Ammonia SOP

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Standard Operating Procedure KTSB/SOP/T-RASL Refrigeration Ammonia Ship Loading

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APPROVAL AND REVISION HISTORY
TITLE OF DOCUMENT
TERMINAL: REFRIGERATION AMMONIA SHIP LOADING
DOCUMENT NO. KTSB/SOP/T-RASL COPY NO.

REVISION
REVISION NO. Issue 3, Rev 2 8 June 2008
DATE
NAME DESIGNATION SIGNATURE DATE
Ahmad Kamal Holidy Terminal

Abd Khohar Specialist
WRITTEN BY
Tengku Shaiful Zahrin Terminal
Tg Shahar Shah Specialist
Ops
Ahmad Idris
REVIEWED BY Superintendent
Abd Majid
(Terminal)
Operations
APPROVED BY Choo Kwok Chiang
Manager
REVISION HISTORY
Revision
Page No. Description of Amendments Effective Date
No.
All O First Issue 15 Sept 2005
All O Revised whole procedure 10 May 2006
All 1 Revise as per current practice 24 Jan 2008
19-23 & To include inspection of KANON Loading Arm before

2 8 June 2008
31-34 connection
TABLE OF CONTENT
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Revision No: 1 Effective Date: 24 Jan 2008 Page 1 of 51

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SECTION TITLE PAGE
APPROVAL AND REVISION HISTORY 1
TABLE OF CONTENT 2
DISTRIBUTION LIST 3
1. PURPOSE 4
2. SCOPE 4
3. DEFINITIONS AND ABBREVIATIONS 4
4. REFERENCE 4
5. RESPONSIBILITY 4
6. PROCEDURE 5
6.1 Safety Procedure 5
6.2 Emergency Procedure 5
6.3 Operating Procedure 6
6.3.1 Tank preparation 6
6.3.2. Pre-Shipment 9
6.3.3. Ship Loading 13
6.3.4 Completion of Loading 34
6.3.5 Cold Holding After Completion Loading Arm
Disconnection 35
7. LIST OF QUALITY RECORDS 37
8. ATTACHMENT 37
DISTRIBUTION LIST
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Copy No. Holder Status
Master Document Control Room Master Document
1 Operations Manager Controlled
2 Ops Superintendent (Terminal) Controlled
3 Terminal Control Room Controlled
4 Ammonia Control Room Controlled
5 Operations Excellence Department Controlled
6 Jetty – B2 & B3 Controlled
7 Jetty – B4 Controlled
Note:
Controlled soft copy is available at Network Neighborhood/ Entire Network/ KTSBow/
KTSBFileServer/ F_iso9001.
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2.1 PURPOSE
This procedure describes all activities related to marine line preparations/ loading ammonia
to vessels in a safe and environmental friendly manner.
3.1 SCOPE
This procedure defines all operating instructions, responsibilities and safety measures to
load refrigerated ammonia into vessels.
4.1 DEFINITIONS AND ABBREVIATIONS

ATG - Automatic Tank Gauging
SCBA - Self Contained Breathing Apparatus
HV - Hand Valve
KPSB - Kertih Port Sdn Bhd
LCV - Level Control Valve
LIC - Level Indicator Controller
MCP - Manual Call Point.
PASB - Petronas Ammonia Sdn. Bhd
PDIC - Pressure Differential Indicator Control
PERC - Powered Emergency Release Coupler
PPE Personal Protective Equipment
PG - Pressure Gauge
TCR - Terminal Control Room
TI - Temperature Indicator
5.1 REFERENCE
4.1 Krupp Uhde ship loading procedure section 2.0 & 7.0
4.2 FMC Operating Procedure section 2.0
6.1 RESPONSIBILITY
5.1 The Terminal Superintendent (TS) is responsible for all operations.
5.2 Operation Shift Supervisor and ammonia competent operators are responsible for
jetty and tank farm operations.
7.1 PROCEDURE
7.1 6.1 Safety Procedure
6.1.1 The PPE requirements are as per the KTSB PPE matrix. The use of Safety
helmet, SCBA, Safety Boots, Chemical Splash Suit and Chemical Gloves are
required at all times within the barricaded area.
6.1.2 PPE is required when performing activities such as connection/ disconnection
of the loading arm, draining process or other activities, which has risk of
leakage or dispersal of ammonia (liquid/ vapor).
6.1.3 Two set of SCBA have to be prepared at the ammonia tankage facility.
6.1.4 Ensure that the PPE used are in satisfactory condition. Any damage, PPE
shall not be worn since it will detriment the safety of users.
6.1.5 Both gate at the tankage facility south and north side have to open for easy
mobilization in case of emergency.
6.1.6 During pumping barricade pumps pad area, no personnel are allowed without
PPE within three-meter radius.
6.1.7 During the preparation of the disconnection of loading arm, no personnel are
allowed within three meters radius.
6.1.8 Ensure that there is ready access to safety showers.
6.1.9 Trouble shooting of loading arm is not allowed without permit to work
approval. The competence maintenance personnel should inform the Chief
Officer and loading master before carry out the troubleshooting.
6.1.10 The ship loading should be stopped for any troubleshooting.
6.1.11 Stop loading operation in the event of loss of hydraulic power.
(Less than 3 hours stop loading operation only)
(More than 3 hours stop loading – drain and disconnect arm)
7.2 Emergency Procedure

6.2.1 Ensure that:
a) Fixed fire monitors are ready to use.
6.2.2. In the event of emergency such as vapor release:

a) Avoid breathing vapor and any contact with liquid or gas.
b) All unprotected personnel must clear the area, move upwind and consider
evacuation.
c) Inform Terminal Control Room/ KPSB Radio Room and vessel at jetties
the location and the nature of accident.
d) Activate of arm ESD-1/ 2 and MCP.
Note: Refer to KTSB/ICS/ERP- Part 3 for details
7.3 Operating Procedure

Operating procedure for the ammonia ship loading consist of three main phases:
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 Tank preparation
 Pre-Shipment
 Ship Loading
6.3.1 Tank preparation

Procedure: For changing Philosophy of Ammonia Tanks Pressure T-
401/2.
Purpose
To know how to changing philosophy of Ammonia Tanks Pressure from
Existing Philosophy of Maintain of both tank at the same pressure to
Maintaining both tanks in difference pressure.
Purpose of Changing Philosophy

To reducing dedicated export tank pressure to 20/23 mbarg to match with –
330C and rundown tank as resultant pressure not more then 95(100 mbarg
will be stop pumps) mbarg.
Scope
To guide Ammonia Operator know how to carry out changing tanks T-401/2
from both tanks at the same pressure to both tanks in difference pressure.
Procedure:
1. Reduce opening vapour valve at Rundown tank gradually until dedicated
tank pressure down to 20/23 mbarg and Rundown tank will increase to
resultant pressure below 100 mbarg. (95mbarg). Line: AG-4-101-250-
11171-90K.
 Close valve at 2/5 turn at a time and wait for 15 minutes.
 Watch carefully both tanks pressure. Can see from PI at the Vapour
Line at the each of top tank.
 Repeat action point I until both tanks in difference pressure and at the
end dedicated export tank reached 20/23 mbarg
 And rundown tank with vapour valve in fully open will resultant
pressure at below 100 mbarg (95 mbarg)
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2. Close Cooling down valve for dedicated export tank, line; AG-4-011-100-
11171-80K
 To protect pressure from rundown tank pressure still migrate into
dedicated tank.
 To send vapour from cooling down line to rundown tank and not
entering dedicated tank.
 For that reason 4-inch valve cooling down line to dedicated tank have
to close.
 4-inch valve at cooling down line to rundown tank have to open.
3. Trims valves vapour return to the tanks ZV-4015 and ZV-4025. By

trimming this valves pressure from the higher pressure tank can migrate
into the lower pressure tank. In this case not to worry if one tank is too
high or the other tank is too low because this ZV easy to reach by
operator. Vapour Return from jetty can be split into both of tanks.
 Normally ZV-4015 / 25 will be fully open into lower tank’s level.
 Trims by close 1 turn from the fully open valve and then open 1 turn
for the other. And watch carefully tank’s pressure.
 Repeat this action until dedicated export tank maintain at 20/23 mbarg
and rundown tank as resultant pressure.
Procedure:
Trouble shoot on system upset due to currently we change Ammonia
tanks mode of operation philosophy from existing both tanks at same
pressure to both of tanks in difference pressure.
Action in the following situation:

1. Lost of K-401’s Boil Off Gas Compressor.
No action Required in the tanks, pressure will be equalized, action plan
same as existing procedure our have when compressor stopped.
2. Tanks pressure Increase due to rundown temperature increase:

Trims ZV-4015 and ZV-4025 valves vapour to the tanks. So Rundown
tank pressure not over then 100 mbarg and then dedicated export tank as
resultant pressure.
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3. Tanks pressure Increase due to vapour return line from jetty.
 Reduce vapour from jetty reduce opening of HV-4003 or if HV-4003 is
close.
 Increase set point PIC-4019.
 Trims ZV-4015 and ZV-4025 valves vapour to the tanks. So Rundown
tank pressure not over then 95 mbarg and then dedicated export tank
as resultant pressure.
4. Dedicated export tank low pressure.

Tank set point low pressure is 15 mbarg and it is not possible to exceed
due to this change of philosophy, because compressor will be tripped at
suction compressor pressure PIC-4001 reached 21 barg
5. Mode of operation ammonia shipment with out vapour return.

 While increasing flow rate to a max flow rate at 1000
ton please look after export tanks pressure not to low pressure at 15
mbarg it will be stopped pumps and compressors. By reduce
compressor load capacity to minimum and then trims ZV-4015 and
ZV-4025 until you get pressure 25 mbarg at export tank.
 Once flow rate is stabilized and all pumps is running
then separate vapour from export tank. Control pressure at export
tank at 25 mbarg by trims ZV-4015 or ZV-4025 (open a little bit to
stabilized pressure at 25 mbarg). Keep running BOG compressor to
reducing rundown tank pressure.
6. Mode of operation ammonia shipment with vapour return.

After flow rate is stabilized as a mention at no.5 point I, II and above. Then
prepare for vapour return line:
 Make sure vapour return line free of liquid.
 Keep close HV-4003.
 Take another one hour from normal flow rate to
stabilized vapour return line pressure.
 Use rundown tank to receive vapour from ship’s vessel.
Because both compressor running to reducing rundown tank pressure.
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 Operate PIC-4019 in manual close while ship’s vessel
start open valve vapour to vapour return line. And watch carefully what
pressure in the line.
 Start receive vapour from ship’s vessel open by
manually PIC-4019 and watch carefully tank pressure increment (for
guidance: Open PIC 5% at a time and watch tank pressure trending)
 Operate tank pressure at maximum 95 mbarg and then
close PIC-4019 to lets compressor work, re-open PIC-4019 once
pressure is reduced.
 Inform Loading Master shore tank’s pressure is a
control point and not ship’s vessel. KTSB will help ship’s vessel to
reduce vessel’s pressure but not all. Make sure vessel’s compressor
all they have is running.
Reminder!
Since ship’s vessel will using Blower to push vapour from vessel to
shore’s tank please continue monitoring tank pressure trending and
use PIC-4019 as controller and keep close HV-4003.
7.3.1 Pre-Shipment
Prior to Ship Loading the liquid ammonia export line from terminal to Jetty B5
and B6 is to be reduced in temperature to minimum -27 0C and lower is better.
To achieve -27oC, the cooling down process is carried out in 4 defined steps:
a) Line Packing for Cold Holding.
b) Cold Holding - maintain shipping line temperature at
between –22ºC to -25C.
c) Pre-Cooling - reducing shipping line temperature to -27oC
d) Pack line after loading arm connected and leak test is completed.
Pre-Cooling will take approximately 3 days or 72 hours if cold holding time

duration is more than 2 weeks but if time duration is less than 2 weeks, do
pre-cooling for 5 days. Line packing is carried out after loading arm
connected and leak test is completed. (Where possible to use liquid Ammonia
rundown from PASB plant for Cold Holding activity).
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The temperature indicator TI-4017 at pump P401 is not to be used as an
indication of the Liquid Ammonia line temperature. Refer to Ammonia Table
12.2.1 temperature/ pressure profile for true line temperature. Remember: 1.5
BarA = 0.5 barg so PI-4017 at 0.5 barg = -25C. TI’s at Jetty B-5/B-6 can be
use for temperature monitoring during cooling process. For successful cool
down of export ammonia line it is essential that all 12-vent stations is in good
condition and working correctly. Icing at a vent station indicates a passing
control valve and must be repaired as soon as possible. Failure to do so will
not allow the line to be cooled down to -30C.
For line packing and cooling process, 2 compressors must be in operation.

From CMS, take Ammonia Tank ‘Snapshot’, including BOG flow meter
reading, before and after Line Packing.
6.3.2.1. Line Packing before Cold Holding
This step is to be carried out at least 1 week before ships scheduled

arrival if the line is empty, and if using liquid ammonia from the storage
tank, but if using rundown ammonia (from PASB) or liquid ammonia
from BOG compressor it will requires 10 days to pack the line. If
between 2 (two) shipments the line packing is carried out after
completion of the first shipment.
a) Upon packing the line set ammonia vapor return line PIC-
4019 to ‘AUTO’ position with a set point of 0.9 BarG and fully close
HC-4003 (to protect tank from high pressure)
b) Set all vent stations to ‘AUTO’ with a set point of 30%.
c) Fully open PDIC-4041 at ammonia export line.
The line will be full when all of vent stations indicate level of more
than 50% and ammonia export line PI-4017 is indicating a
pressure of 1.2 to 1.5 BarG. It will depend on what is the set point
of PDIC-4010 and PIC-4019 or tank outlet pressure if using
ammonia from the tank.
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6.3.2.2 Cold Holding
Cold Holding is achieved by maintaining level as low as possible in

each of the 12 vent stations.
The Ammonia Export line shall be held under Cold Holding conditions
between ships loading, unless otherwise instructed.
a) Ammonia vapor return line PDIC-4019 set to ‘AUTO’ with a

set point of 0.9 BarG at the beginning. Reduce to 0.7; 06 BarG
afterwards, and continue reduce with targeted 0.5 BarG before
pre-cooling stage.
b) Set all vent stations to ‘AUTO’ with a set point of 30% and to
make sure LCV’s is fully open.
c) PDIC-4041 close
d) To monitor PI-4017 at ammonia export line pressure
approximately 0.5 BarG.
d) Maintain tanks pressure at 20 to 23 mBarG
e) Keep two BOG compressors running and maintain the load
capacity at the optimum condition.
Regular inspections must be carried-out, to ensure no icing at vent

stations and ammonia gas return line.
7.3.1.1 Pre- Cooling

Pre-Cooling to -30C or lower shall be carried out 3 days or 72 hours
before ship arrival for duration time of cold holding more than 2 weeks
or 5 days if cold holding duration time less than 2 weeks. If duration of
cold holding is less than 2 weeks, pre cooling shall be started 5 days
before ship arrival. Line is under ‘Cold Holding’ conditions, with
pressure at PI-4017= 0.5 BarG and TI-4095 at the jetty= minus 250C
before starting, with no passing vent stations (pressure 0.4 – 0.5 BarG
at the PIC-4019)
The steps required are as follows:

a) Close PDIC-4010 and isolation valve.
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b) Keep two BOG compressors running and maintain the
load capacity at the optimum condition (100%).
c) Gradually reduce ammonia vapor return line pressure
by reducing PIC-4019 (Auto) set point gradually until zero. This
action will fully open control valve and equalize with tanks
pressure.
d) Fully open HC-4003
e) Maintain all vent station level controllers in ‘AUTO’ with
a set point of 30% and all the LCV’s is fully opened.
f) Maintain ammonia export line pressure, PI-4017 as low
as possible.
g) The temperature can be monitored from the TI 4084 at
the Jetty B-6/ TI 4094 at the jetty B-5.
6.3.2.3 Line Packing After Completion of Loading Arm Connection and

Leak Tested
TCR Operator shall produce Work Instruction from PEPI, print
Opening Tank Gauge and take Ammonia Tank ‘Snapshot’, including
BOG flow meter reading.
This activity can be carried out after completion of loading arm leak
test. The target is to ensure commence loading by gravity and can be
started once line is packed and not delayed. This is to prevent
temperature going higher and not using pump. This is also to prevent
high pressure to the liquid line, which can cause excessive ammonia
vaporization. Under normal condition with Tank level, about 17.5 M
and time duration during cold holding less than two weeks. Time
required to pack the line is between 45 minutes to 60 minutes. In the
event of time duration is more than 2 weeks, time required is between
60 minutes to 90 minutes. This is because of less liquid inside the
line.
Operator has to monitor closely all 12 vent station LCVs during this
activities.
If certain LCV’s level not move for quite sometime, it is because of
vapor locked. Then, operator have to take action to start pump P-
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401A for a moment using 2” bypass to break the vapor and stop the
pump when level is move.
In the event of time required 60 minutes expired and the line still not
event packed, operator have to start the pump P-401A and using 2”
bypass and stop the pump whenever line is packed.
The steps are as follows :

a) Keep all vent stations LIC’s on auto at 30%.
b) Fully open PDIC-4041.
c) Gradually open 2”valve bypass of P-401-A until level appears at
vent station no.1.
d) Fully Open pump’s discharge valves P-401A/B/C/D.
e) The status of the line is packed will be indicated by LIC’s at the
vent stations. At set point 30% LICV will be fully closed. Level will
vary from 30 to 100%. PI-4017 will depend on tank’s liquid level.
f) Start pump P-401A and using 2” bypass if time required of 60
minutes expired and line still not event packed. Stop pump
whenever line is packed.
Note: For the above procedure to be successful the following

conditions must prevail:
T-401 / T-402 20mBarG to 23mBarG or lower

K-401’s (compressor) 2 in services (optimum)
7.3.2 Ship Loading

The ship loading procedure consist of 6 steps:
a) Preparation of loading arm before shipment
b) Inspection of loading arm before shipment:
i) Loading arm
ii) Hydraulic System
iii) Control Panel
iv) Warming-up
c) Connecting the loading arm
d) Loading Operations
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e) Stop Loading
f) Disconnecting the loading arm
6.3.2.2. Preparation Loading Arm Before Shipment

a) 2 weekly checklist by operation (KTSB/OM-
PASB-ALA-04-FMC)
b) 2 weekly checklist by operation (KTSB/OM-
PASB-ALA-04-Kanon)
c) Before vessel alongside checklist (KTSB/OM-
PASB-ALA-05-FMC)
d) Before vessel alongside checklist (KTSB/OM-
PASB-ALA-05-Kanon)
6.3.2.3. Inspection Of Loading Arm Before Connection

Prior to Ship Loading the loading arm should be inspected and tested
as per checklist below:
A) Loading Arm FMC or KANON
The following inspections must be performed accordingly:
i) Loading arm mechanical lock applied
ii) Zero pressure at PI4085 at B6 or PI-4095 at B5.
iii) Safety bolt / clamp installed on PERC (liquid and vapor line)
and liquid line only for KANON.
iv) The following valves should be in close position.
For liquid line

 HV-4091 at B5 or HV-4081at B6
 1 x 10" gate valves at B5 or B6
For vapor line

 PIC-4092 at B5 or PIC-4082 at B6
 1 x 4" gate valve for B5 or B6
All PRV’s are lined-up.
Note: Temperature and pressure indicators must be in working

condition.
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B) Hydraulic System
i) Hydraulic hoses are in good condition (no leak). Stainless steel
tubing’s are in good condition.
ii) Manual control selector valve must be de-energized (It should
be in counter clock wise position @ near riser) - FMC.
iii) Lock pin for "PERC" manual control in place (near riser) –
FMC.
iv) Outboard locking hydraulic valve (near riser) closed – FMC.
v) Hydraulic lube oil level above 70% at transparent indicator.
vi) Pressure gauge valves at lube oil tank are lined up.
C) Control Panel
i) "ON" 415V power supply. FMC/KANON
ii) "ON" 240V power supply. FMC/KANON
iii) “ON” Control panel power supply. - KANON
 Hydraulic pump will automatically start and will stop
hydraulic pressure reached 190 BarG – FMC.
 Alarm will be sounded. Reset alarm by pressing “Alarm
Acknowledge”, “Reset 2nd Stage Alarm”, “Reset 1st Stage
Alarm” and “Power Reset” buttons. Hydraulic pump will
automatically start and will stop at 240 BarG – KANON
iv) Push test lamp button (ensure all bulbs are lighted)
v) Check for any alarms.
 "PERC ARMED" indication should be "OFF" - FMC.
 “ERC UNARMED” indication should be “ON”– KANON.
D) Warming Up
The task will be carried out upon completing the above inspection.
FMC Loading Arm
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i) "PERC ARMED" indication should be “OFF” if arm on resting
position ('PERC' upper and lower ball valve are open). If the
lights "Valve Open" and "Valve Closed" is “ON” or if the light
"Valve Open" is “OFF” and "Valve Closed" is “ON”, open fully
from valve open/ close selector switch.
Note: The arm cannot be selected (operated) if the “PERC is

“ARMED”” (Yellow lamp is lighted).
vi) "Alarm Reset" key button on normal position.

vii) “ON” the pump (green light is “ON”) and the discharge
pressure should be at 190 Barg.
viii) Switch arm selector to position "1" either from local or
remote (yellow light arm selected “ON”).
ix) Open outboard arm lock hydraulic valve near riser.
x) Unlock the arm (mechanical lock).
xi) Operating the arm:
 Raising of the outboard arm=Push button "outboard arm
up"
 Lowering of the outboard arm=Push button "outboard arm
down"
 Raising of the inboard arm=Push button "inboard arm
back"
 Lowering the inboard arm=Push button "inboard arm
forward"
 Right slewing of the arm=Push button "slewing right"
 Left slewing of the arm=Push button "slewing left"
 Test the first and second step alarms on all maneuvers, and
then back the arm to working area.
 Check that the movements of the arm must be smooth
without jerking.
 The arm position should remain as long as it is not operated
and remains selected.
xii) Bring down the loading arm manifold connection
on the jetty floor. (Manual selector valve selected –
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maintenance mode) Reason: If power failure the arm will be
lock at last position.
xiii) Test the "PERC" upper ball valve by opening and
closing from control panel (switch "valve open/ close") and
remain to open position.
xiv) Test the “PERC” system by selecting the PERC
handle to “ARMED” position and check at control panel
whether the “PERC ARMED” light is lighted. On this condition
the arm cannot be maneuvered.
xv) Normalize the “PERC” system by unselecting the
PERC handle valve.
xvi) Ensure that STYLE 80 drain valve must be
closed and blanked.
xvii) Check hydraulic/ vapor hoses condition.
xviii) Safety bolts, shear pin, lock pins are in place.
xix) Park the loading arm and lock (mechanical).
xx) Close outboard arm lock hydraulic valve near
riser.
xxi) Switch arm selector to position "O" either from
local or remote (yellow light arm selected will “OFF”).
xxii) Unselect manual selector valve.
xxiii) Stop hydraulic pump.
xxiv) Switch OFF both supplies
KANON Loading Arm
i) Switch arm selector to “Maneuvering” position either from local

or remote (yellow light, “Maneuvering”, “ON”).
ii) Unlock Hydraulic Lock.
iii) Unlock the arm (mechanical locks).
iv) Operating the arm:
 Raising of the outboard arm=Push button "Up"
 Lowering of the outboard arm=Push button "Down"
 Raising of the inboard arm=Push button "Shore"
 Lowering the inboard arm=Push button "Ship"
 Right slewing of the arm=Push button "Right"
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 Left slewing of the arm=Push button "Left"
 Test the first and second step alarms on all maneuvers, and
then back the arm to working area.
 Ensure that the movements of the arm must be smooth
without jerking.
 The arm position should remain as long as it is not operated
and remains selected.
v) Bring down the loading arm manifold connection on the jetty
floor. (Apply Hydraulic Lock)
Reason: If power failure the arm will be lock at last position.
vi) Check hydraulic hoses condition. Ensure that there are no
deep cuts or kinks.
vii) Check Vapour hose, Insulating flange and other associated
equipments for integrity.
viii) Release Hydraulic Lock.
ix) Park the loading arm and lock (mechanical).
x) Apply Hydraulic Lock.
xi) Switch arm selector to Freewheel position "O".(yellow light,
“Freewheel”, “ON”).
xii) “OFF” Control power supply
xiii) Switch OFF both 240 and 415Vsupplies.
6.3.2.4. Connecting the loading arm
Vapor Return Line, 4 inch manual gate valve and PIC-4092 shall be in
closed position throughout loading and hot gassing operation and
shall only be opened, during emergency.
However since we are operating 2 different Loading Arms, FMC and

KANON, 4 inches manual gate valve MUST BE OPEN after Hot
Gassing operation to enable overpressure in KANON system piping’s
to be released to vapour return line and subsequently to Ammonia
Tanks.
Note: DO not forget to close this valve before starting Loading

Operations.
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Reasons why 4 inch manual gate valve and PIC-4092 shall only be
opened during emergency, is to protect any impurities from the ship’s
tank, like nitrogen or any kind of foreign gas from entering shore
ammonia tanks.
KTSB can only load ammonia liquid into ship’s tank, if the last cargo is
ammonia or after gas exchange is completed and with no nitrogen.
For the purpose of gas exchange, KTSB can provide liquid ammonia
at -30OC and not applicable to provide warm temperature (experience
in the past ship only need warm cargo for the first 10 minutes and then
follow by normal cargo temperature, which is impossible)
Third party inspector shall witness the gas exchange among others
together with Loading Master. The third party inspector shall close
and seal all vessel valves, which can be used for manual venting.
If the third party inspector or loading master determines that the

vessel has violated KTSB gas exchange procedures, KTSB reserves
all rights to protest the ship or banning it from calling the terminal in
the future.
NOTE: Refer To Loading Arm Connection (As per KTSB/OM-PASB-

ALA-06 checklist)
FMC Loading Arm
a) “ON” power supply 415V.

b) “ON” 240V power supply.
c) Push test lamp button (ensure all bulbs are lighted)
d) “PERC” ARMED indication should be “OFF” in resting position
('PERC' upper and lower ball valve opened). If the lights "Valve
Open" and "Valve Closed" are “ON” or if the light "Valve Open is
“OFF” and "Valve Closed" in “ON”, open fully from valve open/
closed selector switch. Check that the yellow lamp PERC
“ARMED" is “OFF”.
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Note: The arm cannot be selected (operated) if the PERC is
“ARMED” (yellow lamp is lighted)
e) "Alarm Reset" key button on normal position.
f) "ON" the pump (green light on) and the discharge pressure should
cut off at 190 BarG.
g) Select arm position to "1" (yellow light arm selected on)
h) Unlock the arm (mechanical lock)
i) Open outboard locking hydraulic valve (near riser)
j) Maneuver the arm for connection.
k) Open QC/ DC coupler, remove blind flange and check “O” ring
condition.
l) Connect the arm and close QC/ DC coupler.
m) Position the mechanical jack.
n) Connect vapor return hose to ship manifold (with new gasket).
o) Once loading arm is secured, switch arm selector to position “O” to
select arm to free wheel mode.
p) Stop hydraulic pump. Remove safety bolts and clamp from liquid
and vapour line.
q) Select "PERC" valve to armed position. The PERC “ARMED"
yellow light will be lighted at the control panel.
r) Conduct leak test at 6 BarG with nitrogen.
s) Ready to start loading.
NOTE: Refer To Loading Arm Connection (As per KTSB/OM-PASB-

ALA-06-Kanon, checklist)
KANON Loading Arm
1. Switch "ON" Main power supply (bottom left side) at control panel.
2. Switch "ON" Control power supply (bottom right side) at control
panel.
3. Switch “ON” Power supply at control panel.
4. An alarm will be sounded.
5. Press “Acknowledge alarm” button.
6. Press “Reset 2nd stage alarm” button.
7. Press “Reset 1st stage alarm” button.
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8. Press “Power reset” button
9. Hydraulic pump will automatically start and stop.
10. Push test lamp button (ensure all bulbs are lighted)
11. Check for any triggered alarms.
12. Arm in “Maneuvering”, "ERC Unarmed", “Power On” and “QCDC
Closed” indication should be "ON".
13. Unlock Loading Arm hydraulic lock valve near riser.
14. Unlock the arm mechanical lock (storm lock)
15. Maneuver the arm for connection
16. Open QCDC coupler, remove blind flange and check “O” ring
condition.
17. Connect the arm and close QCDC coupler
18. Once loading arm is secured, switch arm selector to free wheel
mode.
19. Position the mechanical jack.
20. Connect vapor return hose to ship manifold (with new gasket)
21. Remove safety bolts from liquid line.
22. Select ERC valve to armed position. The ERC “ARMED" yellow
light will be lighted at the control panel.
23. Conduct leak test at 6 BarG with nitrogen.
24. Ready to start loading
6.3.2.5. Loading Procedure

Commence initial loading rate 50 mt/hr (by gravitation) about 30
minutes. This is to slowly bring all marine line, loading arm to
ammonia liquid loading temperature and to safely stop loading if any
leaks detected at flanged area or swivel joints due to sudden
temperature drop. Loading temperature will be indicated by TI-4085
at Jetty 6 and T-4095 at Jetty 5.
It is essential that close communication takes place between the

Ammonia Operator/ TCR Operator/ Loading Master and Chief Officer
at all times throughout the loading operations without fail.
A. Initial Loading 50 Mt/Hr By Gravity.
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When the loading arm has been connected to the ship’s manifold,
leak tested and line packed, Loading Master is to inform Chief
Officer before commence loading.
Ensure that:
i) P-401A/ B/C/D discharge isolation valves and P-401-A
2” by pass valve is in open position.
ii) PDIC-4041 opening is set at 100%
iii) HV-4081 at B6 or HV-4091 at B5 is open
iv) PIC-4082 at B6 or PIC-4092 at B5 is close ( note: this
is on agreement in the meeting between AKH,TJ,SK and KC
0n 23th July’08 to change position from open to close ))
v) 4” vapor return line manual valve is closed, it will be
opened if requested by Ship Officer
Commence loading by gradually opening 10” manual gate valve at
jetty manifold. Communicate closely with the Chief Officer when
opening jetty line 10” manual gate valve. Monitor ammonia liquid
temperature TI-4085 for B6 and TI-4095 for B5 and sign of leaks at
flanged area, swivel joint etc.
B. Starting P-401
Upon receiving Chief Officer confirmation for running pumps:
i) Close P-401A/B/C/D discharge valve and 2” bypass
valve then start P-401A. Open gradually P-401A 2” bypass
valve. This will approximately increase flow rate between 50 –
80 mt/hrs.
ii) Flow rate can be increased gradually by opening
discharge valve one spoke at a time. (One spoke is
approximately 50 mt/hr)
iii) Keep close communication between Loading Master,
Terminal Control Room and ships to monitor the flow rate.
C. Increasing Flow Rate

When the ship is ready to receive higher flow rate, proceed as
follows:
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i) Slowly open P-401 discharge valve and increase flow rate from
100 mt/hr, 150 mt/hr, 200 mt/hr and 300 mt/hr.
ii) Once P-401-A already run and stabilized then close HV-
4003,Manual close all LCV’s vent station and set SP PIC-4019
= 1 barg auto ( note : This is to monitor if any of LCV’s vent
station passing )
iii) While P-401 running alone, keep pressure discharge pump
between 9 to 10 bar by throttling isolation valve discharge
pump.
iv) Starts second pump P-401B.
v) Slowly open pump discharge valve and increase ship-loading
rate to 650 mt/hr.
vi) Starts third pump P-401C.
vii) Slowly open discharge valve and increase loading rate up to
900 mt/hr.
viii) Starts fourth pump P-401D and slowly open discharge valve to
increase ship-loading rate to 1000 mt/hr.
ix) Close pumps cooling down valves whenever pumps is running
TCR operator and Loading Master are required to monitor
hourly loading rate until completion of ship loading.
Note:
1. With all four P-401’s running, flow rate can be maintained at
1000mt/ hr.
2. When loading at 1000 mt/hr, heat generated by friction within
the P-401’s is approximately 0.632C. Heat gain within the
ammonia export line is approximately 0.09C and heat gain
from the non-insulated loading arm and ships manifold is
approximately 0.012C giving an approximate total
temperature rise of 0.734C.
3. Therefore loading at less than 1000 mt/hr with 4 x P-401’s
running will lead to an increase in ship loading temperature.
6.3.2.6. Stop Ammonia Loading

The loading rate should be reduced gradually at the end of shipment
operation.
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_________________________________________________________________________________________________
Do not reduce ship loading by stopping pumps remotely from
control rooms.
a) Reduce from 1000 to 700 mt/hr by stopping P-401C/D.
b) Throttle P-401 A/ B discharge isolation valve to get flow rate 700
mt/h.
c) Reduce from 700 to 400 mt/hr by closing P-401A discharge valve
and leave 2” bypass valve open.
d) Reduce from 400 to 100 mt/hr by stopping P-401B and leave P-
401A running with 2” bypass valve open plus open one spoke at a
time discharge valve to maintain flow rate 100 mt/hrs at the end of
loading.
e) On completion of loading stop P-401A.
f) Close 10” gate valve at jetty manifold. It is essential that close
communication takes place between the Ammonia Operator/ TCR
Operator/ Loading Master/ Chief Officer at all times throughout the
reduction of loading rate operation.
A. Clearing of Inboard and Outboard Arm with Nitrogen

On completion of ammonia ship loading, the ammonia liquid line
and vapor return line valve shall be isolated. The liquid line will
then be cleared, purged with N2 and depressurized before
disconnection.
It is essential that close communication takes place between the
Loading Master and Chief Officer at all times.
The disconnection of Loading Arm is the final task in Ammonia

Ship Loading operations. The task may expose to the release of
liquid/ vapor ammonia if not done according to procedure.
The following steps have to be performed when clearing the

loading arm into jetty liquid line. (Refer to Ammonia Loading Arm
sketch no: (KTSB/OM-PASB-ALA-01)
a) Loading Master to communicate with Chief Officer to ensure
valves A and B are closed at ship’s side.
b) Loading Master to ensure valve D1 is closed at jetty side.
c) Connect 1” drain hose between valve E and F.
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d) Open nitrogen supply valve G to Loading Arm and pressurize
Loading Arm up to 6 BarG.
e) Crack open/close valve D1 to purge Inboard Arm contents
back towards T-401/ 402 until Loading Arm pressure 1 BarG.
f) Repeat steps d and e (minimum 5 times).
g) Pressurize the outboard Loading Arm to 6 BarG with Nitrogen.
h) Open 1" drain valve E, F and H. Crack open/close valve D to
release Outboard Arm liquid back into jetty line to T401/ 402
until Loading Arm pressure 1 BarG.
i) Repeat steps g and h (minimum 5 times).
j) Open expansion tank inlet I and close valve H & D1.
Depressurize system until pressure equalizes with vapor
returns line (0.5 BarG)
k) Open valve G and purge outboard arm with nitrogen into
expansion tank for 5 minutes.
l) Close valve F, open valve H, J (alternately) and continue to
purge inboard arm into expansion tank for 5 minutes.
m) Open valve F again and purge the whole system with nitrogen
for additional 5 minutes, just to ensure the whole system is
purged with N2.
n) Close valve G and depressurize system pressure to vapor
o) Finally, open valve K and release remnant system pressure
(0.5 BarG) via 1”, hose submerged in three quarter full, water
filled drum initially and subsequently with hose out of drum
until pressure reads 0 BarG.
p) When Inboard and Outboard Arm is fully depressurized ensure
valves C, D1, E, F, G, H, I, J, K & HV-4091 (B5)/ HV 4081 (B6)
is in closed position. Disconnect the Loading Arm as per
KTSB/OM-PASB-ALA-07.
B. Emptying Outboard Arm to Ship (If Permitted)

Some ships may permit to clear the remaining ammonia in the
outboard arm to their vessel. Clear instructions and procedure
must be discussed with ship’s Chief Officer during ship’s
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_________________________________________________________________________________________________
conference and agreed upon. In this case this procedure must be
applied;
a) Continuous communication between Loading Master and Chief
Officer must be carried out throughout this operation.
b) After the loading operation, ensure valve A, B and D1 is
closed.
c) Connect 1” drain hose between valve E and F.
d) Open nitrogen valve G and pressurize Loading Arm to 6 BarG.
e) Inform ship’s Chief Officer to open valve A. This will empty out
Ammonia liquid from outboard arm.
f) Repeat step d & e until outboard arm is empty.
g) Inform Chief Officer to close valve A.
h) Pressurize Loading Arm with nitrogen to 6 BarG again for
clearing inboard arm. Crack open/close valve D1 and purge
inboard Loading Arm contents back towards T-401/ 402 until
Loading Arm pressure 1 BarG.
i) Repeat steps h (minimum 5 times).
j) Open expansion tank inlet valve I , valve E , F and H.
Depressurize system until pressure equalizes with vapor
k) Close valve H.
l) Purge outboard arm into expansion tank with nitrogen for 5
minutes.
m) Close valve F, open valve H, J (alternately) and continue to
purge inboard arm into expansion tank with nitrogen for 5
minutes.
n) Close valve G and depressurize system pressure to vapor
o) Finally open valve K and release remnant system pressure
(0.5 BarG) via 1” hose submerged in three quarter full, water
filled drum initially and subsequently with hose out of drum
until pressure reads 0 BarG.
p) When Inboard and Outboard Arm is fully depressurized ensure
valves C, D1, E, F, G, H, I, J, K and HV 4091 (B5)/ HV 4081
(B6) is in closed position.
q) Disconnect the Loading Arm as per KTSB/OM-PASB-ALA-07.
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_________________________________________________________________________________________________
C. Emptying Loading Arm with Hot Gas from Vessel
The purpose is to empty inboard and outboard arm back to shore
tank with hot gas from vessel.
On completion of loading operations, shipside will purge our

outboard and inboard Loading Arm using compressed ammonia
gas. This will eventually empty out remaining liquid Ammonia in
the Loading Arm back to shore tank via Ammonia liquid line.
The normal temperature of the hot compressed gas is about +/-

133oC and a vessel can normally deliver pressure of up to 5 bars
During ship/ shore conference, Loading Master should emphasize

in advising ship’s Chief Officer to strictly follow and understand the
procedure to avoid any complications. Any doubt highlighted by
the Chief Officer should be clarified beforehand. All procedures
must be agreed by both parties before any activities shall
commence.
Continuous communication between Loading Master and Ship's

Chief Officer is important to ensure safe and smooth operation
(Refer to Ammonia Loading Arm sketch – KTSB/OM-PASB-ALA-

01)
Note: Ensure NH3 liquid line 2” bypass at P401A is open while Hot
Gassing operations and close once Hot Gassing is completed and
HIC4003 is closed during Hot Gassing operations. Intake of NH3
vapor from jetty line into designated shore tank shall only be done
by controlling PIC4019. Adjust PIC4019 set point to control
receiving tank pressure accordingly. Shore tank pressure shall not
exceed 125mbarg (flaring at 125mbarg). All vent stations LCV
shall be set at 30% and in auto position except for vent station No
11, 12 (B5) and No 10 (B6) should be 20% in manual open ,Failing
to do so will result in hammering of liquid line.
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Using FMC Loading Arm
o Close ship’s side liquid (valve A) and vapor return line
(valve B) manifold valve as soon as loading activities
completed.
o Shore side liquid line HV 4091 (B5)/ HV 4081 (B6), manual
gate valves D1 remain open and vent station LCV’s no 11, 12
(B5)/ no 10 (B6) shall remain 20% open. P401 A/B/C & D
discharge valves shall be closed. Failing to do so will result in
hammering of NH3 liquid line.
o Once the ship has already built up 5 bar pressure based on
PI at ship’s liquid line manifold, open ship’s liquid line valve
(valve A) slowly. This will result in liquid Ammonia in the
outboard and inboard line to be pushed into shore liquid line.
The hot gas will immediately leave the liquid line into vapor line
via vent stations no 11, 12 (B5) or 10 (B6). Continue purging
for 30 minutes or until TI at shore liquid line reads 3oC to 5oC
for a minimum of 2 to 3 minutes and pressure indicates at PI-
4094 between 3,5 to 4.0 barg. During this time, constant
monitoring of shore tank pressure and line pressure is crucial.
Line pressure shall not at any time be more than 4 barg as
indicated by shore side PI 4094 (B5)/ PI4084 (B6) and shore
vapour return line at jetty at 4,5 mbarg
o Once shore temperature reads 3oC to 5oC or 30 minutes
(whichever comes first), Loading master to advise ship’s duty
officer to stop Hot Gassing operation and close ship’s side
manifold (valve A).
o At the same time, close jetty side manual gate valve D1.
Advise TCR Operator and Ammonia Operator to control PCV-
4019 in automatic with set point of 3.5 barg.
Nitrogen purge
Stated are referred from Ammonia Ship Loading Procedure under
Clearing of inboard and outboard arm: -
When carrying out Nitrogen Purge, observe ship connection spool
Piece for ice:
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 If ice start to form on spool piece liquid ammonia still present.
 If ice is present in the lower area only it indicates spool piece
not fully clear.
 If ice present for more then 50% of spool piece it indicates
spool piece and arm still not clear.
Action must be taken to purge outboard arm again with nitrogen
and drain from low point drain of style 80 into drum filled with
water. That is why; do not immediately remove drain hose unless
you are sure spool piece clear.
After purge is completed observe for ice again. Never disconnect
loading arm if spool piece still not clear
a) Continuous communication between loading
master and chief officer must be carried out throughout this
operation.
b) Connect 1” drain hose between E &F.
c) Continuous communication between loading
operation.
d) Continuous communication between loading
operation.
e) Continuous communication between loading

operation.
f) Open valve G, E, F & I and purge outboard arm
into expansion tank with nitrogen for 5 minutes.
g) Close valve F, open valve H, J (alternately) and
continue to purge inboard arm into expansion tank with
nitrogen for 5 minutes.
h) Close valve G and depressurize system
pressure to vapor returns line until it equalizes at +- 0.5BarG.
i) Finally open valve K and release remnant
system pressure via 1” hose submerged in three quarter full,
water filled drum initially and subsequently with hose out of
drum until pressure reads 0 BarG.
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_________________________________________________________________________________________________
j) When inboard and Outboard Arm is fully
depressurized ensure valves C, D1, E, F, G, H, I, J, K and HV
4091 (B5)/ HV 4081 (B6) is in closed position. Disconnect the
Loading Arm as per KTSB/OM-PASB-ALA-07.
Using KANON Loading Arm
o Close ship’s side liquid (valve A) and vapor return line

(valve B) manifold valve as soon as loading activities
completed.
o Shore side liquid line HV 4091 (B5), manual gate valves D1
and vent station are remain open LCV’s no 11, 12 (B5) shall
remain 20% open. P401 A/B/C & D discharge valves shall be
closed. 2” valves bypass line P-401-A open Failing to do so will
result in hammering of NH3 liquid line.
o Once the ship has already built up 5 bar pressure based on
PI at ship’s liquid line manifold, open ship’s liquid line valve
(valve A) slowly. This will result in liquid Ammonia in the
outboard and inboard line to be pushed into shore liquid line.
The hot gas will immediately leave the liquid line into vapor line
via vent stations no 11, 12 (B5) or 10 (B6). Continue purging
for 30 minutes or until TI at shore liquid line reads 3oC to 5oC
for a minimum of 2 to 3 minutes and pressure indicates at PI-
4094 between 3,5 to 4.0 barg. During this time, constant
monitoring of shore tank pressure and line pressure is crucial.
Line pressure shall not at any time be more than 4 barg as
indicated by shore side PI 4094 (B5) and shore vapour return
line at jetty at 4,5 mbarg
o Once shore temperature reads 3oC to 5oC or 30 minutes
(whichever comes first), Loading master to advise ship’s duty
officer to stop Hot Gassing operation and close ship’s side
manifold (valve A).
o At the same time, close jetty side manual gate valve D1.
Advise TCR Operator and Ammonia Operator to control PCV-
4019 in automatic with set point of 3.5 barg.
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_________________________________________________________________________________________________
Nitrogen purge
Stated are referred from Ammonia Ship Loading Procedure under
Clearing of inboard and outboard arm: -
When carrying out Nitrogen Purge, observe ship connection spool
piece for ice:
 If ice starts to form on spool piece means liquid ammonia is
still present.
 If ice is present in the lower area only it indicates spool piece
not fully clear.
 If ice present for more then 50% of spool piece it indicates
spool piece and arm still not clear.
Action must be taken to purge outboard arm again with nitrogen
and drain from low point drain of style 80 into drum filled with
water. Do not immediately remove drain hose unless you are sure
spool piece is clear.
After N2 purge is completed, observe for ice formation again.
Never disconnect loading arm if spool piece is still not clear
a) Continuous communication between loading master and chief
officer must be carried out throughout this operation.
b) Connect 2” drain hose between E & F.
c) Open valve G, E, F & I and purge outboard arm into expansion
tank with nitrogen for 5 minutes.
d) Close valve F, open valve H, J and K (alternately) and
continue to purge inboard arm into expansion tank with
nitrogen for 5 minutes.
e) Close valve G, E, F, H, I, J and K and depressurize system
pressure to vapor returns line until it equalizes at +- 0.5BarG.
f) Finally open valve L to release remnant system pressure via 2”
hose submerged in three quarter full, water filled drum initially
and subsequently with hose out of drum until pressure reads
0 BarG.
g) When Inboard and Outboard Arm is fully depressurized ensure
valves D1, E, F, G, H, I, J, K, L and HV 4091 (B5) is in closed
position. Disconnect the Loading Arm as per KTSB/OM-PASB-
ALA-07-Kanon.
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_________________________________________________________________________________________________
6.3.2.7. Loading Arm Disconnection using FMC Loading Arm
Disconnect the Loading Arm as per KTSB/OM-PASB-ALA-07 work
instruction. Ensure that the loading arm must be completely drained
as per draining procedure.
a) Manually close the “PERC” locking valve to deactivate the “PERC
ARMED” (yellow light will go off at the control panel).
b) Install the safety bolts to the liquid and vapor line.
c) Disconnect vapor return line 1” drain hoses and blank-off.
d) Retract the mechanical jack of the arm.
e) “ON” the hydraulic pump (Green light “ON”) and the pressure
should cut off at 190 BarG. (Remote control unit)
f) Switch arm selector to position “1” (Yellow Light arm selected ON)
g) Disconnect 6“ Vapour Return Hose from ship manifold and install
blind flange.
Note : Before disconnection, ensure vapour line downstream of
PIC 4092 to ship manifold is depressurized by opening
10 mm vent valve located between PIC-4082/92 and PI-
4081/91 into ¾ filled water drum, to ensure line is empty
before disconnection.
h) Open QC/ DC coupler on liquid line and install blind flange. Close
QC/ DC coupler.
i) Maneuver the loading arm to storage position.
j) Park and lock (mechanically) the arm.
k) Close outboard arm lock hydraulic valve near riser.
l) Deselect arm, selector to “O”.
m) Switch OFF the hydraulic pump.
n) Switch OFF the power supplies.
o) Cover-up panel and hydraulic power unit
6.3.2.8. Loading Arm Disconnection using KANON Loading Arm
Disconnect the Loading Arm as per KTSB/OM-PASB-ALA-07-Kanon

work instruction. Ensure that the loading arm must be completely
drained and depressurized as per draining procedure.
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_________________________________________________________________________________________________
a) Deactivate the ERC. “ERC UNARMED” (yellow light will go on at
the control panel).
b) Install safety bolts to the liquid line.
c) Disconnect vapor return line 2” drain hoses and blank-off.
d) Retract the mechanical jack of the arm.
e) Switch arm selector to maneuvering position ” (Yellow Light
“Maneuvering” ON)
p) Disconnect 6 “ Vapour Return Hose from ship manifold and install
blind flange.
Note : Before disconnection, ensure vapour line downstream of

PIC 4092 to ship manifold is depressurized by opening
10 mm vent valve located between PIC-4082/92 and PI-
4081/91 into ¾ filled water drum, to ensure line is empty
before disconnection.( note.
g) Maneuver the loading arm to parking position.
h) Park and lock (mechanically) the arm.
i) Apply hydraulic lock.
j) Deselect arm, selector to “Freewheel”.
k) Switch "OFF" Main power supply (bottom left side) at control
panel.
l) Switch "OFF" Control power supply (bottom right side) at control
panel.
m) Switch “OFF” Power supply at control panel.
7.3.3 Completion of Loading

6.3.4.1 Upon completion of loading, Surveyor and Shift Supervisor shall check
Product Tank stop gauge level and print the closing gauge via
Automatic Tank Gauge (ATG) and confirm the quantity delivered.
6.3.4.2 Surveyor shall record the ship’s tank levels and temperature to
determine the ship’s loaded quantity or determine the Bill of Lading
(B/L) quantity.
6.3.4.3 The Shift Supervisor and the Surveyor will prepare the Certificate of
Quantity (CQ) and enter the quantity into PEPI to determine the Bill of
Lading (B/L) figure. If there is are discrepancies, Shift Supervisor will
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_________________________________________________________________________________________________
inform Loading Master to clear and disconnect Ammonia Loading Arm
as per 6.3.2.5 and 6.3.2.6
6.3.4.4 After finalizing the loaded quantity the TCR Operator shall issue
copies of the Certificate of Quantity (QC) to Loading Master for
handing over to vessel. The Certificate of Quantity (QC) must be
signed by TCR Operator, Shift Supervisor, Surveyor and vessel Chief
Officer.
6.3.4.5 Loading Master to issue Certificate of Quantity (QC) to Ship’s Agent.
6.3.4.6 All documentation to be returned to Customer Service.
7.3.4 Cold Holding After Completion Loading Arm Disconnection

After shipment completed tanks pressure normally will be 20 to 23mBarG and
temperature –32. 800C, marine line will be at -320C as indicated by TG-4097
(B5)/ PG-4087 (B6) and pressure close to 3.0BarG as indicated by PI-4017.
To protect tanks pressure from increasing special procedure to bring back this
line to cold holding status must be followed.
Status after loading:

a) All LIC’s at vent station still manually closed.
b) PDIC-4041 set opening 100%
c) PDIC-4010 closed including the isolation valves.
d) Marine line is still packed.
e) PIC-4019 still fully open with set point 0 BarG
f) HIC-4003 still fully open.
g) Pumps cooling down valve still close.
h) All pumps discharge valves closed.
The following should be performed as follows:

a) Close HIC-4003.
b) Set PIC-4019 to 0.8 BarG. Maintain this condition for another couple
of hours to stabilize the condition. Then slowly reduce set point with 0.05
BarG gradients at a time up to 0.5 BarG. It is important to maintain tanks
pressure between 20 to 25 mbarg during this operation.
c) One day before pre-cooling reduce set point PIC-4019 to 0.3 BarG (it
was start reducing 5 days or 3 days before depend on cold holding time
duration).
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_________________________________________________________________________________________________
d) Open for pumps cooling down valves.
e) Switch over LIC’s vent stations from manual to auto with set point of
25 to 30% at the beginning to release vapor. After LIC’s starts controlling
reduce back set point to 30%.
f) If condition is stable then switch PIC-4010 to auto and lower set point
to 0.015 – 0.02 BarG. Maintain marine line pressure to be lower depends
on set point of PDIC-4010 plus set point of PIC-4019.
g) Incase of next shipment with in 7 days or back to back then push back
liquid ammonia inside the marine line to the tank during Hot Gassing, for
that reason the below steps have to be follow:
 Close HV-4003.
 Close manually PIC-4019.
 Open 2 inch bypass P-401-A.
 Use the previous tank with lower level.
 Make sure all LCV vent station is open
position in auto mode and switch to manual and open about 20% which is
LCV is closed except no 11 & 12 fully open.
 Loading Master can proceed hot gassing
and carry out these activities until PIC-4019 / PI-4017 slightly higher then
pressure suction pumps. For example = Suction pump = 0.5 bar/ PIC
4019 = 0.7 bar, then stop gassing when TI at jetty is 3oC to 5oC
 Once point 6 is achieved close 2 inch
bypass P-401-A to avoid product from tank flow back to marine line,
switch over all LCV to auto.
 Close HV-4003 and set PIC-4019 at 0.3 bar
G for 7 days notice of next shipment OR ,
 Open HV-4003 and set PIC-4019 at 0.0 bar
G for back to back notice of shipment.
Activity during Cold Holding

a) Reduce slowly set point of PIC-4019 from 0.9 BarG to 0.3 BarG.
b) Set all LIC’s vent stations on auto at 30% and LCV’s vent station
should be on controlling the level and not at the static closed position. (It
should fluctuated opening = 0% to 100%)
c) Monitor closely temperature of jetty marine line at –220C to – 250C.
d) Running two BOG Compressor at optimum capacity
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e) Tanks Pressure between = 20 to mbarg.
8.1 LIST OF QUALITY RECORDS

Person Retention
Record Name Ref. No.
Responsible Period
Ammonia Ship Loading Customer
KTSB/OM-PASB-ALA-02 2 years
requirement Service
Loading Arm Monitoring Customer
During Loading Service
Loading Arm 2 Weekly Customer
KTSB/OM/PASB-ALA-04 2 years
Checklist Service
Loading Arm 2 Weekly Customer
KTSB/OM/PASB-ALA-04 2 years
Checklist Service
Loading Arm 2 Weekly KTSB/OM/PASB-ALA-04- Customer
2 years
Checklist Kanon Service
Before Vessel Alongside Customer
Checklist Service
Before Vessel Alongside KTSB/OM-PASB-ALA-05- Customer
2 years
Checklist Kanon Service
Customer
Loading Arm Connection KTSB/OM-PASB-ALA-06 2 years
Service
KTSB/OM-PASB-ALA-06- Customer
Loading Arm Connection 2 years
Kanon Service
Customer
Loading Arm Disconnection KTSB/EMP-PASB-ALA-07 2 years
Service
KTSB/EMP-PASB-ALA-07- Customer
Loading Arm Disconnection 2 years
Kanon Service
9.1 ATTACHMENT
Attachment I - Ammonia Ship Loading Requirements
Attachment II - Loading Arm Monitoring During Loading
Attachment III - Loading Arm 2 Weekly Checklist
Attachment III A - Loading Arm 2 Weekly Checklist Kanon
Attachment IV - Before Vessel Along side Checklist
Attachment IV A - Before Vessel Along side Checklist Kanon
Attachment V - Loading Arm Connection
Attachment V A - Loading Arm Connection Kanon
Attachment VI - Loading Arm Disconnection
_________________________________________________________________________________________________

_________________________________________________________________________________________________
Attachment VI A - Loading Arm Disconnection Kanon
Attachment VII - Ammonia Loading Arm Sketch
Attachment VIII - Ammonia Loading Arm Sketch Kanon
_________________________________________________________________________________________________

_________________________________________________________________________________________________
ATTACHMENT I
Doc. No : KTSB/OM-PASB-ALA-02
Rev No : 5
AMMONIA SHIPLOADING REQUIREMENTS
To :
Date:
Please comply with the requirements for the ship loading operations as follows:
1. At time of Loading Arm connection, disconnection or troubleshooting, all personnel attending to the
operation is required to wear Chemical Suit and Breathing Apparatus Set.
2. At all time, 3 meters area around the ship manifold is to be cordoned off. For monitoring purpose, Full
Face Mask, must be worn during access into this area.
3. If wind speed increases persistently above 22 knots, loading operations is to be terminated. Tugs can
be called for assistance through Kertih Port Control – channel 72 VHF.
4. Ship’s ESD valve closure time shall be more than 20 seconds.
5. Loading Master to witness any ship’s tank lining-up (manual or auto) during loading to prevent total
closure.
6. Before Loading Arm disconnection, ship will commence HOT GASSING operations until advised to stop
by on duty Loading Master.
Your full cooperation is required to ensure safety is adhered always. Failure to comply with the above
requirements will lead to the ceasing of loading operation.
-------------------------------------------
KTSB Loading Master
Name :
Date/Time :
Acknowledge Receipt By:
------------------------------------ ---------------------------------------
KPSB Duty Pilot Vessel Master / Chief Officer
Name : Name :
Date/Time : Date/Time :
ATTACHMENT II
D o c N o : K T S B /O M - P A S B -A L A -0 3
R ev N o : 03
L O A D IN G A R M M O N IT O R IN G D U R IN G L O A D IN G
L O A D IN G A R M S T A T U S
P IP IN G , V A L V E S
IN B O A R D A N D H Y D R A U L IC
T IM E PERC PANEL AN D
O UTBO ARD ARM SYSTEM
E Q U IP M E N T S
L o a d in g M a s te r / O p e r a t o r S h if t S u p e r v is o r
ATTACHMENT III
Loading Arm 2 Weekly Checklist
Date : Doc No : KTSB/OM-PASB-
ALA-04
Rev No : 04
Item Descriptions Remarks

1.1 Loading Arm Visual inspections Yes No
A Loading Arm in resting position & storm lock in place .
B Check hydraulic system for leaks and hoses integrity .
C Check cables , glands and fittings for integrity or damages .
Check proximity switches cable and glands for integrity or
D
damages .
E Check wire rope integrity or damages .
F System no pressure and empty .
G Liquid and vapour valves in closed position .
H Temperature and pressure indicators in good working condition .
Before proceeding any further , select the Loading Arm manually at the manual selector valve control
box and ensure “ Maintenance Override ” switch is in “ ON ” position .
1.2 Check electric control panel Yes No

a Switch ‘ ON ’ power supply ( 415V and 240V ) .
b Test panel light ( ensure all bulbs is lighted ) .
Check position of " PERC" upper ball valve . If both lights is “ON” Upper ball-valve
( Red and Green ) , open valve completely ( until , only Green shall not be used
c light is “ON” )
for Isolation
Before
‘ PERC ARMED ’ indication should be ‘OFF’ in resting position
d
( The arm cannot be selected if the "PERC" is "ARMED" ) .
‘ ESD 2 alarm reset ’ key switch in normal position ( key available
e
in break glass box ) .
1.3 Check hydraulic power unit

Check oil level for correct level ( 80% ) . Top up if necessary also
a
check reservoir / tank condition and rectify any leaks.
Switch on the pump ( green light is lighted ) Hydraulic pump will
cut off at when ( 32 litres ) accumulator pressure reaches 190
b BarG ( cut in at 160 BarG ) . At new pump selector switch and
maintenance override panel , try selecting new pump for
functionality .
Check selector switch , normally open and close handles are lined
c
up as per procedure .
Item DESCRIPTIONS
1.4 Operating of Arm movement REMARKS
( To perform on Local / Radio ) LOCAL RADIO
a Select either Local / Radio position at control panel .
Select Arm selector to position ' 1 ' ( Arm selected
b
Yellow light will be ‘ON’ ) and start hydraulic pump .
OK N/OK OK N/OK
Open Outboard Arm hydraulic lock valve near riser
and unlock
c
Storm Lock ( inboard arm mechnical lock ) . Do not DONE NOT DONE
unlock if the
arm is not selected .
Position Arm in " Maintenance Position " and
perform Functional
Test ( beacon light and audio alarm only ) :
Inboard arm movement OK / NOT OK
Outboard arm movement OK / NOT OK
First outboard alarm ( ESD 1 ) Activated / Not Activated

d
Second outboard alarm ( ESD 2 ) Activated / Not Activated
First left slewing alarm ( ESD 1 ) Activated / Not Activated
Second left slewing alarm ( ESD 2 ) Activated / Not Activated
First right slewing alarm ( ESD 1 ) Activated / Not Activated
Second right slewing alarm ( ESD 2 ) Activated / Not Activated
Beacon light and audio alarms activation ( ESD 1
e Activated / Not Activated
Intermittent / ESD 2 continuous ) .
Bring down Loading Arm Style 80 on jetty floor and
f DONE NOT DONE
inspect ‘PERC’ system .
Test open and close upper ball valve from control DONE NOT DONE
g
panel .
Test open / close Hydraulic Clamp and check ‘ O ’ Local Radio Local Radio
i
ring is in good condition . OK/NOK OK/NOK OK/NOK OK/NOK
j Pins and washers are in place and secured . YES NO
k Shear pin is in place and in good condition . YES NO
Hydraulic hoses / tubing is free of leaks and in good
l YES NO
condition . ( No deep cuts and abbrassion etc. )
m Safety bolts are tighten properly on both lines YES NO
n Unselect Arm and stop hydraulic pump DONE NOT DONE
At style-80 ; remove "PERC" cylinder/plunger's " PIN
" and secure
plunger away from any obstruction . ( plunger shall DONE NOT DONE
o
extend during
actual test )
At vapour line ; remove ‘snap-tite’ activation , clamp
p DONE NOT DONE
nut ( ensure it's removed from the plunger )
Position ‘ PERC ’ valve ( lever ) to 'armed' position . ‘
PERC ARMED ’ yellow light at panel must be lighted
h ( In ‘ PERC ARMED ’ condition , maneuverability DONE NOT DONE
isn't possible even if the arm is selected ) .
After each ESD 2 activation , DONE NDONE
System must be reseted with " Alarm Reset " key at control panel .
Lower ball valve must reopened by pressing SV 12 plunger at manual control box .
Upper ball valve must be reopened at the control panel .
Diagram 1
Done By :Group :Verified by :
Vai 05 ( Rev 0 )
ATTACHMENT IV
Before Vessel Alongside Checklist

Date : Doc No : KTSB/OM-PASB-
ALA-05
Rev No : 04
Item Descriptions Remarks

1.1 Loading Arm Visual inspections Yes No
A Loading Arm in resting position & storm lock in place .
B Check hydraulic system for leaks and hoses integrity .
C Check cables , glands and fittings for integrity or damages .
Check proximity switches cable and glands for integrity or
D
damages .
E Check wire rope integrity or damages .
F System no pressure and empty .
G Liquid and vapour valves in closed position .
H Temperature and pressure indicators in good working condition .
Before proceeding any further , select the Loading Arm manually at the manual selector valve control
box and ensure “ Maintenance Override ” switch is in “ ON ” position .
1.2 Check electric control panel Yes No

a Switch ‘ ON ’ power supply ( 415V and 240V ) .
b Test panel light ( ensure all bulbs is lighted ) .
Check position of " PERC" upper ball valve . If both lights is “ON” Upper ball-valve
( Red and Green ) , open valve completely ( until , only Green shall not be used
c light is “ON” )
for Isolation
Before
‘ PERC ARMED ’ indication should be ‘OFF’ in resting position
d
( The arm cannot be selected if the "PERC" is "ARMED" ) .
‘ ESD 2 alarm reset ’ key switch in normal position ( key available
e
in break glass box ) .
1.3 Check hydraulic power unit

Check oil level for correct level ( 80% ) . Top up if necessary also
a
check reservoir / tank condition and rectify any leaks.
Switch on the pump ( green light is lighted ) Hydraulic pump will
cut off at when ( 32 litres ) accumulator pressure reaches 190
b BarG ( cut in at 160 BarG ) . At new pump selector switch and
maintenance override panel , try selecting new pump for
functionality .
Check selector switch , normally open and close handles are lined
c
up as per procedure .
Item DESCRIPTIONS
1.4 Operating of Arm movement REMARKS
( To perform on Local / Radio ) LOCAL RADIO
a Select either Local / Radio position at control panel .
Select Arm selector to position ' 1 ' ( Arm selected
b
Yellow light will be ‘ON’ ) and start hydraulic pump .
OK N/OK OK N/OK
Open Outboard Arm hydraulic lock valve near riser
and unlock
c
Storm Lock ( inboard arm mechnical lock ) . Do not DONE NOT DONE
unlock if the
arm is not selected .
Position Arm in " Maintenance Position " and
perform Functional
Test ( beacon light and audio alarm only ) :
Inboard arm movement OK / NOT OK
Outboard arm movement OK / NOT OK
First outboard alarm ( ESD 1 ) Activated / Not Activated

d
Second outboard alarm ( ESD 2 ) Activated / Not Activated
First left slewing alarm ( ESD 1 ) Activated / Not Activated
Second left slewing alarm ( ESD 2 ) Activated / Not Activated
First right slewing alarm ( ESD 1 ) Activated / Not Activated
Second right slewing alarm ( ESD 2 ) Activated / Not Activated
Beacon light and audio alarms activation ( ESD 1
e Activated / Not Activated
Intermittent / ESD 2 continuous ) .
Bring down Loading Arm Style 80 on jetty floor and
f DONE NOT DONE
inspect ‘PERC’ system .
Test open and close upper ball valve from control DONE NOT DONE
g
panel .
Test open / close Hydraulic Clamp and check ‘ O ’ Local Radio Local Radio
i
ring is in good condition . OK/NOK OK/NOK OK/NOK OK/NOK
j Pins and washers are in place and secured . YES NO
k Shear pin is in place and in good condition . YES NO
Hydraulic hoses / tubing is free of leaks and in good
l YES NO
condition . ( No deep cuts and abbrassion etc. )
m Safety bolts are tighten properly on both lines YES NO
n Unselect Arm and stop hydraulic pump DONE NOT DONE
At style-80 ; remove "PERC" cylinder/plunger's " PIN
" and secure
plunger away from any obstruction . ( plunger shall DONE NOT DONE
o
extend during
actual test )
At vapour line ; remove ‘snap-tite’ activation , clamp
p DONE NOT DONE
nut ( ensure it's removed from the plunger )
Position ‘ PERC ’ valve ( lever ) to 'armed' position . ‘
PERC ARMED ’ yellow light at panel must be lighted
h ( In ‘ PERC ARMED ’ condition , maneuverability DONE NOT DONE
isn't possible even if the arm is selected ) .
After each ESD 2 activation , DONE NDONE
System must be reseted with " Alarm Reset " key at control panel .
Lower ball valve must reopened by pressing SV 12 plunger at manual control box .
Upper ball valve must be reopened at the control panel .
Diagram 1
Done By :Group :Verified by :
Vai 05 ( Rev 0 )
ATTACHMENT V
Doc No : KTSB / OM-PASB-ALA-06
Rev No : 04
LOADING ARM CONNECTION
VESSEL: ……………………………………. BERTH NO : ………………...…
BEFORE/ DURING and AFTER CONNECTION
Item Description Y N Remarks

1 Has the loading arm been tested and authorized to be used ?
2 Check loading arm empty / no pressure and jetty valves are closed
3 Start up control panel : ( Remote or local panel )
 ‘ ON ’ power supply ( 415V and 240V )
 Test panel light ( ensure all bulbs is lighted )
 ‘ PERC ARMED ’ indication should be ‘off ’ in resting position
( The arm cannot be selected if the PERC is ARMED )
 Upper valve indication in opened position
 ‘ Alarm Reset ’ key switch in normal position
 Switch on the pump ( green light is lighted ) Hydraulic systems
pressure will rise and cut off at 190 BarG .
 Select ‘Arm selector ’ to position ‘1’
 Open Outboard Arm hydraulic lock valve near riser and unlock
Storm Lock ( Do not unlock if the arm is not selected ) and move
the arm for connection .
4 Inspect ‘ PERC ’system before connection
 Pins and washers are in place and secured
 Shear pin is in place
 Hydraulic hoses / tubing free of leaks and in good condition
 Safety bolts are tighten properly
 ‘ PERC ’ locking valve ( lever ) in closed position
5 Open Hydraulic Clamp , remove blind flange and check ‘ O ’ ring is in
good condition
6 Connect the arm and close Hydraulic Clamp
7 Switch arm selector to position ‘ 0 ’ to put arm in free wheel mode
8 Stop hydraulic pump
9 Position the mechanical jack
10 Connect vapor return line
11 Remove safety bolts from both lines
12 Open ‘ PERC ’ locking valve ( lever ) and ‘ PERC ARMED ’ yellow light
at panel must be ‘ ON ’
13 Leak test both line at 6 BarG with nitrogen
14 Power for 415V and 240V must be ‘ ON ’
* To attach the KTSB/OM-PASB-ALA-04 or KTSB/OM-PASB-ALA-05 checklist .

* Action shall be taken immediately on any ‘ NO ’ or remarked items
By (Name & Sign) : ………………………….… Date & Time: ……………………….
Verify by (Name& Sign) : …………………………….

ATTACHMENT VI
Doc. No : KTSB / OM-PASB-ALA-07
Rev No : 03
LOADING ARM DISCONNECTION
VESSEL : ……………………………………. BERTH NO : ……………………
Item Description Y N Remarks

1 On completion of loading : After Hot Gassing ( As per detailed
procedure )
 Close ship’s / shore’s manifold valves and install 1” stainless
steel drain hose . ( Use PPE as per PPE matrix )
 Purge Inboard Arm with nitrogen at 6 BarG back to
expansion tank back to vapor return line. ( Until icing melt )
 Purge Outboard Arm with nitrogen at 6 BarG thru 1”
stainless steel hose to expansion tank back to vapor return
line . ( Until icing melt )
 Purge Inboard and Outboard Arm with nitrogen into
expansion tank back to vapor return line
 Depressurize system to zero pressure
2 Close ‘ PERC ’ locking valve ( lever ) and ‘ PERC ARMED ’ yellow
light at panel must be ‘ OFF ’
3 Install safety bolts on both lines
4 Disconnect vapor return line and 1” SS hoses. ( Use PPE as per
PPE matrix)
5 Retract the mechanical jack
6 Disconnection of liquid line: ( Remote or local panel )
 Start hydraulic pump
 Select arm selector to position “1”
 Open Hydraulic Clamp , install blind flange and close
Hydraulic Clamp
 Move , park the arm and engage Storm Lock
 Close Outboard Arm hydraulic lock valve near riser
 Deselect arm selector to ‘ O ’
 Stop hydraulic pump
 Switch-off power supply ( 415V and 240V )
 Cover-up panel and hydraulic power unit
* To attach the maintenance report.

* Action shall be taken immediately on any ‘ NO ’ or remarked items
By ( Name & Sign ) : ………………………… Date & Time:……………………….
Verify by (Name& Sign): …………………………

___________________________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________________________
ATTACHMENT VII
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___________________________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________________________
ATTACHMENT VIII
___________________________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________________________

Ammonia SOP

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_________________________________________________________________________________________________

Standard Operating Procedure KTSB/SOP/T-RASL Refrigeration Ammonia Ship Loading

APPROVAL AND REVISION HISTORY

TERMINAL: REFRIGERATION AMMONIA SHIP LOADING

DOCUMENT NO. KTSB/SOP/T-RASL COPY NO.

Ahmad Kamal Holidy Terminal

All 1 Revise as per current practice 24 Jan 2008

19-23 & To include inspection of KANON Loading Arm before

Revision No: 1 Effective Date: 24 Jan 2008 Page 1 of 51

Standard Operating Procedure KTSB/SOP/T-RASL Refrigeration Ammonia Ship Loading

SECTION TITLE PAGE

APPROVAL AND REVISION HISTORY 1

3. DEFINITIONS AND ABBREVIATIONS 4

6.1 Safety Procedure 5

6.2 Emergency Procedure 5

6.3 Operating Procedure 6

6.3.1 Tank preparation 6

6.3.3. Ship Loading 13

6.3.4 Completion of Loading 34

6.3.5 Cold Holding After Completion Loading Arm

7. LIST OF QUALITY RECORDS 37

Revision No: 1 Effective Date: 24 Jan 2008 Page 2 of 51

Standard Operating Procedure KTSB/SOP/T-RASL Refrigeration Ammonia Ship Loading

Copy No. Holder Status

Master Document Control Room Master Document

1 Operations Manager Controlled

2 Ops Superintendent (Terminal) Controlled

3 Terminal Control Room Controlled

4 Ammonia Control Room Controlled

5 Operations Excellence Department Controlled

6 Jetty – B2 & B3 Controlled

Revision No: 1 Effective Date: 24 Jan 2008 Page 3 of 51

4.1 DEFINITIONS AND ABBREVIATIONS

7.2 Emergency Procedure

6.2.2. In the event of emergency such as vapor release:

7.3 Operating Procedure

Revision No: 1 Effective Date: 24 Jan 2008 Page 5 of 51

6.3.1 Tank preparation

Purpose of Changing Philosophy

Revision No: 1 Effective Date: 24 Jan 2008 Page 6 of 51

3. Trims valves vapour return to the tanks ZV-4015 and ZV-4025. By

Action in the following situation:

2. Tanks pressure Increase due to rundown temperature increase:

Revision No: 1 Effective Date: 24 Jan 2008 Page 7 of 51

4. Dedicated export tank low pressure.

5. Mode of operation ammonia shipment with out vapour return.

6. Mode of operation ammonia shipment with vapour return.

Revision No: 1 Effective Date: 24 Jan 2008 Page 8 of 51

Pre-Cooling will take approximately 3 days or 72 hours if cold holding time

Revision No: 1 Effective Date: 24 Jan 2008 Page 9 of 51

For line packing and cooling process, 2 compressors must be in operation.

6.3.2.1. Line Packing before Cold Holding

This step is to be carried out at least 1 week before ships scheduled

Revision No: 1 Effective Date: 24 Jan 2008 Page 10 of 51

Cold Holding is achieved by maintaining level as low as possible in

a) Ammonia vapor return line PDIC-4019 set to ‘AUTO’ with a

Regular inspections must be carried-out, to ensure no icing at vent

7.3.1.1 Pre- Cooling

The steps required are as follows:

Revision No: 1 Effective Date: 24 Jan 2008 Page 11 of 51

6.3.2.3 Line Packing After Completion of Loading Arm Connection and

Revision No: 1 Effective Date: 24 Jan 2008 Page 12 of 51

The steps are as follows :

Note: For the above procedure to be successful the following