normal operation and in case of power failure. Cold water
recirculation line is provided on the common discharge of the Cooling Water Pump in
order to run the pumps at their rated point independently from the cooling water
request of the Plant, spilling back water into the common section of the cooling tower
basin.
The Side-stream Filters (UT-5124001) are provided to reduce the suspended solids
in the circulating water so reducing also the chemical consumption and the suspended
solids in the circulating water; they are fed from the discharge line of the Cooling
Water Pumps (B-5124001 A/B/C/D) and are designed to treat a portion of the design
circulating cooling water flow. Filtered water coming from the package is sent back to
the common section of the tower basin.
Side Stream Filters will be self-cleaning siphon type and the effluent coming from the
backwashing will be collected into a dedicated basin from which the effluent shall be
sent to Rainy Sewer together with blow downstream.
To avoid biological growth, to protect the equipment from scale and corrosion
phenomena and to adjust the pH if necessary, the Cooling Water will be chemically
treated:
Corrosion Inhibitor and Anti-scale Treatment Package (UQ-5124002);
Corrosion Inhibitor and Dispersant Treatment Package (UQ-5124001);
Non-Oxidant Biocide Treatment Package (UQ-5124003), provided in shotdosage;

Oxidant Biocide Treatment Package (UQ-5124004), sodium hypochlorite shall be
foreseen for this purpose;
Sulphuric Acid Treatment Package (UQ-5124005).
The injection of these chemicals is made through a deep pipe directly in the common
section of the Cooling Tower Basin.
The chemical dosage control will be performed through an automatic control system.
The packages UQ-5124001/5124002/5124003 are composed by a Porta-feed and
two dosing pump to inject the chemicals.
The packages UQ-5124004/5124005 will receive chemicals from centralized storage
system:
sodium hypochlorite make-up feed will be sent from Unit 5121 by means of B5121016A/B;
sulphuric acid make-up feed will be sent from Unit 5128 by means of B5128003A/B.
The main characteristics of the circulating cooling water are continuously monitored
through in-line analyzers: pH, conductivity, free chlorine and turbidity analyzers are
installed in the cooling water return.
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Design Condition
The design of Cooling Water System shall be consistent with the overall plant
operating scenarios.
The design shall ensure the continuous supply of the produced streams in quantities
adequate for normal and abnormal operating conditions and also maintaining stable
product quality.
Cooling Water System

The Cooling Water Circuit is designed for 26100 m 3/h: this figure is calculated with a
design margin of 30% to the maximum operating flow rate and considering a
differential temperature of 10C. The cooling water balance, without design margin, is
summarized in the following table:.
Cooling Water Balance
Unit
Cooling Water
[m3/h]
Ammonia Unit 3211
15470
Unit 5128
60
Unit 5132
4127
Unit 5136
30
Unit 6351
285
a)
T
[C]
8.3
10
8
10
10
Feedstock characteristics:
The filtered water, used as make-up of Cooling Water, will be available with the
following characteristics:
Filtered Water (1)
Normal
Design
Pressure [kgf/cm2]
3.8
Temperature [C]
31
70
(1) Filtered Water as product water from Dual Media Filtration Package (UT-5121002).
Component
pH
TSS [mg/L]
Normal
Maximum
7.35 (1)
Calcium
(as CaCO3) [mg/L]
12
Magnesium
(as CaCO3) [mg/L]
15
Sodium (Balance) (as CaCO3) [mg/L]
14,7
Sulphates
(as CaCO3) [mg/L]
18
Chlorides
(as CaCO3) [mg/L]
19,7
Bicarbonates
(as CaCO3) [mg/L]
- della Magliana,
Silica
(as SiO2)
[mg/L]
13 68
TECHNIP
ITALY S.p.A.
- 00148
ROMA - Viale Castello
Free Chlorine
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In the Cooling Water Basin will be also routed the following streams:
Boiler Blow Down
Condensate from CO2 Compressor
Condensate from Air Compressor
STREAM
Boiler Blowdown
Condensate from
CO2 Compressor
Condensate from
Air Compressor
Condition
Normal
Design
Normal
Design
Normal
Design
Pressure [kgf/cm2]
1.5
3.5
1.5
1.5
3.5
Temperature [C]
50
155
41
70
41
70
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b)
Product characteristics:
Cooling Water characteristics, at Unit 5124 battery limits, are the following:
Cooling Water Supply
Norm.
Design
Cooling Water
Return
Norm.
Design
Pressure [kgf/cm 2] (1)
Pressure [kgf/cm 2]
(1)
Temperature [C]
31
70
Temperature [C]
41(4)
70
Ph
HOLD (3)
Chloride [ppm wt]
115140 max (2)
TDS
[mg/l]
500600
TSS
[mg/l]
50
(1)
(2)
(3)
(4)
Pressure at B.L. users.

Maximum Chlorides content corresponds to Nc=10 (Design Case)
The pH value depends on the Cooling Water Chemical Treatment selection
Maximum return temperature from individual user.
Control and Interlock Description

The most relevant control points are:
Cooling Tower blow-down is controlled through 5124- AIC-0002 by acting on
5124-AV-0002 valve.
Cooling Tower level is controlled through basin level control
by acting on 5124-LV-0001 valve.
5124-LIC-0001
Reduction of suspended solids in the circulating water is controlled by

5124-FIC-0020 by acting on 5124-FV-0020 valve.
5124-FIC-0020 by acting on 5124-FV-0020 valve sent part of the water to the
Side Stream Filters UT-5124001 to maintain at proper level the suspended solid
continent in the circulated cooling water.
All DCS control are covered in the following table:
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Logic
Block
Description
I-001
In case of Low Low Level inside the

basin (BBC-5124001) the running
Cooling Water Pump
(B-5124001AD) and Emergency
Cooling Water Pump
(B-5124002A/B) are automatically
stopped. Pump start is not permitted
till level is recovered.
Low Low Level in the Cooling Tower
Basin shall prevail on pump
autostart I-012/ESD
I-002
In case of Low/High Pressure on the

pump discharge header, the
equipment is automatically stopped
I-003

Low/High Pressure on the

line 44-AR-5124-084-AbNI detected by5124- PT0004
line 44-AR-5124-086-AbNI detected by
5124- PT-0006.
I-004


line 44-AR-5124-088-AbNI detected by
5124- PT-0008
stop the pump

B-5124001C
I-005


line 44-AR-5124-090-AbNI detected by PT-0010
stop the pump

B-5124001D
Low Level inside Sodium

Hypochlorite Dosing
Package (UQ-5124004
open the 5124-XV-0008
I-006
In case of Low/High Level in the

storage drum inside Sodium
Hypochlorite Dosing Package (UQ5124004), the ON/OFF valve XV0008 on the line 2-CH-5121-155Xa-NI is automatically
opened/closed.
High Level inside Sodium

Hypochlorite Dosing
Package (UQ-5124004).
close the 5124- XV-0008
I-007
In case of Low/High Level in the

storage drum inside Sulphuric Acid
Treatment Package (UQ-5124005),
the XV-0007 on the line 2-CH-5128092-01CS4S01-NI is automatically
opened/closed
detected
Action
Low Low Level in the

Cooling Tower Basin
(BBC-5124001) detected
by 5124- LT-0002
Stop the running pumps.
Low Level inside Sulphuric

Acid Treatment Package
(UQ-5124005).
High Level inside
Sulphuric Acid Treatment
Package (UQ-5124005)
stop the pump

B-5124001A.
.
stop the pump

B-5124001B
open 5124-XV-0007
Close 5124- XV-0007
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PREPARATION FOR INITIAL START-UP

General
This chapter covers those activities required to bring the units to a "ready for start up"
condition. This part of precommissioning activities will be implemented by the
precommissioning team, in close coordination with construction personnel.
The details of all the precommissioning activities (such as cleaning, water flushing, air
blowing, tightness test, loop testing, etc.) are not part of this manual.
The information described hereafter concern the preliminary operations for the first
start-up of the new unit.
In addition, for subsequent start-up, it may happen that some preliminary operations
described hereafter have to be performed or repeated, depending on the current
situation (case of shutdowns for maintenance works, etc.).
General plant inspection

The plant should be carefully checked to assure that it is constructed according to the
applicable drawings, standards, specifications and fulfilling the local laws. A check off
against the P&ID.s is done for piping, equipment and instrumentation. A "punch list" of
missing, incomplete, or incorrect items is then prepared for correction. In addition
temporary identification tags, signs for various lines can be installed at this time to
assist in subsequent start-up and operation.
This check is carried out before the end of construction work in order to check that the
Unit is satisfactory from an operation point of view. All the individual operations
needed for unit precommissioning, start-up and shut-down are applied on site.
The work described hereafter is carried out during the final stages of construction
work under the direction of the precommissioning group in charge of the Unit.
Typically, this checking (which can be called preliminary conformity to P&ID.s check) is
useful as soon as construction progress is 70% and above. Several checks can be
made simultaneously depending upon the completeness of each section or system of
plant at that time.
Smooth start-up will depend to a large degree on the thoroughness with which the unit
is checked out beforehand. Every installation details must be checked against the
design specifications and standards and for good construction practice.
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3.2.1
Equipment inspection and cleaning

Static Equipment
a.
General Inspection
A general inspection of tanks, vessels, drums, columns, reactors and exchangers
is made against the design drawings soon after erection. This check includes:
Verification of temperature/pressure and vacuum rating on nameplate;

Verification of lining condition (if applicable);
Nozzles location/size, flanges face;
Thermowell location and length of immersion;
Cleanliness.
When equipment experiences a temperature change it undergoes thermal

growth. Supports are provided to allow and guide this growth. If supports do not
function as they are intended then damage could result to vessels, columns, heat
exchangers nozzles or piping as the case might be. It is therefore of great
importance that all supports are inspected and special attention shall be given to
large horizontal vessels and heat exchangers.
b.
Equipment and Structure

Especially in high temperatures process, as relative dilation of pipes liaison with
structure is important due to high temperatures:
c.
Check that relevant lines and expansion joints are free to move in all
directions. Be sure shipping stops are removed on the expansion joints if any.
Check that the platforms and other structures will not interfere with the free
expansion of the equipment in any direction.
Check that instrument piping, electrical conduit and other equipment are in no
danger of bending.
Internal Inspection
Tanks, vessels, drums and columns will be inspected internally.
The bottom manhole should be left open in case tools or other materials are
accidentally dropped down.
Check that no scaffolding or trash remains in the vessel.
Internals must be inspected carefully and checked against the designs
documents to ensure that the installation was properly carried out. This check
should include:
Trays: number, location, type, spacing, levelness, weir height, down-comers,

valves number and operation, support bolting (tightness testing is usual for
chimneys trays).
Check that all valves on valve tray type are clean and free to move. Check
that weep holes, where provided, are not plugged;
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d.
Distributors: location, alignment, size and number of openings;

Vortex breakers: type, size and orientation;
Demisters: size, material, support;
Check that baffles in the bottom of the columns are correctly fitted, type,
orientation and levelness;
Check that instrument nozzles are clear.
Cleaning
All tanks, vessels, columns, drums, basins, reactors, etc. have to be inspected
and cleaned if required, before final closure, boxing-up.
The final cleaning is witnessed by the precommissioning team, especially if the
relevant vessel has been integrated in a cleaning sequence.
In such case, it is normal practice that the equipment is finally closed/boxed-up
after inspection.
When the vessel is used as "collecting device", it must be finally closed only after
cleaning.
Vessels cleaning is normally done through different ways according to the
equipment materials and vessels service.
Equipment internal materials generally are the following:
Carbon steel;
Stainless steel;
Carbon steel lined with different coating material.
The following procedure will be applied:

e.
Carbon Steel Equipment

Carbon steel equipment will be brushed or wiped when required with brush to
remove scale flakes if any, rust, protection oil, etc. before final closure.
After successful inspection, the equipment will be closed definitely with final
gasket.
During precommissioning phase all activities relevant to piping connected with
such equipment will be done with care in order to avoid sending foreign material
into the equipment.
Note:
Storage tanks must be clean of any corrosion scales or rust flakes and dust.
Depending on the initial condition of these tanks a cleaning by means of sand
blasting may have to be performed. Afterwards these tanks must be put under
nitrogen atmosphere to prevent corrosion (or dry air if nitrogen is not available).
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f.
Stainless Steel Equipment

Stainless steel equipment will be cleaned by using cloth rag before final check
(wire brush should not be used). After successful inspection, the equipment will
be closed definitely with the final gasket.
g.
Carbon Steel with Lining

Such equipment will be cleaned by using a water spray, to prevent lining
damages.
Note:
For equipment on which internals have to be installed during precommissioning
phase, final inspection will be done after internals installation.
h.
Final Inspection
After hydrotest, cleaning and dry-out as required, a final vessel inspection should
be done. When vessels have been shop-tested, they will not be further tested in
the field but may be included as part of a piping system test.
Carefully inspect for cleanliness. After the final inspection, immediately close,
after mutual agreement on "final closure / boxing-up" document.
Caution:
Before entering a vessel, the plant safety precautions should be observed. These
include sampling of vessel internal for toxic vapours and oxygen concentration,
wearing a safety harness and having an attendant outside the vessel. AN
UNATTENDED VESSEL SHOULD NEVER BE ENTERED.
Pumps
a. Initial Checking
The most critical period in the life of a pump is during its initial start and several
minutes immediately thereafter. Proper installation and start-up is essential for
trouble-free performance. Before the equipment is ever started it should be
checked as follows:
Review carefully the manufacturer's operating instructions;

Check that the overall installation is complete;
Verify that the pump and driver are properly aligned;
Verify that cooling water piping is connected and in service where required:
pedestals, bearing jackets, stuffing boxes, etc. Run cooling water through
bearing housing, stuffing boxes, etc. until flushed clear;
Check gland or seal oil piping. Conventionally packed pumps in hot service
are generally furnished with gland oil. When a pump is furnished with
mechanical seals, verify that all components of the flushing system such as
strainers, separators, restriction orifices and coolers have been correctly
installed and are clean;
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Verify that bearings shafts are clean and properly lubricated. All bearings
should be flushed clean and the correct lubricant in the proper quantity must
be provided. Records for type of lubricant used and date of lubrication follow
up will be recorded;
Temporary strainers are provided for the suction of each pump to be installed
on the pump side of the suction block valves. These strainers should be
installed after the suction lines are flushed. These should be cleaned
frequently to keep lines free of foreign matter. The strainers should be
cleaned frequently by alternating pumps where possible. Except on severe
services which may require installation of fine mesh on both pumps A and B,
it is normally sufficient to equip only one pump with fine mesh (on all "A"
pumps for instance).
Consequently, the "A" pumps will be the ones preferentially started during
initial start-up. Then when temporary strainers are not anymore required they
should be removed and only the permanent strainer installed to prevent
further possible pump damage;
Pumps are not field hydrostatically tested.
b. Running Tests
When piping systems are sufficiently complete, means that a system or subsystem can be released from construction activity to precommissioning activity for
dynamic operations; some pumps will be put into operation to determine whether
they are in good mechanical condition and to verify proper installation of support
systems and test running. Keep in mind that medium other than the design fluid is
not always possible. Typical example is the case for LPG pumps when use of
water leads to adverse effect that may damage mechanical seals and introduce
water in the system where drastic drying is being implemented before start-up.
The circulating fluid for pump test running, when applicable, is often water. Due to
differences in specific gravity between water and the design fluid care must be
taken not to overload the motors on motor driven pumps. The amperage on motor
driven centrifugal pumps should be monitored. If the amount of current drawn is
too high the discharge valve should be throttled until the amperage drawn by the
motor is acceptable, keeping in mind that the pump minimum flow should always
be achieved.
Note:
Running test of pumps will be done when applicable only. The selection of the
pumps subject to running test with water will be done by the
precommissioning/commissioning group.
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Electrical Motors
In conjunction with final inspection of the electrical construction work the following
testing and preparation is to be carried out in order to perform the initial run-in of
electrical motors for rotational check:
Open all circuit breakers and switches;
Check all bus bars to see that they are free of foreign material;
Check that all electrical equipment are connected to the equipment grounding
system in accordance with the drawings and specifications;
Check that the cables are correctly installed on the tray supports and that electrical
equipment is properly connected;
Check grounding systems for continuity and resistance;
Check piping systems with electrical bonding at flanges for continuity and
resistance;
Close both main transfer primary disconnect switches;
Close switchgear main circuit breakers;
Check voltmeter on switchgear for proper voltage;
Check all thermal overload heaters;

Close first switchgear feeder circuit breakers, then second, etc;
Close first motor control center main circuit breaker, then close each motor starter
circuit breaker and repeat for each motor control center;
Check each motor for proper lubrication;
Check rotation of each motor making sure that the motor driven equipment (i.e.
pump, compressor, etc) is either disconnected or free to be turned.
Before switching on any electrical equipment, agreement from an electrical engineer
is needed. When a motor has been started by pressing the starter button, NEVER
(except in emergency conditions) push the stop button until the motor has attained full
speed and the amperage has fallen back to the normal running figure. If a motor is
stopped before it has risen to maximum speed, damage can be done to the
switchgear due to the heavy load it is carrying. !t is bad practice and could be
dangerous for an operator to press the starter button to see if a motor is live" and
then immediately press the stop button as soon as the motor turns. Said "bumped
test" is a bad practice.
3.2.2
Piping Inspection
Piping Sliding Support and Anchors
All comments applying to sliding supports on static equipment also apply to piping.
Long straight runs of piping should be checked for bowing when up to temperature.
Bowing causes pipe overstressing and could result in pipe failure. The probable cause
for bowing is that the line is unintentionally anchored at each extremity and this should
be checked and corrected.
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Spring Support
Inspection prior to Hydrostatic Testing
Check that the spring stops are installed. If the stop is not installed on the spring
support of a vapour line, the weight of water in the pipe during hydrostatic testing
could deform the spring. The characteristic of the spring would thus change and its
performance may not be as predicted. Pipe normally transporting water would not be
affected as the spring would be designed for the weight of water but rather than make
them an exception it is simpler to state that all spring supports have their stops
installed.
Inspection after Hydrostatic Testing
After draining the water and prior to any heating the spring stops should be removed.
If the stops are not removed, the springs will not flex with the pipe thermal growth and
nozzles will be over stressed resulting in possible damage.
After the spring stop is removed, check that the spring pointer is somewhere between
the hot and cold settings stamped on the support. The thermal growth of the pipe will
result in the spring being either compressed or stretched.
If the spring pointer is not between the hot and cold settings, the spring could become
fully compressed or stretched before the full load is imposed on it. At this point, the
spring would cease to function as such, resulting in nozzle over stressing with
possible damage.
3.2.3
Electrical Equipment Inspection

The following functional tests for electrical systems will be performed:
For motors where they have more than one control and automatic operation, first
check manual operation, then automatic. Test each control operation to be sure the
control is operating in accordance with process requirements;
Interlocked control circuits for permissive start and automatic shutdown must be
checked to ensure correct relay and control valve actions from each alarm function.
This is deeply linked with instrumentation loop testing;
Check emergency power supply if installed for correct operation on power failure;
Close lighting transformer primary circuit breaker;
Close lighting distribution panels feeders circuit breaker and emergency lighting;
Check all seal fitting to be sure they are filled with sealing compound;
Check all explosion-proof, vapour-tight, dust-tight and weather-tight enclosure to be
sure that the enclosure are secured and closed properly;
Check all nameplates and lighting panel directories to be sure that each circuit
breaker controls the proper circuit.
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3.2.4
Instrumentation Preparation
Before energizing field instrumentation and proceed to energized loop checks,
confirm that the following static checks are actually implemented:
Clean the instrument air supply headers by blowing with clean, dry air, and check
them for leak tightness before connecting to instruments;
Verify that pneumatic tubing is hooked up, that instrument air is available at the
instrument;
Check tubing from instruments to process piping and equipment for leak
tightness;
Check orifice plate bore diameters;
Install orifice plates after completion of testing, draining, flushing and cleaning of
lines;
Isolate or remove in line components for flushing and cleaning operations.
Reinstall and/or reconnect after completion of cleaning and flushing operations;
Verify correct positions and installation of inline instrumentation (control valve flow
direction and fail position, orifice plate installed in correct relation to flow etc.);
Perform all non-operating tests that ensure instrument operability: remove
shipping stops, check pointer travel, verify and adjust the instrument's capability
to measure, operate, stroke, etc. in the direction and manner required by the
process application (direct or reverse controllers, etc.);
Perform functional loop checks and demonstrate correct operation (a
precommissioning record sheet with the relevant loop diagram);
Fully pressurize and energize the transmitting and control signal systems by
opening process connections at primary sensors and regulators and by making
control mode settings for automatic operation of equipment as the process unit is
charged and brought on stream;
Check on the DCS the operability of the system and interfaces to other
subsystems.
3.2.5
Heating, Ventilation Air Conditioning Equipment

Verify conformity of the installation with drawings, specifications, safety rules,
supplier instructions;
Verify the free rotation of fans and motors;
Verify the correct installation of anti-vibrations mountings and sealing compound
of fire dampers, if any;
Verify that leakage and blades of dampers run freely;
Verify that dampers actuators are in good running order;
Verify that air flow direction in pre-heater is correct;
Perform ductwork leak tests;
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Start the unit test sequences, interlocks, vibrations;

Start air flow and make balancing test (air distribution adjustment);
Adjust rooms temperature and pressurization.
3.2.6
Telecommunications
Inspection of all telecommunication equipments is performed to ensure compliance
with specifications, drawings, Codes of Practice, regulations and manufacturer's
particular requirements. In general, inspections should ensure satisfactory jointing and
continuity of all conductors, satisfactory alignment and tightness of bolting,
acceptance levels of insulation, and a high standard of cleanliness.
Main telecommunication systems are:
Message switch system;
Radio communication system;
Telephone network.
Cleaning of Piping and Equipment
3.3.1
General
Lines and equipments cleaning is intended to eliminate welds rods and slags,
abrasive dusts, oxides and in general other substances which might impede the
normal unit operation or damage the equipment (valves, pumps, compressors,
turbines, etc.). Cleaning is usually carried out either by hand cleaning for large
equipment and lines having a diameter higher than (or equal to) 24", by water
flushing, by air/steam blowing, chemical cleaning, etc.
The cleaning of lines and associated equipment will be treated during the construction
and precommissioning phases in two steps:
1.
2.
During the construction phase, preliminary checking is implemented to avoid

pipelines retaining construction materials until the actual cleaning takes place
later;
To reach the readiness for start-up, a cleaning is implemented for each
system/subsystem. This cleaning will use efficient methods which could be
implemented only after part of the plant is available.
As a summary, only above (1) can be implemented at the hydraulic test stage of the
work. The cleaning (2), of course will be performed as soon as the site facilities allow
for it, the optimum being that both cleanings are implemented in sequence.
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The cleaning sequence is the following:

Pipes installation after the prefabricated spools have been transferred to the site
must be checked for removal (by gravity) any foreign material as tools, gloves, etc.
(they are placed vertically before installation);
For big lines, inspection is carried out by construction group after each spool is
welded, and a manual rubbing/wiping is performed, if necessary;
After hydrotest, the hydrotesting medium (mainly water) is drained; through drain
valves or one open flange (if water is dirty, the network is rinsed until clean);
The relevant pipes are then air swept to remove free water;
When the system or part of the hydrotested system (so called Test Pack), is
released, a provisional reinstatement is implemented, with exceptions list agreed
by precommissioning group and list given to construction to allow the use of
permanent facilities (columns/vessels/pipes themselves) to perform the cleaning
to meet the precommissioning cleanliness requirement.
Some of this cleanings may need the utilities, (such as instrument air, utility air, service
water, etc.), in this case of course utilities should have been precommissioned before
with the normal required checks.
Above step is followed by final reinstatement and conformity to P&ID.s checks, air
tightness test, etc.
The requirements for start-up are such that a cleaning as per above does not meet,
for all systems, the requirements for readiness for start-up. However, some lines could
not be subject to additional cleaning (such as some columns overhead lines, flare
headers, etc.). For these lines, above steps should be well monitored and controlled,
and it is normal practice for these cases that the precommissioning group witnesses
and records the status of these lines before (or after) hydrotest.
3.3.2
Water Flushing
Water flushing will be performed using clean water.
The following guidelines should be observed for flushing operations:
It should be stressed that brackish or salt water must not be used for piping
flushing. Demineralized water or condensate should be used for stainless steel
pipes.
Flush main headers first, then subheaders;
When practical, lines should always be flushed away from a vessel rather than into
a vessel. Any vessel that has been flushed or blown into should be opened and
manually cleaned following flushing;
Flushing should be preferentially from the highest elevation to the lowest elevation.
This restrain is not compulsory for blowing;
Vessels and systems should be vented when filling or emptying to prevent vacuum
pulling;
During flushing, maximum volume and velocity should be used to ensure through
cleaning, the rate of flushing medium should be regulated at the source;
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Instruments (i.e. pressure gauges and transmitters, differential flow meter

transmitters, moisture and other in-line analyzers, etc.) should be positively isolated
from the system during cleaning;
All drains should be flushed through to check for blockage;
Where possible, open-end lines should be flushed through. This is the case of
process units provided with end flanges for all utilities lines which make easier
either flushing/air blowing/steam blowing. Flow should not be restricted drastically;
Pump suction and discharge lines should be flushed while protecting the pump
casing;
Lines should be flushed in the following sequences, where possible:
first the main header;
then each sub-header;
at last, each branch line.
Lines should not be flushed into exchangers without flushing at the inlet first. Only
when the inlet is checked clean, and when the exchanger is not equipped with a
bypass, flushing is allowed to pass through the exchangers if required to proceed
further;
Flushing should continue in each line or piece of equipment until the water is
reasonably clean (or as clear as the make-up water);
Unit P&ID.s should be used as a cleaning check off record to ensure that all lines
are flushed cleaned including lines to and from tankage.
After completion of the flushing operations, all water should be drained from the unit.
If necessary, break flanges at low points to facilitate drainage and airblow as required
removing as much water as possible.
3.3.3
Air Blowing
Cleaning of circuits will be carried out by air blowing for lines and pieces of equipment
which have to be kept free from water and for some big piping (for reasons as:
unacceptable weight, or too large quantity of water would be required, or water
flushing not efficient).
By experience, the air blowing method is usually also extended and applicable to
small size lines, as this leads to good results and dry conditions are obtained rapidly.
Air blowing will be carried out with compressed air. Air blowing of a circuit should be
performed by using temporary connection with compressed air network, in a
continuous manner for small lines or by using vessels (drum, column, etc.,) as
holdup/buffer capacity to get a quick air release. The vessel will be pressurized with
compressed air, then the air will be released through the circuit (of course first, check
that design pressure of the vessels is in accordance with compressed air maximum
operating pressure). This design pressure is reminded in the specific procedure to be
applied to each system.
In some huge systems, it is sometimes not possible to use valves to blow the relevant
lines. In this case, a bursting disc or quick opening valves can be used to proceed to a
sudden depressurization (ensure that no equipment may be damaged).
This will be the case for some lines in the process unit and interconnecting mainly.
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Piping system blowing will be considered completed when air at the exit point will
appear clear (the air has not to be orange dust colour).
3.3.4
Steam Blowing
Cleaning by steam blowing is carried out essentially for steam circuits. Due to
problems of expansion or draining of condensate, this type of cleaning is not used for
other circuits except for small parts and with the utmost care.
Steam blowing will be carried out as follows:
Before putting steam into the system, control valves, turbines meters, instruments,
vacuum ejector, and strainers should be removed or blinded off from the system. The
steam headers should be slowly warmed up, one header at a time, while expansion of
the line is observed. Special attention should be given to pipe support shoes.
Condensate must be drained manually to prevent steam hammering. The headers
should now be blown using a low pressure, high-velocity sweep as explained
hereafter.
When the headers are warm, the drain valves should be opened, blown vigorously for
a few moments before reclosing. Each lateral to heater, exchangers, or service lines
should be blown in the same manner, usually not more than one at a time.
Condensate lines may be cleaned in the same manner as steam lines, but close
observation of the pressure on the condensate line is necessary since the working
pressure and temperature of the condensate lines are generally lower than of the
steam headers. A temporary movable silencer could be used to avoid exceeding noise
level limitations during the steam blowing operation, if necessary. Nevertheless, this
minimizes the efficiency of the steam blowing and steam blowing without silencer is
preferable. (Coordination with people working in the vicinity is required).
When blowing of the steam system is completed, equipment that were removed prior
to the blowing can be reconnected. The system can then be preheated and placed in
service.
3.3.5
Chemical Cleaning
Some piping must be cleaned by chemicals when either the product can react with oil
left inside of the piping or in case it can lead to adverse effect to leave even very small
parts of debris inside the piping. Proper neutralizing and flushing of these systems
after the chemical cleaning are of utmost importance.
3.3.6
Lubrication Systems Flushing

Necessary instructions for cleaning of the lubricant and seal oil piping systems are
given in manufacturer's data books. They have to be strictly followed to proceed with
the cleaning of such piping systems.
3.4.1
Leak Test
General Procedure
After hydrostatic pressure testing and flushing, a tightness test must be conducted to
check all flanges and fittings for leaks, especially those opened during hydrostatic
tests and flushing.
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Unit should be isolated with blinds from every part containing hydrocarbons, nitrogen
or steam.
All the relief valves should be in place and their isolation block valves in the current
position. The flare header inside the unit is isolated from the flare header already
under hydrocarbon (if any) and is open to atmosphere (by means of a PSV
dismantled for instance) to prevent overpressure during the air leak test.
3.4.2
Tightness Test
Tightness test for the process units should be carried out with air (or nitrogen when
applicable and when air is prohibited) at the maximum allowable pressure which
doesn't exceed the design pressure of equipment (check design data). Soap solution
should be prepared for the tightness checking and all flanged connections checked
with soap. Bubbling indicates if tightening is required.
The pressure raise should be checked on manometers and recorded. The leaks
should be carefully located and tightened.
This pressure follow-up gives an indication on the tightness of the system.
Nevertheless, it does not prevent from leak test on each flange with soap.
Using soap solution check for any sign of soap bubbles being formed;
Pressure the system with air (or nitrogen) at the highest possible pressure
compatible with the IA/PA supply, without exceeding the normal operating pressure;
Check pressure over a length of time. If the test is not satisfactory, every flange and
connection must be inspected with soap solution. After correction of leaks, the test
will be repeated until satisfactory.
3.4.3
Leak Repairs / Tightening

In most cases, leaks can be eliminated by tightening the flanges in the correct manner
to ensure that compression on the flange gasket is uniform. If this is not sufficient the
equipment must be isolated, depressurized, and the gasket replaced.
In most cases, the leakage from a valve bonnet can be eliminated by correct
repacking.
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NORMAL START-UP
The operational sequence described below is not intended, nor should be used, to
train the operator or start up the plant. The following procedures can be used as a
guideline for developing final operating procedures during detailed engineering stage
of the project.
Start Up Preparation
This chapter describes the sequential operations to be performed in order to start-up
the Cooling Water Unit, assuming certain prerequisites be satisfied before actual unit
start-up can commence.
Prior to any unit start up, ensure that:
Feedstock import and Ammonia plant products export are set up
Procedures to achieve ready for start-up have been duly followed
Any issue raised in the pre-start up safety readiness review has been addressed
and cleared
Trained and experienced field and control room operation personnel is mobilised
Unit/Equipment is prepared and ready to start up as per Vendor requirements
Upstream and downstream interconnected units and other entities (fire brigade,
laboratories personnel, etc) have been duly informed and positively confirmed the
readiness to start operations.
Administration buildings, workshops, warehouses and other building and other
support facilities are ready for service
Assuming the following is available, unit start-up can begin:

1.
Power available for start up
2.
Full energization of the electrical network of the main SS and secondary SSs
3.
Energization of DCS and other systems such as ESD, F&G and other auxiliary
control and information system (e.g. MMS, machine PLC, etc.)
4.
Instrument Air Unit
5.
Telecommunication system
Start Up Sequence
4.2.1
Main operation:
In order to start-up the cooling water system several water treatment packages and
some upstream units should be put in service first.
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4.2.2
1.
Start-up the chlorine injection package, the sodium hypochlorite dosing

package, the corrosion inhibitor dosing package and the anti-scale/dispersant
package making sure they have all been filled with the correct product
2.
Before cooling water can be introduced in the cooling water basin, Raw Water
Unit 5121 should be started-up as it includes the filter. A filtered water should be
used as make-up water to account for evaporation and drift losses in the circuit
3.
Introduce the cooling water in the cooling tower basin until the correct level is
reached.
4.
Start the cooling water pumps progressively using the electric motor drivers
5.
Put the cooling tower fans in service
6.
Put all controllers in auto mode. Now the cooling water is circulating to the users
Operating description
Preliminary checks:
All units connected to the Cooling system are not yet in service (positively isolated
through valves + spectacles + chain locks at battery limit).
Blind flanges lists are checked.
All control loops are checked.
All emergency system are checked.
All the electrical motors are unlocked.
All the rotating equipment are stopped.
All instrumentation is available and prepared.
All chemicals packages are available and prepared.
All utilities are available at battery limit and in service inside the unit as follow:
LP NITROGEN
INSTRUMENT AIR
PLANT AIR
POTABLE WATER
DEMINERALIZED WATER
RAW WATER
LP FLARE
Extinguishers are in position
Steam horses are available
Monitor hoses are available

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Safety shower and rinsing facilities are available
Verify that all pre-commissioning and commissioning activities have been carried
out.
Verify that electrical power and utilities are available.
4.2.3
Verify that normal start-up work permit has been issued. All other work permits
should be closed.
Start-up of cooling water system.
Plug all the drains and vents of the unit.
Close butterfly block valve upstream Control Valve LV-0001, Open by-pass
butterfly valve on Filtered water.
Make up water level into the cooling tower basin BBC-5124001 with filtered water
from B-5121013A/B .
Close 5124-HV-002 to 5124-HV-0011, open 5124-HV-0012 and bypassing the
tower cell through the 24 line directly to the basin to avoid any rust or dirty to foul
the cooling tower.
Open XV-0001 to XV-0006 on pump B-5124001A/B/C/D and B-5124002A/B
discharge and all butterfly valves
on pump B-5124001A/B/C/D and B5124002A/B suction to fill, as much as possible, the pipes by gravity.
Start cooling water circulation pump B-5124001A (B/C/D) and circulate water back
to the basin. (When starting the pump the headers are not completely filled and
operator to pay attention to the pump electric load (amperage). Eventually, and
for short time, maintain the pump discharge valve partially closed to control
absorbed Ampere and possible hammering that can damage the installation. In
this last case stop the pump and investigate).
Establish cooling water circulation through the supply and return headers.
When the return water is clean, open 5124-HV-002 to 5124-HV-0011 and close
24 by-pass valve 5124-HV-0012 and establish circulation through the cooling
cells.
Make up level in cooling water basin as required.
When the circulation tower-Basin / pump / main header / back to tower is
stabilized:
- make up basin level to maximum
- as user start their internal cooling circulations the Ampere absorber by the
pump in operation will approach the nominal value as indicated in the pump
name plate.
- Start the other pump and make up level as required.
Open inlet butterfly valve on 5124-LV-0001 and close the relative by-pass
butterfly valve.
Commission in auto mode basin level control 5124-LIC-0001.
Commission cooling water fan as required.

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Start the following chemical dosing package:

For Dosage refer to Vendor Documentation
- UQ-5124001 Corrosion inhibitor & dispersant treatment package
- UQ-5124002 Corrosion inhibitor & anti scale treatment package
- UQ-5124003 Non oxidant biocide treatment package
- UQ-5124004 Sodium hypochlorite dosing package
- UQ-5124004 Sulphuric acid treatment package
Commission the following analysers :

- 5124-AT-0001, Amperometric
- 5124-AT-0002, Conductivity Analyzer and establish cooling water blowdown
flow.
- 5124-AT-0003, pH Analyzer
Commission 5124-FIC-0020 and after UT-5124001 SIDE - STREAM FILTER

according to vendor documentation.
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NORMAL OPERATION AND PROCESS VARIABLES

General
The following guidelines should be followed during normal unit operation:
The content of residual free chlorine in the cooling water return should be 0.3
ppm. Chlorine should be injected in water producing a solution which satisfies the
above requirement. Sodium Hypochlorite solution should be dosed at 1 ppm in
the circulating water, the solutions concentration being 20% minimum. A chlorine
analyzer and ph Analyzer are installed on the cooling water return header to
monitor water quality
The normal operating water level in the cooling tower basin should be kept 150
mm above low water level which in turn is 150mm above the top of the pumps.
This is automatically achieved by the level controller acting on the quantity of
required make-up water.
Feedstock
The Cooling Water Unit has been designed to provide all the users with treated
cooling water. Therefore the unit processes make-up water (filtered raw water from the
Raw Water Treatment - Unit 5121) and the products used in the injection packages
(chlorine, sodium hypochlorite, the corrosion inhibitor and the anti-scale/dispersant) to
produce circulated cooling water.
Products
The product of the unit is chemically conditioned cooling water.
Process Variables
The most important and critical variables for the Cooling water Unit are:
Cooling Water level inside the Cooling Tower Basin
Cooling Water pH
Cooling Water Conductivity
Cooling water residual chlorine
Water level inside the Cooling Tower Basin

The correct water level inside the basin is essential:
to maintain the cooling water circuit filled

to avoid to damage the cooling water pumps
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Cooling Water pH
The pH analyser is important to control the status of the cooling water regarding the
water corrosiveness.
Cooling Water Conductivity
This variable is essential to maintain the correct concentration of the cooling water.
This control open or close the water outlet to blow down.
Cooling Water Residual Chlorine
This parameter is essential to avoid biological growth.
Analytical procedures for sampling

N/A
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NORMAL SHUT DOWN

Shutdown Preparation
The operational sequence described below is not intended, nor should be used, to
train the operator or shutdown the plant. The following procedures can be used as a
guideline for developing final operating procedures during detailed engineering stage
of the project.
Inform all utilities and other process units that the Cooling Water Unit is starting to
shut down. Work carefully and safely, think before you act. Keep everyone informed
about what you are doing or going to do. Communication is vitally important during
shutdown. Do not attempt to do more than available manpower can safely handle.
Shutdown Sequence (cold shutdown)
6.2.1
Main operation:
1. Switch off the cooling tower fans
2. Switch off the Cooling Water Pumps
3. Shutdown all water treatment packages
4. Drain all the cooling water circuit by emptying the cooling water basin and the sidestream filters back-wash basin
6.2.2
Operating Description:
Most of the maintenance works will be carried out one cell at time without stopping the
cooling water system.
Flow rate are reduced as user unit shutdown. During this phase CW return
temperature and CW supply pressure are monitored to decide when stopping cooling
fans and one by one of the circulation pumps. If necessary the pump left running can
recycle the water back to the basin through the recycle line. When it is expected a
plant total or partial shutdown it would be better to prevent low flow by preventive
opening of said by-pass in reason of the number of pump in service and, anyhow,
giving high attention to the amperage of the motor to avoid pup cavitation.
A good indication of pump extra capacity is given by the amperemeter of the electrical
motor. When the ampere absorption fall below 70% (Vendor to confirm) of the value
indicated in the name plate of the motor, the pump can be stopped.
Another control element is the total flow indicated by 5124-FI-0015. The number of
pumps in operation will be in accordance with the indicated flow.
Pressure indications are not too much helpful in deciding when one pump can be
stopped being the pump curve almost flat.Shutdown Sequence:
Confirm process units shutdown is completed.Confirm all users in utility units are
down.
Continue cooling water circulation until no more thermal load is present, that is
same temperature in supply and return.
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Stop all cooling towers fan.
Close Cooling Water to Stream Filter.
Close cooling water blowdown
Stop all chemicals injections.
Stop circulation pumps and close discharge valves.
If necessary empty the cooling water basin and the side-stream filters back-wash
basin. If the basin does not drain completely by gravity use portable pumps
and/or ejectors.
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Emergency Shut Down

Emergency Shut Down System (ESD) will be designed to minimise the consequences
of emergency situations, related to typically uncontrolled flooding, escape of
hydrocarbons, or outbreak of fire in hydrocarbon carrying areas or areas which may
otherwise be hazardous.
No Emergency Shutdown System or the whole Cooling Water Unit is foreseen or
installed.
There are local shut down action limited to some equipment, i.e. cooling water
circulation pumps, that can lead to the total shut down of the complex if not
immediately restarted.
When water circulation is completely stopped the water entrapped in the users may
become very hot.
If the user cooling water system is segregated that portion of system is protected
against overpressure with specific disposal.
When the circulation of Cooling Water is restored the hot water will return to the
cooling tower where it is cooled. Normally in very short time (depending in the length
of time in which the entrapped water has been subject to elevate temperatures)
temperature return to normal value but in these occasion it is necessary to keep under
observation the level in the basin to avoid sudden low level for the heavy evaporation.
Power failure
In case of power failure the four available pumps B.5124001A/B/C/D are down, one
Emergency Diesel Generator will supply power to Emergency Cooling Water Pump
(B-5124002 A/B). Emergency Cooling Water Pump (B-5124002 A/B), one (1)
operating and one (1) spare which has the purpose to ensure the cooling of the
equipment that must run even in case of power failure:
These equipments are:
-
Inst./Plant Air Compressor (Unit 5136)
Ammonia Refrigeration Package (Unit 6351)
The logic 5124-I-012 on ESD start-up B-5124002A(/B) and open 5124-XV-0005 or

5124-XV-0006 (refer to cause and effect diagrams at the end of the chapter). This
pumps have an independent circuit pertaining to the same Cooling Tower (TR5124001) has its own supply/return header
Keep under control the tower basin level and reset instrumentation for next start-up of
pumps with setting arranged to have them started in manual mode one by one.
Cooling water fans are also stopped as well as all dosing pumps.
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Instrument Air Failure.

In case of instrument air failure to avoid basin overfilling or emptying care should be
taken on the action of:
5124-LV-0001 Basin make up valve, failure last.
5124-AV-0002 Basin blow down valve, close.
5124-FV-0020 Side stream filter valve, close.
With the following effects:
5124-LV-0001, keep the last position, if it is open the basin will overflow, check
and control of basin level with manual by-pass.
5124-AV-0002, Cooling water blowdown valve is closed, cooling water supply can
be maintained for several hours considered the large capacity of the system.,
keep under control the 5124-AI-0002 value.
5124-FV-0020, the side stream filters should be put in stand by conditions to
avoid entertainments of filtering element when IA is restored.
Presence of Hydrocarbons.
There should be no hydrocarbons in the system. Any hydrocarbons arriving with the
CW return flow are gasiform, and it will be eliminate by the top of the tower. For this
reason all fans are provided explosion prof.
Presence of Ammonia
There should be no ammonia in the system. In case of presence of ammonia detected
by 5334-AI-0010 (on unit 5334) the cooling tower blow down has to be closed and the
problem will be investigated and checked.
Excess of Chemical
If the chemical exceeds the normal concentration, and it is out of the range of
tolerance, close the chemical, open Blow down valve 5124-AV-0002, drain the cooling
water to blow down as far as the concentration of chemical is acceptable. Re-open
the chemical to cooling water system and investigate the causes.
Automatic interlock operations
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All
ESD
interlock
are
covered
in
the
following
table:
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PLANT SAFETY
Introduction to Hazardous Material
On the basis of Health Safety Environmental (HSE) Guidelines for Nitrogenous
Fertilizer Production dated APRIL 30, 2007 by IFC (International Finance Corporation
Word Bank Group), the following chemical hazards are applicable to typical
nitrogenous fertilizer production processes.
Chemical Hazards
Toxic chemicals in the nitrogenous fertilizer facilities include ammonia, nitric acid
vapour, gaseous formaldehyde and urea or AN (Ammonium Nitrate) dust. Threshold
value associated with specific health effects can be found in the internationally
published exposure guidelines
Ammonia only is applicable in this case.
8.1.1
Physical and Chemical Properties of Ammonia

PARAMETER
VALUE
Physical state (gas, liquid, solid):
Gas
Vapor pressure at 70F:
94 psia
Vapor density at 60oF (Air = 1 :
0.62
Evaporation point:
Not Available
Boiling point:
-33C
Freezing point:
-77.7C
pH :
Not Available
Specific gravity:
Not Available
Oil/water partition coefficient:
Not Available
Solubility (H20):
Very soluble
Odor threshold:
Not Available
Odor and appearance:
A colorless gas with a pungent odor
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Stability and Reactivity

STABILITY:
Unstable
CONDITIONS TO AVOID (STABILITY):
None
INCOMPATIBLE MATERIALS:
Reacts vigorously with fluorine, chlorine, HCl, HBr, nitrosyl chloride, chromyl chloride,
nitrogen dioxide, trioxygen difluoride, and nitrogen trichloride.
8.1.2
Hazards Identification
Acute risk:
Ammonia (NH3)
Apart of the flammable characteristic, NH3 can be classified as toxic by inhalation,
thus it exposes risk to personnel by acute exposure.
Concentration threshold categorisation for TOXIC is the follow:
NH3 concentration weight in vapour phase equal or greater than 5%
Above concentration refers to vapour streams. Nevertheless processes comprise

liquid stream; since the risks are related to acute exposure by inhalation the liquid
stream is dangerous when significant vapour (assumed as 5% weight) is generated
from released liquid, and when the vapour concentration exceeds the limit above.
Irritating or corrosive to exposed tissues. Inhalation of vapors may result in pulmonary
edema and chemical pneumonitis. Slightly flammable.
ROUTE OF ENTRY:
Skin Contact
Eye Contact
Inhalation
HEALTH EFFECTS:
Exposure Limits
Irritant
Mutagen
Synergistic Effects
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EYE EFFECTS:
Mild concentrations of product will cause conjunctivitis. Contact with higher
concentrations of product will cause swelling of the eyes and lesions with a possible
loss of vision.
SKIN EFFECTS:
Mild concentrations of product will cause dermatitis or conjunctivitis. Contact with
higher concentrations of product will cause caustic-like dermal burns and
inflammation. Toxic level exposure may cause skin lesions resulting in early necrosis
and scarring.
INGESTION EFFECTS:
Since product is a gas at room temperature, ingestion is unlikely.
INHALATION EFFECTS:
Corrosive and irritating to the upper respiratory system and all mucous type tissue.
Depending on the concentration inhaled, it may cause burning sensations, coughing,
wheezing, shortness of breath, headache, nausea, with eventual collapse.
Inhalation of excessive amounts affects the upper airway (larynx and bronchi) by
causing caustic-like burning resulting in edema and chemical pneumonitis. If it enters
the deep lung, pulmonary edema will result.
Pulmonary edema and chemical pneumonitis are potentially fatal conditions.
8.1.3
First Aid Measures

EYES:
Flush contaminated eye(s) with copious quantities of water. Part eyelids to assure
complete flushing. Continue for a minimum of 15 minutes. PERSONS WITH
POTENTIAL EXPOSURE TO AMMONIA SHOULD NOT WEAR CONTACT LENSES.
SKIN:
Remove contaminated clothing as rapidly as possible. Flush affected area with
copious quantities of water. In cases of frostbite or cryogenic "burns" flush area with
lukewarm water. DO NOT USE HOT WATER. A physician should see the patient
promptly if the cryogenic "burn" has resulted in blistering of the dermal surface or
deep tissue freezing.
INGESTION:
Not specified. Seek immediate medical attention.
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INHALATION
PROMPT MEDICAL ATTENTION IS MANDATORY IN ALL CASES OF
OVEREXPOSURE. RESCUE PERSONNEL SHOULD BE EQUIPPED WITH SELFCONTAINED BREATHING APPARATUS.
Conscious persons should be assisted to an uncontaminated area and inhale fresh
air. Quick removal from the contaminated area is most important. Unconscious
persons should be moved to an uncontaminated area, given mouth-to-mouth
resuscitation and supplemental oxygen. Keep victim warm and quiet. Assure that
mucus or vomited material does not obstruct the airway by positional drainage.
8.1.4
Fire Fighting Measures
FIRE AND EXPLOSION HAZARDS:

The minimum ignition energy for ammonia is very high. It is approximately 500 times
greater than the energy required for igniting hydrocarbons and 1000 to 10,000 times
greater than that required for hydrogen.
EXTINGUISHING MEDIA:
Water fog. Use media suitable for surrounding fire.
FIRE FIGHTING INSTRUCTIONS:
If possible, stop the flow of gas. Since ammonia is soluble in water, it is the best
extinguishing media--not only in extinguishing the fire, but also absorbing the escaped
ammonia gas. Use water spray to cool surrounding containers.
General safe working procedure

Operating and maintenance procedures will be useless if personnel are not
adequately trained in their correct implementation. Supervisory personnel in
charge of such training should be adequately experienced themselves,
preferably in Ammonia Plants of similar type and handling similar materials.
THE BEST SAFEGUARD OF PERSONNEL SAFETY IS TO PREVENT THE
OCCURRENCE OF HAZARDOUS SITUATIONS.
The standing instruction is that no gases, vapours, liquids or chemicals are present in
the atmosphere or on the ground in plant area. If a leak develops it should be stopped
or repaired at once.
8.2.1
Personal protective equipment

Protective equipment is not a substitute for safe working conditions: adequate
ventilation and intelligent conduct of the operators are fundamental for accident
prevention. When protective equipment is necessary, it must be properly used. The
equipment selected must be suitable for the purpose and the person using the
protective equipment must be familiar with it. All protective equipment for safety of
personnel must be kept in good working condition at all times. Frequent inspections
and immediate repairs are essential.
Respiratory protection
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All gases other than air are harmful to man when inhaled in sufficient concentrations.
Toxic gases may be classified as either asphyxiating or irritating.
Asphyxiating gases may cause death by replacing air in the lungs or by reacting with
the oxygen carried in the blood, for example: hydrogen sulphide, carbon monoxide,
smoke.
Irritating gases may cause injury or death not only by asphyxiation but also by both
internal and external burning, for example: chlorine, sulphur dioxide, hydrogen
fluoride.
To guard against inhalation of harmful gases, the operator should:
Secure a gas test certificate showing the gas conditions of the atmosphere
(vessel, etc.).
Avoid entering a confined space, which has not been purged and tested.
Avoid facing an opening where escaping gas will be blow at him.
Provide ventilation.
Wear the correct type of gas mask.
Three types of gas masks are in common use:
Oxygen cylinder and masks set: give 100% protection regardless of the presence
of the toxic gas. Their disadvantage are that they can be used for a limited time
only and require skill in proper use.
Canister type masks: are full-face masks equipped with a cartridge containing
chemicals to remove the toxic component from the air breathed through the
canister. Different cartridges are supplied for different groups of toxic gases. This
type can only be used at low concentrations of toxic gas, so that the
concentration of oxygen in the filtered air is not below 18% by volume. A
disadvantage of this type is the relatively limited capacity of the cartridge. When
the chemicals are exhausted, the toxic gas will not be trapped and therefore the
wearer must leave the contaminated area.
Air line masks: are full-face masks into which fresh air is blown through a long
hose from a manually operated blower placed outside the hazardous area.
The masks can be used in any concentration of toxic gases, can be used for a long
time and permit relatively easy breathing.
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Body protection
In order to limit the possibility of hazards, operators should be compelled to wear
suitable protective equipment, as follows:
8.2.2
Head protection: hard hats whenever working in the plant. These provide
protection from falling objects and against head injury in general.
Eye protection: while cleaning or purging a line with air, steam or inert gas, all
operators and supervisors must wear goggles or other safety equipment. Goggles
should be fitted to prevent splashes from entering the eye. Plastic shields with
facial protection should be used in addition to goggles when full face protection is
required.
Ear protection: in some parts of the plant (e.g. compressor room) personal
comfort or safety ear protection. This can take the form of ear plugs or ear muffs
provided individually or located in enclosed stations adjacent to high noise areas.
Personnel should be instructed to wear ear protection before they enter high
noise level areas.
Foot protection: sturdy footwear, preferably leather, with built-in steel toe cap.
When necessary, boots of chemical resistant material can be worn over safety
shoes.
Skin and hand protection: suits made of synthetic rubber or other approved
material when complete body protection is necessary. Gloves made of synthetic
rubber or other approved material should be worn to protect the hands. In case of
severe leaks only properly protected personnel should remain in the area.
Fire prevention, protection and Fire Fighting

Prevention
The best protection against fires is to prevent the conditions that may lead to fire. The
3 components of any fire are: combustible material, air (oxygen), and source of
ignition.
Combustible gases and liquids normally must not be present in the atmosphere or on
the ground in process areas.
All leaks must be immediately stopped. When not possible, all available means to
prevent spreading must be applied.
Sources of ignition must be kept away from process areas.
Where possible, air (oxygen) can be excluded by purging or blanketing with steam or
nitrogen.
A FIRE IS ALWAYS A HAZARD TO PERSONNEL AND ALWAYS LEADS TO DAMAGE
OF EQUIPMENT. PREVENTION IS A MAJOR OBLIGATION OF PLANT
PERSONNEL.
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Common sources of ignition are:
open flames;
hot work (welding, cutting, etc.);
defective electrical equipment;
automotive vehicles;
overheated metal surfaces;
static electricity.
Smoking as well as carrying matches and lighters is prohibited.

Hot works such as welding, cutting, grinding, chipping, etc. may be carried out inside
process areas only after written permit with specify procedures and precautions to be
taken. Portable lights and lamps of approved explosion proof design must be used.
Gasoline and diesel engines are allowed to operate in process areas only after written
permit has been obtained from the undesired combustibles in process areas.
Frequent inspections must be made to detect leaks and prevent spillage. Spills must
be immediately flushed with water or covered with absorbent materials for subsequent
removal.
Protection
The main aim of active fire protection is to minimize risk to personnel, installation and
environment from fire and explosion hazards.
The objectives are:
To extinguish fires,
To prevent escalation of an incident by cooling equipment which contain

combustible /flammable material ,
To limit the effects of heat radiation,
To confine or dissipate a cloud of combustible.
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Fire protection shall be provided by a partial or total combination/selection of the

following systems and equipment:
Firewater
Deluge systems
Hydrants
Hose boxes
Fixed monitors (oscillating, manual and remote controlled)
Water extinguishers
Fire trucks (first intervention and foam trucks)
Foam
First intervention vehicle

Foam fire trucks foam monitors
Storage tanks fixed generators
Carbon
Portable or wheeled extinguishers
Dioxide
Dry chemical
Portable or wheeled extinguishers
Clean Agent
Fixed total flooding system (technical room and area below

false floor of control building)
Each type of extinguishing shall be selected according to the hazards present.

The fire protection system design shall be based on the principle that there will be
only one major fire at a given time.
Fire fighting
In many cases operators can prevent large plant fires by extinguishing small flameups in their incipient stage. For this purpose fire fighting equipment is located
strategically inside process areas.
Fire fighting equipment consists of:
STATIONARY FACILITIES including fire hydrants connected to the fire water

network and snuffing steam connections;
MOBILE FACILITIES including fire truck and extinguishers.
Common fire extinguishing agents are:
WATER to extinguish paper and wood fires; to cool equipment, tanks, etc.; to
protect personnel against radiant heat; to extinguish small hydrocarbon fire;
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STEAM to extinguish hydrocarbon fires in trenches and confined spaces; to

extinguish small flame, (on leaking flanges, for example); to prevent flashing of
hot vapors and gases;
FOAM to extinguish oil fires large and small;
CARBON DIOXIDE to extinguish small fires of oil and other combustibles or dry
powder to extinguish fires in confined spaces.
To extinguish a fire in electrical equipment (switches, transformers, motors, etc.) only

carbon dioxide and dry powder extinguishers must be used. Never use water, steam
or foam on electrical fires.
Large oil fires are extinguished by plant fire fighting crews using water and foam.
In case of fire it is often necessary to protect personnel. An adequate supply of
protective equipment must be available in the process area. Water mist serves the
same purpose when properly applied. Fire blankets are used to extinguish flaming
clothing.
Safety hats and gloves are usually necessary.
All operators must be thoroughly familiar with the location of portable fire
extinguishers, steam hoses, hydrants and water hoses, and protective equipment.
Operators must know when and how to apply portable extinguishers. They must also
know handling of water hose, foam generators, water mist nozzles, etc. When a fire
occurs, operators must extinguish it immediately using the extinguishers, steam or
water and actuate fire alarm.
In case of large fire caused by mechanical failure, operators must:
Isolate fire and shut down unit.
Fight the fire.
The general procedure is as follows:
Stop flow of gas and liquid to equipment on fire, and depressurize to blow down
system, but keep a slight positive pressure inside the equipment. Where possible
inject snuffing steam.
If flame is extinguished but elate continues, gas may spread as an explosive
cloud which may re-ignite; follow as closely as possible unit emergency shutdown procedure.
Cool any endangered adjacent structure or equipment by water jet or mist.
Fight with appropriate extinguishing agent, bearing in mind that oil floating on
water can easily spread the fire. Use foam in such cases.
A way to extinguish a fire produced by a leak is to eject steam or nitrogen into the
fire through a temporary connection from the nearest possible location, after
cutting off the fire causing fluid.
Persons not actually participating in the operations of the unit or in the fire fighting
are not allowed to be present in the area.
Project N
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Document Code
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5124
ML 901
Serial N
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I-MA-9525.05-5124-000-TPI-001
PETROBRAS
UBERABA (BRAZIL)
Fire protection equipment

Hydrants
The hydrants shall be connected with fire main and located at no more than 50 meters
each others in all areas of the plant.
The hydrants shall be installed at 15 meters minimum and 70 meters maximum from
the risk area to be protected.
Hydrants shall be positioned at a minimum distance of edge of road shoulder of 1,5
meters and not more than 12 meters from any road crossing center. Guard post for
hydrant's protections shall be provided where necessary in accordance with Civil
Standard Drawings.
The hydrant body dimension shall be 6" (150 mm) diameter. Each hydrant shall be
provided with two 2 1/2" diameter connections for hose service, one 4" diameter
connection for fire truck service (pumper connection) and one 4" diameter flange for
monitor connection, where necessary.
Hose Boxes
Hose boxes shall be installed near each hydrant. Each hose box consists of red steel
cabinet containing four hoses having 2 1/2" diameter and 15 meters length and one
adjustable straight/fog nozzle.
Water Monitors (mounted on hydrant)

Fixed type, mounted on hydrant, monitors shall be installed for protection of high
columns and elevated process structures. Monitor water capacity shall be 120 m 3/h at
a minimum supply pressure of 7 barg, the rotation angle shall be 360 and elevation
angle shall be 80. The horizontal operating range with straight jet will be as minimum
45 meters.
The monitors shall be manually operated and suitable for the generation of adjustable
straight/fog jet stream. Straight to fog change will be done manually.
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Document Code
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5124
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I-MA-9525.05-5124-000-TPI-001
PETROBRAS
UBERABA (BRAZIL)
Water Spray Fixed System

Water spray fixed systems shall be provided for fire protection of the following
compressors and relevant lube oil consoles:
Ammonia Refrigeration Compressors;
The specific water flow rate shall be in accordance with NFPA 15 and equal to 10
lit/min/m2.
Each system shall be activated automatically by means of deluge valve; manual
activation shall be also foreseen.
FIRE AND GAS DETECTION & ALARM SIGNALLING PHILOSOPHY

An automatic detection and alarm system for hazardous material leaks shall be
studied according to the following principles and objectives:
detection of large quantity of combustible gas/vapour resulting in probable fire
detection of an occurred fire
detection of toxic vapours in all zones where they may appear and accumulate
warning all people present on the site concerned
automatic warning at control room, fire station, plant gate and or other location
deemed to emergency response action.
A manual alarm system (e.g. telephones, sound-powered telephones, pushbuttons

clearly marked and identified) shall be installed in order to enable the personnel to
give the alarm from any point whatsoever on the site.
8.3.1
Fire Detection and Alarm

This paragraph covers location of equipment and device to be installed for fire
detection and alarm purpose. Fire detection signals shall be started automatically by
detectors/devices or by operators by means of manual call points.
Field installed equipment shall be in accordance with the hazardous area
classification requirements.
The fire detection system in process area consists of the following:
Heat Detection (HD)
Heat detection system is made by means of a combination rate-of-rise and fixed
temperature type detectors.
The detectors are installed in the compressors areas for automatically actuation of
water spray fixed systems.
Activation of any one detector shall initiate an alarm relevant to the subject area, and
shall send signal to the Central Master Fire and Gas Alarm Panel (CMFGAP) located
on Control Room for relevant water spray fixed system actuation .
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Document Code
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5124
ML 901
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I-MA-9525.05-5124-000-TPI-001
PETROBRAS
UBERABA (BRAZIL)
Fixed Temperature Heat Detection (FD)

The fixed temperature heat detection system is installed in the following areas:
Administration building
Alarm only
Maintenance Shop
Alarm only
Laboratory
Alarm only
on Control Room .
Manual Call Point (MCP)
Manual call points are provided throughout the plant areas, connected in a various
loops, relevant to the various units.
The manual call points are installed so that the maximum travelling distance is no
more than 60 meters from any point as per NFPA standard.
Activation of any one manual call point shall send signal to the Central Master Fire
and Gas Alarm Panel (CMFGAP) located on Control Room for alarm only.
Manual call points are, also, installed inside the following buildings:
Warehouse
Maintenance shop
Administration
Laboratory.
Smoke detection (SD)

The smoke detection system is made by means of optical type or ionization type
smoke detectors.
They are provided for fire alarm purpose and for activation of the CO2 or Clean agent
(FM - 200) fire suppression systems , where those systems are installed .
Detectors for alarm purpose only are connected in common loops depending on the
area to be monitored, single zone voting.
on Control Room.
Detectors for alarm purpose and automatic activation are connected in two
independent lines in the same area , cross zone voting .
Activation of one detector only shall initiate an alarm only , while activation of both
lines ( one detector per line at least ) shall initiate an alarm and automatically activate
the relevant Clean agent fire suppression systems by means of the Central Master
Fire and Gas Alarm Panel (CMFGAP ) located on Control Room .
Project N
Unit
Document Code
2417
5124
ML 901
Serial N
Rev.
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I-MA-9525.05-5124-000-TPI-001
PETROBRAS
UBERABA (BRAZIL)
The smoke detection system is installed in the following areas:
Electric Substations
Alarm only
Technical rooms of Control building
Alarm and clean agent discharge
Laboratory
Alarm only
Warehouse
Alarm only
Maintenance shop
Alarm only
Administration building
Alarm only
Area below false floor of technical rooms of Control building - Alarm and Clean agent
discharge
Gas Detection and Alarm
This paragraph covers location of equipment and devices to be installed for
combustible and toxic gas detection and alarm purpose.
Combustible gas detection
Combustible gas detectors, catalytic combustion type, are installed around

compressors and at critical points where there is danger of large leakage of
combustible gas within the process units.
In addition gas detectors are installed in the suction duct of control room and electric
substations air conditioning.
The signals coming from gas detectors shall be send to the Central Master Fire and
Gas Alarm Panel (CMFGAP ) located on Control Room for alarm , the signals coming
from the detectors installed in the suction ducts of air conditioning are able to stop the
air suction .
Toxic gas detection
Toxic (NH3) gas detectors, electrochemical cell type , are located strategically over the
process units.
In addition toxic gas detectors are installed in the suction duct of control room air
conditioning.
The signals coming from toxic gas detectors shall be send to the Central Master Fire
and Gas Alarm Panel (CMFGAP ) located on Control Room for alarm and for
activation of relevant optical / acoustical alarm located in field, the signals coming
from the detectors installed in the suction ducts of air conditioning are able to stop the
air suction.
Project N
Unit
Document Code
2417
5124
ML 901
Serial N
Rev.
Page
52/56
I-MA-9525.05-5124-000-TPI-001
PETROBRAS
UBERABA (BRAZIL)
Fire and Gas Monitoring System

This system consists essentially of the Central Master Fire and Gas Alarm Panel
(CMFGAP) located on Control Room and an alarm repeater display located in the
main gate house.
The Central Master Fire and Gas Alarm Panel (CMFGAP) is suitable for the following
tasks:
a) To receive signals coming from:
Heat detection system (HD detectors and FD detectors )
Smoke detection system.
Manual call points.
Fire and Gas system and relevant fire suppression system of turbogas
Gas detection system .
b) To actuate audible and visible alarm in control room and in main gate house for
each received signal.
c) To actuate automatically:
The CO2 discharge systems and relevant optical / acoustical alarm of
electric substation (after reception of the relevant smoke detectors alarm)
The Clean agent discharge system and relevant optical / acoustical alarm of
area below false floor of control building (after reception of the relevant
smoke detectors alarm).
Optical / acoustical alarm in field (after reception of the relevant toxic gas
alarm)
The water spray fixed systems (after reception of the relevant heat
detectors alarm).
d) To actuate , by push button :
Water spray fixed systems for compressors area
Siren for general alarm
e) To shut-down the air conditioning system before the total flooding fire
suppression gas discharge for control building and electric substations.
f)
To close the fresh air suction of air conditioning system ( after reception of the
relevant gas detectors alarm ) for control building and electric substations.
g) To send grouped signals to the mimic type annunciator panels located one in
the fire station, one in the main guard house.
h) To send single alarms and common alarms (summarized per process area) to
the DCS.
Project N
Unit
Document Code
2417
5124
ML 901
Serial N
Rev.
Page
53/56
I-MA-9525.05-5124-000-TPI-001
PETROBRAS
UBERABA (BRAZIL)
For Fire and gas location refer to Fire and Gas Layout: 2417-3200-DW-1950-01.
Project N
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Document Code
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5124
ML 901
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I-MA-9525.05-5124-000-TPI-001
PETROBRAS
UBERABA (BRAZIL)
REFERENCE DOCUMENTATION
PFD
2417-3200-PFD-0010-02
I-DE-9525.05-3200-943-TPI-002
Water block diagram
2417-5124-PFD-0010-01
I-DE-9525.05-5124-943-TPI-001
Cooling water system
2417-5124-PID-0031-01-
I-DE-9525.05-5124-944-TPI-001
Cooling Tower
2417-5124-PID-0031-02-01
I-DE-9525.05-5124-944-TPI-002
Cooling Tower
2417-5124-PID-0031-03-01
I-DE-9525.05-5124-944-TPI-003
Cooling Pump
2417-5124-PID-0031-04-01
I-DE-9525.05-5124-944-TPI-004
Cooling Tower
2417-5124-PID-0031-05-01
I-DE-9525.05-5124-944-TPI-005
Emergency Cooling Water Pump
2417-5124-PID-0031-06-01
I-DE-9525.05-5124-944-TPI-006
CW Chemical treatment
2417-5124-PID-0031-07-01
I-DE-9525.05-5124-944-TPI-007
2417-5124-PID-0031-08-01
I-DE-9525.05-5124-944-TPI-008
2417-5124-PID-0031-09-01
I-DE-9525.05-5124-944-TPI-009
Side treatment Filter
2417-5124-PID-0031-51-01
I-DE-9525.05-5124-940-TPI-001
2417-5124-PID-0031-52-01
I-DE-9525.05-5124-940-TPI-002
2417-5124-PID-0031-53-01
I-DE-9525.05-5124-940-TPI-003
I-MD-9525.05-5124-941-TPI-001
Basis of Design
PID
Basis of Design
2417-5124-JSD-0001.01
Project N
Unit
Document Code
2417
5124
ML 901
Serial N
Rev.
Page
55/56
I-MA-9525.05-5124-000-TPI-001
PETROBRAS
UBERABA (BRAZIL)
Data Sheets
2417-5124-SP-0271.01
I-FD-9525.05-5124-563-TPI-001
Data sheet for Basins
2417-5124-SP-0212-01
I-ET-9525.05-5124-561-TPI-001
DUTY SPECIFICATION FOR

SIDE STREAM FILTER UT5124001
2417-5124-SP-0310-01
I-FD-9525.05-5124-440-TPI-001
2417-5124-SP-0910-01
I-FD-9525.05-5124-311-TPI-001
2417-5124-SP-0910-02
I-FD-9525.05-5124-311-TPI-002
2417-5124-SP-4046-01
I-FD-9525.05-5124-642-TPI-001
2417-5124-SP-4046-02
2417-5124-SP-4046-03
2417-5124-SP-4046-04
2417-5124-SP-4046-05
I-FD-9525.05-5124-642-TPI-002
DATA
SHEET
FOR
MECHANICAL
DRAFT
WET
COOLING TOWERS - COOLING
TOWER - TR-5124001
DATA
SHEET
FOR
CENTRIFUGAL
PUMP
COOLING WATER PUMP - B5124001AD
DATA
SHEET
FOR
CENTRIFUGAL
PUMP
EMERGENCY
COOLING
WATER PUMP - B-5124002A/B
DATA SHEET FOR CHEMICAL
DOSING
SYSTEMS
CORROSION
INHIBITOR
&
DISPERSANT
TREATMENT
PACKAGE - UQ-5124001
DOSING
SYSTEMS
CORROSION
INHIBITOR
&
ANTI-SCALE
TREATMENT
I-FD-9525.05-5124-642-TPI-003

DOSING SYSTEMS - NONOXIDANT BIOCIDE TREATMENT
I-FD-9525.05-5124-642-TPI-004

DOSING SYSTEMS - SODIUM
HYPOCHLORITE TREATMENT
I-FD-9525.05-5124-642-TPI-005

DOSING
SYSTEMS
SULPHURIC ACID TREATMENT
Project N
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Document Code
2417
5124
ML 901
Serial N
Rev.
Page
56/56
I-MA-9525.05-5124-000-TPI-001
PETROBRAS
UBERABA (BRAZIL)
Cause and effect Diagrams

2417-5000-NM-0010-01
Cause and effect diagrams
I-MD-9525.05-5000-800-TPI-002
Interlock Narrative
I-DE-9525.05-3200-947-TPI-002
Fire and gas layout
Interlock Narrative
2417-5000-SP--0000-04
I-DE-9525.05-5000-947-TPI-001
Fire and gas Layout

2417-3200-DW-1950-01

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MANUAL

OPERATING INSTRUCTION MANUAL

DESCRIPTION AND/OR REVISED SHEETS

HTAS Doc. No.

PETROBRAS DOC. NUMBER:

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

PETROBRAS DOC. NUMBER:

OPERATING INSTRUCTION MANUAL

ISSUE FOR BASIC DESIGN

ISSUE FOR REVIEW

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

PETROBRAS DOC. NUMBER:

List of Process Equipment....................................................................................5

PREPARATION FOR INITIAL START-UP...........................................................14

NORMAL OPERATION AND PROCESS VARIABLES.......................................31

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

PETROBRAS DOC. NUMBER:

NORMAL SHUT DOWN......................................................................................33

EMERGENCY SHUT DOWN..............................................................................35

Introduction to Hazardous Material.....................................................................38

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

PETROBRAS DOC. NUMBER:

List of Process Equipment.

Emergency Cooling Water Pump

Cooling Tower Basin

Corrosion Inhibitor and Dispersant Treatment Package

Corrosion Inhibitor and Anti-scale Treatment Package

Non-Oxidant Biocide Treatment Package

Sodium Hypochlorite Dosing Package

Sulphuric Acid Treatment Package

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

PETROBRAS DOC. NUMBER:

Cooling Water System

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

PETROBRAS DOC. NUMBER:

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

PETROBRAS DOC. NUMBER:

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

PETROBRAS DOC. NUMBER:

Corrosion Inhibitor and Anti-scale Treatment Package (UQ-5124002);

Corrosion Inhibitor and Dispersant Treatment Package (UQ-5124001);

Non-Oxidant Biocide Treatment Package (UQ-5124003), provided in shotdosage;

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

PETROBRAS DOC. NUMBER:

Cooling Water System

(as CaCO3) [mg/L]

(as CaCO3) [mg/L]

Sodium (Balance) (as CaCO3) [mg/L]

(as CaCO3) [mg/L]

(as CaCO3) [mg/L]

(as CaCO3) [mg/L]

PETROBRAS DOC. NUMBER:

Boiler Blow Down

Condensate from CO2 Compressor

Condensate from Air Compressor

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

PETROBRAS DOC. NUMBER:

Cooling Water Supply

Pressure [kgf/cm 2] (1)

Chloride [ppm wt]

115140 max (2)

Pressure at B.L. users.

Control and Interlock Description