Rotating equipment operating procedures:

Centrifugal pumps start-up:

Inspect whether all the mechanical jobs are over.
No load test of the motor during decoupling condition.
De-energize the motor for coupling with pump.
Clean pump suction strainer and self coolant strainer (if any)
Establish bearing cooling water flow
Establish seal steam system.
Commission seals coolant systems to seals and check for leaks.
Check bearing housing oil level and check the oil content is free of
foreign material.
Rotate the shaft by hand for free movement.
Check the coupling guard intact or not.
Check the pump bay is clean and clear.
Check and remove all the foreign materials like cotton waste , used
gaskets
And bolts lying in and around pump area.
Keep discharge valve and warm up valve in closed position. open
suction
valve slightly and ensure that the casing is full of liquid by priming.
After wards keep the pump in warm up condition by opening warm up
valve slightly.
Check for leaks and open suction valve fully.Hot bolting of flanges
are
to be done.Close the warm up valve.
Energize the motor and start the motor and check the pump direction ,
Rectify if the direction is incorrect.
Check the discharge pressure.
Open the discharge valve slowly while watch the discharge pressure
and Amps in the ammeter.
After steady state is attained check the flow ,temperature of the
bearings
and vibration readings.
Check for gland\seal leaks for tightness.
CBD related blinds on pumps are to be blinded.
Update the blind register.

Shut down :
First close the discharge valve then only stop the pump. Then to keep
warm up
condition warm up valve is to be opened slightly.
If the pump is to be released for maintenance proceed as follows
Close suction warm-up and discharge valves.
Close seal oil systems to pump.
Keep the pump for cool down.
Flush the pump content to CBD after deblinding the concerned blinds .
Depressurise the pump for blinding.
Close cooling water to bearings.
Close seal steam system.
Open pump bleeder and check for passing of valves before handing over to
maintainance for blinding.
Blind suction,Discharge ,warm-up seal oil and seal steam systems.
Cut off electrical supply to pump motor before handing over to maintenance.
Pump under repair sign board is to be tagged \displayed.
Trouble shooting problems:
A . Pump is not developing pressure due to improper priming or cavitation
1. Check bleed \vent pump casing.
2. Check the line up of the system \suction.
3. Check the suction strainer.
4. Check the level where the pump is taking suction.
5. Check pump coupling and pump rotation.
6. Check the temperature of the liquid.
B. Unusual sounds
1. Check coupling gaurds.
2. Check pump,motor fan gland and motor guard.
3. Check for pump cavitation.
4. Get it further checked by rotary after stopping the pump.
C. Raise of bearing temperature:

1. Improper lubrication due to low oil level

2. Insufficient bearing cooling water to bearing housing.
3. Stop the pump if the temperature is more than 75 0 C and inform to
rotary to check the pump and to do acid cleaning of BCW lines and
bearing housing system.
D. Unusual sounds :
1. Check the foundation bolts.
2. Check the fan cover for looseness.
3. Stop the pump to check alignment.
E. Leaky glands:
1. Check pump discharge pressure.
2. Thighten the gland nut slowly if possible.
f. Mechanical seal leak :
1. Stop , Isolate ,Depressurize and hand over to maintainance for reapirs
after blinding.

Manual up datation topic details

I (a) Pumps / Turbines seal repairs:
1. Isolate suction,discharge and warm up valves
2. Allow the system to cool down and then flush it with cutter to CBD
through casing after removing blinds on cutter and CBD of the
concerned.
3. After ensuring the stock becomes light depressurize it to CBD
\OWS.Open pump vent \D\d PG point value for proper
depressurizing.
4. Blinding is to be done for proper isolation on S\C,D\S,warm up
,flushing oil ,seal oil ,seal steam and CBD lines and update blinds
register.
5. isolate power to the pump.
6. Isolate steam to the turbine .If
depressurize and blind it on
steam side.
7. Issue permit ,Decouple turbine \pump after ensuring the above.
8. Keep equipment under maintenance display board.
Note: disconnect instrument thermocouples as per rotary.
I (b) After the seal replacement on pump \ Turbine:
1. Check BCW, seal system, seal oil systems and remove any foreign
materials in and around pump \turbine basements
2. Remove blinds on s\c ,d\s ,warm up , CBD, seal systems,seal oil and
flushing oil. Ensure proper gaskets are installed.
3. Close pump vent ,open casing drain to OWS\CBD. Throttle pump
discharge PG drain valve to remove air.
4. Open flushing oil slightly to fill casing and to remove air from D\S
PG point.
5. Once oil is coming through D\S PG point close it. Also close casing
drain to CBD\ows and check pump blind flanges with FLO Pr (9
Kg\Cm2) for leaks.
6. Depressure the cutter to OWS\CBD and open pump warm up valve
slightly for warm up condition(only for hot service pumps).
7. Allow rotary to do hot alignment.
8. Allow maintenance to do hot bolting on blind flanges.

9. After hot alignment and coupling fixing, check for free movement of
shaft.
10.Check no load before coupling as per rotary\Electrical and isolate
power.
11.After ensuring all the jobs are over power to motor is to be released .
Steam blind to turbine is to be removed.
12.Check the direction of the motor while placing the pump\Turbine.
13.When all the above factors are ok place the pump \Turbine and see the
performance.
14.keep casing drain to CBD\OWS blind.
15.Ensure updating of gaskets and blind registers .
16.Remove equipment under maintenance display board.
II (a) Pump \ Turbine suction strainers cleaning repeat steps 1,2,3,4,5,6
and 8.
(b) after pump\turbine suction strainers cleaned follow the steps
1,3,4,5,6,11,13,14,15 and 16.
III (a): LPG\ Naphtha pumps repairs:
1.
2.
3.
4.
5.

Isolate suction,discharge and warm up valves

Isolate self coolant lines.
Depressurize the content to flare through casing vent to flare .
Provide steam hose connection pump D\S PG point.
After ensuring gas is depressurized close casing vent to flare, Open
casing drain to OWS and check if any gas is coming.
6. Observe passing of valves during depressuring to flare through
of lines.
7. Ensuring system is depressurized blind S\C,D\S ,self coolant ,casing
CBD\OWS and flare systems ,update blind register.
8. Isolate power to the pump and disconnect steam hose.
9. Issue permit to rotary to carry out the seal replacement job.
10.Keep equipment under maintenance display board.
Note: Inform instrument people to check and repair seal pot pressure and
low level switches if any.

III (B): When seal replacement job is over

1. Provide steam hose at pump D\S PG point.
2. Check self coolant systems.
3. Check and remove all foreign materials in and around pump
basement area.
4. Remove blinds on S\C ,D\S,self coolant systems.
5. Open steam and pressure test the pump for blinding flange leaks.
6. Close vents and bleeders.
7. During slight steam purge open suction valve and casing vent to flare
for some time, and close steam completely.
8. Close casing vent to flare after some time.
9. Open casing drain to displace condensate if any.
10.Blind pump casing drain to OWS\CBD.
11.check for no load test before fixing coupling as per rotary \ electrical.
12.When all jobs are over release power to motor and check direction of
pump.
13.Place the pump online slowly and check the performance.
14.Ensure updation of blind and gasket registers.
15.Remove equipment under maintenance display board.

VBU Feed suction \coarse\fine filters cleaning

1. Isolate strainers inlet and outlet valves.
2. Allow the filters for some time to cool down (min 1 hr up to 2 hrs )
3. Open flushing oil and flush the filter to CBD to dilute the stock for
some time. When stock is diluted close FLO and drain CBD\OWS.
4. Realease to maintenance for cleaning after ensuring no valve is
passing.
5. During depressurizing allow maintenance to do alternate bolting also.

Strainer commissioning:
1. Once the strainer is cleaned check the strainer physically before
fixing.
2. Allow the maintenance to fix the strainer with new gasket. Update
gasket register.
3. Presuure test the gasket with flushing oil after fixing and depressure it
to CBD\OWS.
4. Slowly open strainer I\L valve to displace the strainer content to CBD
for some time.
5. Then slowly open outlet valve and leave it for some time to ensure
proper displacement of inside stock without atarving the running
pump.
6. allow maintenance to do hot bolting of strainers flange.
7. When everything is normal then open inlet and outlet valves wide
open and isolate the other one. Keep it as standby after flushing.
8. Keep FLO and CBD blinds and update blind register.

Depressurizing,Steaming and commissioning of coolers,condensers and

exchangers for tube leaks
1. Isolate inlet and outlet valves. On shell and tube and open bypass
valve.
2. Depressurize the content to CBD\OWS after removing blind.
3. Cooling water is to be depressured to intermediate sewer.
4. Provide steam connection on shell side vent and start initial steaming.
5. After ensuring sweat steam and non passing of isolation valves stop
steaming and blind both sides shelland tube inlet and outlet lines and
update blind register.
6. Again carry out final steaming for 2 to 3 hrs then stop steam.
7. again put blinds.
8. Allow maintainance to carry tube leak jobs.
9. Care should be taken while bundle is pulled out and when fixing and
dropping of components.
For exchanger :
1. Isolate I\L ,O\L,warm up valves,TSVs on shell and tube sides and
open bypass.
2. Steam connections are to be given to vents and depressurize to
CBD\OWS on both sides.
3. Ensuring sweat steam and non passing of isolation valves blind both
shell and tube sides I\L and O\l.
4. Release exchanger for dropping components after closing steam
valve. Disconnect it only after final staming for 2 to 3 hours.
5. Blind CBD lines and update blind register.
Commissioning of steam gens :
1.

2.
3.
4.
5.
6.
7.

After the maintenance jobs are over connect steam hoses on shell and
tube side vents.
Deblind the shell and tube sides.
Steam test the blinding flanges at 5 to 6 Kg\Cm2.
When there is no leak deblind FLO and CBD blinds.
Cutter flush to CBD\OWS.
Remove all steam hoses and cap off vents.
Build up levels in steam gens and V21 upto 30 %.

8.
9.

10.

11.
12.

13.
14.

15.
16.
17.

Keep steam gen vents open.

After filling with cutter displace cutter to CBD\OWS with SR through
top of the bundle.
Ensuring cutter is displaced open I\L and O\L valves slightly keeping
bypass in wide open condition.Slowly open I\L and O\L valves and
slowly close bypass of one steam gen.
Keep 42V21 warm up open.
Observe steam gen pressure and temperature and slowly open steam
O\L valves.
Slowly close SR side bypass and steam gens one by one online.
Close local vent and keep the steam pressure control on system
finally.
Check for leaks for flanges if any.
Blind CBD\OWS and FLO lines.
Update gasket and blind register.

Hotwell off gas routing to 42 F01 :

1. Check all hotwell burners readiness.
2. Check the hot well off gas system from hotwell to heater and flame
arrestors.
3. Drain the liquid content at flame arrestoe and catch pot.
4. Keep the hotwell off gas plug cock in close position.
5. Reset hotwell offgas SDV and check the system once again for leaks
and free of liquid content.
6. During this activity one person at heater one person at hotwell and one
person at feed pumps PA has to coordinate with MOI person for
effective operation .
7. Ensure the system is ok and light up pilots of hotwell off gas burners
and main gas fires before routing hotwell off gas.
8. Keep one hotwell off gas burner plug cock valve open and close hot
well vent slowly.
9. Ensure hot well off gases are burning in the burner . Observe this
flame then light up all four burners.
10.Slowly close the hot well vent and observe the flame pattern in the
heater.
11.Finally check the system and vacuum of the column after routing.

ID fan placing :
Field observation :
Check readiness of ID fan for lube oil level,motor,suction and discharge
dampers openings,cooling water and circulating oil systems , foreign
material removal and stack damper opening.
MOI observation :
1.
2.
3.
4.
5.
6.

Check whether the furnace arch temperature is >400

Keep fuel cutoff .
Keep ID fan fail bypass and interlocks in bypass mode.
start the fan from field.
Load the fan from PC5007 after resetting.
Observe the RPM, loading indication and check in the field about
shaft movement.
7. Slowly increase the loading to increase the temperature of APH
gradually.
8. Once the temperature of APH reached to the normal state ,then
damper can be closed.
Introduction of bottom stripping steam to the columns(Atmos ans vac):
1. During the introduction of bottom stripping steam to the column
ensure whether the shell vave , C\V,B\P and D\S isolation valves are
closed or not.
2. Before introduction of steam drain the condensate from U\S and D\S
bleeders of the C\V.
3. After ensuring that the system is condensate free open the C\V by 2 to
3 % and ensure dry steam from the drains.
4. Then crack open the shell valve of the column.
5. Open shell valve and control valve gradually for the introduction of
steam to the column.
6. Check whether oil is being backed up during this activity.
7. Slowly establish the steam flow.
8. Finally cheak for leaks.

Crude feed pump change over procedure:

1. First take clearance from CPP as it is a HT pump.
2. Check all the parameters like BCW, seal stream ,self coolant system
,suction valve opening and discharge valve closed position.
3. Check the pump basement for foreign materials removal.
4. Inform the field person to start the pump after CPP clearance.
5. Start the pump and adjust the discharge pressure around 27 Kg\Cm2
by opening the discharge and simultaneously close the running pump
discharge valve gradually so that the discharge pressure PT1111 is
maintained at 27 Kg\Cm2 , also watch the amps of the two pumps
6. When the running pump discharge is fully closed and amps become
lower side stop the feed pump after taking permission from control
man in MOI.
7. check for leaks after changeover of pumps.

Crude feed booster pump change over procedure:

1. Check all the parameters like BCW, seal stream ,self coolant system
,suction valve opening and discharge valve closed position.
2. Ensure the discharge is fully closed and in warm up condition.
3. Close warm up after readiness of pump and motor,take out feed pass
C\V from APC mode to operator mode.
4. Reduce desalter pressure to 11.5 Kg\Cm2
5. Keep pass flow low low and desalter low pressure trip in bypass mode
during this activity.
6. take clearance from CPP as it is a HT pump.
7. Start the pump and adjust the discharge pressure around 32 to 34
Kg\Cm2 by opening the discharge and simultaneously close the
running pump discharge valve gradually so that the discharge pressure
42PT1112 is maintained at 11 to 12 Kg\Cm2 , also watch the amps of
the two pumps.
8. When the running pump discharge is fully closed and amps become
lower side stop the feed pump after taking permission from control man
in MOI.
9. check for leaks after changeover of pumps.
10. Keep the stand by booster pump warm up condition.
11.place necessary trips online after the activity.

Power failure:
1. Open Atmos flare control valve bypass to control the top pressure by
observing the 42V13 O\H pressure gauge.
2. Stop Feed , Booster pumps and take out all fires.
3. Bypass desalter and stop water injection.
4. Run top reflux pump on bypass mode.
5. Stop all stripping steams, R\Ds ,pumps and chemical injections.
6. close V21 BFW shell valve.
VBU field activity:
1. Open bypass of 46HV1601 on V02 and control 46C01 pressure by
observing the 42V02 O\H pressure gauge.
2. Take out all fires and BFW injection to passes.
3. keep top reflux on bypass mode and stop all pumps.
4. Close all rundowns.
5. Close 46F01 emergency steam, stripping steams to 46c01 and 46c02.
6. Close BFW to steam gens and desuperheater.
7. Open MP and LP steam gens vents.

Fluid coupling oil coolers change over ;

Each fan is having two coolers for circulating oil. One is in online and
other is stand by. If the online cooler performance is poor then the stand
by is to be taken online to reduce circulating oil temperature.
The following steps are to be followed
1. Keep FD FAN A fail bypass , FD FAN B fail bypass FD FAN A\B fail
bypass and interlocks PB5051,PB 5057 in bypass mode.
2. Combustion air fail PB 5053 in bypass.
3. Fuel cutoff in bypass(PB 5055)
4. Keep stack damper in open condition.
5. Then establish cooling water flow through stand by cooler by
pinching down 3 way valve on inlet and outlet lines with out affecting
flow to running fan.(observe 42FT5012).
6. Same way adjust circulating oil flow by watching the meter
42FT5010.
7. Adjust flows on water and oil and slowly close the flows through
running cooler and increase stand by cooler.Finally establish flows
through the stand by cooler. This way the fan does not get starvation
of flows either on circulating oil or water side.
8. Then check the temperature physically and also observe leaks on the
system.
9. Finally keep all trips in online position.