Ammonia SOP
Ammonia SOP
Ammonia SOP
TITLE OF DOCUMENT
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
TABLE OF CONTENT
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TABLE OF CONTENT 2
DISTRIBUTION LIST 3
1. PURPOSE 4
2. SCOPE 4
4. REFERENCE 4
5. RESPONSIBILITY 4
6. PROCEDURE 5
6.3.2. Pre-Shipment 9
Disconnection 35
8. ATTACHMENT 37
DISTRIBUTION LIST
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7 Jetty – B4 Controlled
8 Jetty – B5 Controlled
9 Jetty – B6 Controlled
Note:
Controlled soft copy is available at Network Neighborhood/ Entire Network/ KTSBow/
KTSBFileServer/ F_iso9001.
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3.1 SCOPE
This procedure defines all operating instructions, responsibilities and safety measures to
load refrigerated ammonia into vessels.
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)
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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.
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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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.
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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 -25C.
c) Pre-Cooling - reducing shipping line temperature to -27oC
d) Pack line after loading arm connected and leak test is completed.
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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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The Ammonia Export line shall be held under Cold Holding conditions
between ships loading, unless otherwise instructed.
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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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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.
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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.
D) Warming Up
The task will be carried out upon completing the above inspection.
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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.
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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.
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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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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.
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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 0.632C. Heat gain within the
ammonia export line is approximately 0.09C and heat gain
from the non-insulated loading arm and ships manifold is
approximately 0.012C giving an approximate total
temperature rise of 0.734C.
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.
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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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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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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
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Doc. No : KTSB/OM-PASB-ALA-02
Rev No : 5
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.
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KTSB Loading Master
Name :
Date/Time :
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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
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 .
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
Rev No : 04
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 .
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
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ATTACHMENT VIII
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