Chapter VIII OPERATION

OPERATION
Internal working Group (IWG) Meeting
IWG Meeting is generally held with representatives fro Pipeline !ead
"#arter$ Noida$ Refineries !ead "#arters$ New %elhi$ ONGC$ &hipping towards
the end of every onth' %etailed dis(#ssions are held and inforation is
f#rnished on the following)
* Review of Operational perforan(e d#ring (#rrent onth'
* Tan+ers (alling at Vadinar d#ring the following onth for #nloading
different varieties of iported as well as ,!-Panna (r#de'
* Monthly pro(ess Nos' .&PM Nos'/ of vario#s Refineries i'e' GR$ MR 0 PR'
* &h#tdowns planned in &MP1 as well as refineries for vario#s reasons i'e'
aintenan(e$ #llage pro2le et(' d#ring the following onth'
* Any other inforation of relevan(e to pipeline operation$ vi3'$ (ois4
sioning- de(oissioning of storage tan+s for sl#dge reoval$ M0I of
tan+s et('

Central Despatc Control
Central %espat(h Control$ Ga#ridad$ (losely onitors the p#ping operations
in &MP1 to ens#re that the p#ping s(hed#le de(ided is adhered to and the
set targets are a(hieved' The vario#s f#n(tions$ in this regard (arried o#t 2y
operation wing of &MP1 !ead "#arters$ Ga#ridad in(l#de the following)
* Coordination with Ref' !'"$ N'%elhi$ &hipping a#thorities$ Vadinar on
tan+ers at the &,Ms at Vadinar on parti(#lars of tan+ers vi3'$ nae of
tan+er$ the type of (r#de 2ro#ght 2y tan+er$ ,ill of 1ading 5#antity et('
* 6i7ing the tan+er 2erthing priority in (ons#ltation with Refinery !ead
"#arters$ Noida'
* Monitoring of tan+er dis(harge operation'
%e(iding the re(eiving se5#en(e for (argo dis(harge'
Preparation of P#ping &(hed#le 2ased on Tan+er Inp#ts and Monthly
Pro(ess Plan of individ#al Refineries re(eived fro Refinery !5$ New
%elhi'
* Coordination with individ#al refineries for ipleentation of p#ping
s(hed#le'
* Monitoring of tan+ #llage at Vadinar$ Viraga$ Cha+s#$ 8oyali$
Math#ra and Panipat'
1
* Review of sto(+ position at Vadinar- Viraga- Cha+s# and a+ing any
alteration in p#ping s(hed#le depending on operational e7igen(ies-
(onstraints and (r#de oil deands at the refineries'
4 Planning and onitoring p#ping of spe(ial type of (r#des fro Vadinar
and rea(hed to Refineries as it is witho#t interi7ing with other (r#des'
- Integrity testing of ainline and asso(iated fa(ilities
- Preparation of Cr#de Mi7 (oposition'
* Giving (learan(e for M-1 e5#ipent aintenan(e s#(h as 9:::- ;:::-
<:::- =:::- >?:::- ?;::: !R&$ +eeping in view the operational
re5#ireents'
* Coparison of p#ped ,&0W and density fro Vadinar with
delivered ,&0W and density at Math#ra$ 8oyali and Panipat'
* Monitoring of pipeline start #p-sh#tdown'
* G#iding operational personnel at different p#p stations as well as
terinals for aintaining desired operational paraeters towards
a(hieving the targeted thro#ghp#ts'
* Gathering inforation on operational (onstraints vi3' e5#ipent 2rea+4
downs et(' and ta+ing #p with the (on(erned departent to over(oe
the (onstraints'
* Appraising the Manageent on day4to4day operations- operational
(onstraints et('
* Oil a((o#nting and re(on(iliation'
* Planning and onitoring of pipeline pigging operations'
* Monitoring of (o#ni(ation syste'
* C#stos-Port (learan(e foralities'

The agen(ies involved in (arrying o#t the a2ove operations in(l#de 2esides
IOC$ 8andla Port Tr#st$ Tan+er Master- Chief Engineer$ &hipping Agents$
&#rveyors$ C#sto a#thorities$ &CI M#2ai and ONGC M#2ai' Ne(essary
(oordination is re5#ired to 2e (arried o#t aong these agen(ies for sooth
tan+er operation'
%etailed 5#ality pro(ed#res are given in Pro(ed#re and Wor+ Instr#(tion
Man#al on @OperationsA whi(h are as followsB
TAN! "ARM OPERATION
GENERA#
Tan+ ga#ging'
* Meas#reent of water 2otto$ (r#de teperat#re$ ta+ing saples for
deterining density'
* Tan+ i7ers operation'
* Allo(ation of tan+s 2ased on type of (r#de and (opati2ility with
other (r#des' The (r#de oils generally re(eived are ,o2ay !igh$
Panna$ Oan ,lend$ &#e3 ,lend$ Ara2ian Mi7$ Nigerian$ &#e3 Mi7$ 8PC$
Cpper Da+#$ Es(ra2os$ %#2ai (r#de$ ,onny 1ight$ Iran Mi7$ Girasol$
Od#d#$ and Ratawi et('
%etailed 5#ality pro(ed#res are given in Pro(ed#re and Wor+ Instr#(tion
Man#al on @OperationsA'
2
$a%inar Tank "ar&
* A((o#nting of (r#de 2ro#ght 2y tan+ers and O(ean 1osses'
* 1ining #p of tan+ for re(eipt of (r#de oil fro tan+er'
* &wit(hing over of tan+s'
* Re(eipt of interfa(e'
* &ettling tie'
* R#nning of stirrers 2efore withdrawal of (r#de'
* Water draining operation
1ining #p of tan+ for p#ping operation
4 Tan+ Ga#ging

$ira&ga& Tank "ar&
* 1ining #p of tan+ for re(eipt of (r#de'
* P#ping fro tan+s into VC-V8 &e(tions #sing 2oosters'
* Inter tan+ transfer'
* 1ining #p of tan+s and p#ping the re5#ired 2at(h lengths of parti(#lar
types of (r#de into the pipeline'
* Tra(+ing of interfa(e and diverting the (r#de to the noinated tan+'
R#nning of stirrers 2efore withdrawal of (r#de'
Tan+ Ga#ging'

Caksu Tank "ar&
* 1ining #p of tan+ for re(eipt of (r#de'
* P#ping fro tan+s into CP-CM &e(tions #sing 2oosters'
* Inter tan+ transfer'
* 1ining #p of tan+s and p#ping the re5#ired 2at(h lengths of parti(#lar
types of (r#de into the pipeline'
* Tra(+ing of interfa(e and diverting the (r#de to the noinated tan+'
R#nning of stirrers 2efore withdrawal of (r#de'
4 Tan+ Ga#ging'
Ter&inal Operation
The different operational a(tivities at the Terinal &tations in(l#de the
following)
* Maintaining (onstant (onta(t with Central %espat(h Control$ Ga#ridad
and Refineries a#thorities on ipleentation of p#ping s(hed#le and
to a+e any (hange in p#ping prograe d#e to any e7igen(ies'
* Maintaining (onta(t with Central %espat(h and the #pstrea station
2efore res#ption of p#ping operation d#ring p#ping and 2efore
stopping of p#ping operation 2y the #pstrea station.s/'
* Coordination with refineries and lining #p of tan+s for re(eipt of (r#de'
* Tra(+ing of interfa(e and diversion of (r#de to the noinated tan+'
- Physi(al dipping and sapling of tan+s$ 2efore and after the
(opletion of re(eipt of (r#de$ along with refinery personnel to
assess the 5#antity re(eived'
3
* Opening-Closing of PCV and aintaining the re5#ired 2a(+
press#re as advised 2y Central %espat(h or #pstrea station to
a(hieve the desired thro#ghp#ts and operational re5#ireent'
* Physi(al dipping of tan+s$ 2efore and after the (opletion of re(eipt of
(r#de$ alongwith refinery personnel to assess the 5#antity re(eived'
* Opening-Closing of PCV and aintaining the re5#ired 2a(+ pres#re as
advised 2y Central %espat(h to a(hieve the desired thro#ghp#ts'
* Conveying daily (r#de sto(+ position at the refinery and other
operational data to (entral despat(h$ Ga#ridad'
%etailed 5#ality pro(ed#res are given in Pro(ed#re and Wor+ Instr#(tion
Man#al on @OperationsA'
'tation Operation
All the p#p stations of &MP1 syste have engines as prieovers for the
ainline p#ps'
The a(tivities involved in station operation in(l#de the following)
* Maintenan(e of ade5#ate air press#re in starting air 2ottles of all the
engines'
* Ens#ring the availa2ility of e5#ipent and ade5#ate sto(+ of f#el and
l#2e oil for r#nning of the station'
* Maintaining (onta(t with Central %espat(h and #pstrea-downstrea
stations for starting-stopping the ainline p#ping #nits'
* &tarting$ r#nning and stopping the engines and aintaining the
re5#ired flow paraeters to a(hieve the desired thro#ghp#ts as per the
advi(e of Central %espat(h'
* &(hed#ling of engines r#nning in s#(h a way so that s(hed#le
aintenan(es do not overlap'
* Attending to the r#nning aintenan(e of the station'
* 1ogging of station-e5#ipent paraetes and onitoring the health of
the e5#ipents while r#nning'
* Assisting the Central Maintenan(e tea in regard to s(hed#led
aintenan(es'
* &tarting and stopping the Eergen(y Generator in (ase of power
pro2le to ens#re (ontin#o#s and safe operation of pipeline'
* To aintain and infor &MP1$ !O regarding the p#r(hase$ draw off and
(ons#ption of diesel$ (r#de$ l#2ri(ants et('
* Ro#tine operation and (he(+ing of fire fighting syste vi3' Engine-
P#p- Motor for perforan(e$ water level in fire water pond et('
* Operation of s#p p#p as and when re5#ired'
* Trial r#n of eergen(y generator and fire fighting #nits in every shift'
* Cond#(ting fire o(+ drill$ ro#tine (he(+ing of fire siren and other fire
applian(es'
* &tarting$ r#nning and stopping of (entrif#ge$ air (opressor$ diesel
#nloading p#p as per re5#ireent'
* Copiling and inforing operational data$ daily thro#ghp#t- (r#de
sto(+ position in different tan+s$ e5#ipent r#nning ho#rs$ sh#tdown
details et(' to Central %espat(h'
4
* Maintaining proper re(ord of f#el-l#2e oil (ons#ption of engine and
other e5#ipent'
* Ens#ring the PCV$ &#rge Relief &yste and other essential e5#ipents
li+e flow eters- totalisers are aintained in good (ondition'
* Reg#lar (ali2ration of t#r2ine eters and (ross (he(+ing NRC readings
with dip eos'

&oe of the fa(tors whi(h affe(t the flow rate and re5#ire (onstant onitoring
and advi(e to other stations are given 2elow)
>' 6ail#re of e5#ipent'
?' Power fail#re'
9' Voltage dips$ res#lting in the otors drawing higher (#rrent has to 2e
reedied 2y lowering the engine RPM there2y red#(ing the flow rate'
;' The p#p sele(tion is ade on the 2asis of a fi7ed flow rate and
differential head at the rated RPM' Th#s when a lighter (r#de is in the
syste the line press#re will 2e lower and in (ase of a heavier (r#des
in the line the flow rate will red#(e as it will offer greater resistan(e'
E' When the heavier (r#de is at the p#p station$ the station develops
higher press#re and in (ase the linefill has lighter (r#de$ the flow rate
tends to in(rease res#lting in low s#(tion fail#re of ne7t station'
<' %#ring the winter onths$ when the p#ping teperat#re is lower$
(r#de density and vis(osity goes #p and the flow rate falls down'
P#ping of higher flow rates re5#ires higher dis(harge press#re whi(h
ay often res#lt in fre5#ent triping of the syste d#e to the MAOP
liitations'
%etailed 5#ality pro(ed#res are given in Pro(ed#re and Wor+ Instr#(tion
Man#al on @OperationsA'
TAN!ER OPERATION AGENCIE' IN$O#$ED
%ifferent agen(ies involved in tan+er #nloading operation at Vadinar and their
role in 2rief is des(ri2ed as #nder)
() !an%la Port Trust (!PT)

.A/ Arranging Pilots
* To 2ring the tan+er fro o#ter an(horage to &PM'
* To oor the tan+er to &PM'
* To stay on tan+er for giving instr#(tions to p#ll 2a(+ vessel and to
eet any e7igen(ies vi3'$ deooring of tan+er in (ase of 2ad weather$
poll#tion (ontrol in (ase of lea+age of (r#de oil et('
* To deoor the vessel after (opletion of dis(harge'
* To (ast off the vessel #pto the o#ter an(horage'

5
.,/ Arranging transportation for
* IOC ,oarding Offi(er$ &#rveyor$ &hipping AgentFs representatives fro
Getty to &PM and vi(e versa to attend the tan+er dis(harge operation'
* Tan+er (rew for shifting of edi(al aid-provisions et('
* Transporting fresh water as per the re5#ireent of tan+er'

.C/ Providing relia2le (o#ni(ation 2etween 8PT Control$ IOC Control and
tan+er' 8PT Control (onta(ts the vessel in advan(e (onveys the (orre(t
ETA-(ast off tie to IOC (ontrol'
.%/ Monitoring the dis(harge operation 2y having (ontin#o#s (onta(t with
tan+er and IOC Control'
*) 'ipping Agents

* ,oo+ing of Pilot eo with 8PT'
* Port foralities for 2ringing the vessel to &PM and to (lear the vessel
fro Vadinar port'
* C#sto foralities) To infor (#stos a2o#t the arrival of the vessel$
to (oplete the (#sto foralities to 2ring the vessel to &PM and to
(ast off the vessel fro Vadinar Port after the dis(harge operation'
* Conversion of tan+ers)
To arrange for (onversion of tan+ers fro 6oreign to Coastal and vi(e4
versa'
* To arrange fresh water thro#gh 8PT as per the re5#ireent of tan+er'
* To arrange edi(al aid-provisions et(' for the tan+er personnel'
* &#2ission of iport general anifesto to C#sto a#thorities'
+) 'ur,e-ors

A' On Tan+ers

* Assessent of Cr#de Oil-Water 2ro#ght 2y tan+er'
* Colle(tion of representative saples fro all the tan+s on 2oard the
tan+er and to eas#re the spe(ifi( gravity and teperat#re of (r#de$ if
re5#ired' In general$ the spe(ifi( gravity of (r#de oil is eas#red in the
la2oratory at Vadinar'
* Contin#o#s onitoring of dis(harge operation'
* Inspe(tion of all tan+s in(l#ding slop tan+ on the after (opletion of
dis(harge$ iss#e of epty (ertifi(ate et('
,' &hore Tan+s

* Initial dipping of noinated tan+ for re(eipt of (r#de alongwith the
C#stos representative'
* Monitoring (r#de re(eipt in shore tan+s d#ring dis(harge operation and
ens#ring the 5#antity dis(harged fro tan+er and re(eived in shore
tan+s tallies 2y ta+ing RTG -physi(al dips at reg#lar intervals'
* 6inal dipping of shore tan+s after proper settleent to assess the
5#antity of (r#de and water re(eived in shore tan+s'
6

.) Tanker (Master/Cie0 O00icer)

* To (onvey inforation on dis(harge anifold si3e and re5#ireent of
red#(er$ if any$ to IOC Control'
* Assisting the Pilot in tan+er ooring and deooring operations'
* To f#rnish the following do(#ents to IOC ,oarding Offi(er'
,ill of 1ading
"#ality Certifi(ate and 1oadport saples
Other do(#ents as detailed later #nder post 2erthing operations'
* Providing win(h-(rane for (onne(ting and dis(onne(ting fle7i2le hose
strings to tan+er anifold'
* Assessent of (r#de oil-water on 2oard the tan+er alongwith s#rveyors
and IOC ,oarding Offi(er'
* To dis(#ss and finalise p#ping porgrae with IOC ,oarding Offi(er'
* To +eep fire fighting e5#ipents on 2oard the tan+ers in tip top
(ondition to eet any event#ality'
* Convey (r#de oil 5#antity dis(harged at reg#lar intervals to IOC
,oarding Offi(er to verify with shore re(eipt 5#antity'
* Infor IOC ,oarding Offi(er in (ase p#ping is dis(ontin#ed d#e to any
pro2le on tan+er'
* To +eep (onstant (onta(t with IOC Control and 8PT d#ring tan+er
dis(harge operation'
* To a+e arrangeents for ro#nd the (lo(+ (lose wat(h on &PM d#ring
dis(harge operation'
* To follow the Pilot instr#(tions and (oordinate with &#rveyor$ &hipping
Agents and IOC ,oarding Offi(er for sooth operation of tan+er'
* To follow the Port R#les and Reg#lations stri(tly'
* To (onvey e7a(t tie of starting and stopping of dis(harge operation'

TAN!ER OPERATION $ARIO1' ACTI$ITIE' IN$O#$ED
%etailed 5#ality pro(ed#res are given in Pro(ed#re and Wor+ Instr#(tion
Man#al on @OperationsA'
Prior to Tanker Arri,al
Inforation on ETA of tan+er is re(eived H?-;=-?; ho#rs in advan(e
fro the Master of the tan+er' As soon as this inforation is re(eived)
.a/ Infor the shipping Agents to 2oo+ Pilot Meo with 8PT in
(ons#ltation with Central %espat(h'
.2/ Infor C#stos a#thorities and iss#e re5#est letter for perission
to #nload the (r#de 2ro#ght 2y the tan+er into shore tan+s'
.(/ Infor &#rveyors'

* Conta(t the Master of tan+er and en5#ire the tan+ers (argo dis(harge
anifold diensions' If red#(er is re5#ired for (onne(ting the floating
hoses to tan+er anifold$ the sae sho#ld 2e +ept ready'
* &#2it wharfage and overtie papers to 8PT' .%etails of tan+er-(argo$
2ill of lading 5#antity$ loadport et('/
* %e(ide whether the tan+er is to 2e 2erthed in &PM I or &PM II'
7
Pre23ert Cecks on 'PM
* Inspe(t the ,#oy for any lea+s in prod#(t distri2#tion #nit'
* Inspe(t the ooring hawsers and ens#re that they are free fro any
entangleent'
* Inspe(t the floating hose strings and ens#re that they are free fro any
overlapping- +in+s et('
* !and4over the ooring gears to the in(oing tan+er at the o#ter
an(horage'
* Tow the floating hoses away fro the path of approa(hing tan+er 2y
foring a loop'
Mooring o0 tankers
* While everything is ready at the 2#oy$ give (learan(e to the tan+er for
2erthing'
* Maintain (onta(t with tan+er$ pilot and ,#oy operation (rew while
2erthing'
* !andover the ooring ropes to 8PT Mooring vessel in free floating
(ondition'
* Ens#re that the tan+er is oored to the 2#oy with 2oth ooring ropes'

Post 4erting Operation
* As soon as the tan+er is oored$ tow the floating hose strings along4
side the tan+er'
* 8eep liaison with &hipFs Chief Offi(er to pi(+ #p hoses and (onne(t to
the tan+er anifold'
* Colle(t the following do(#ents fro Master of the tan+er)
* Noti(e of readiness
* ,ill of 1ading
* Certifi(ate of origin
* Certifi(ate of 5#antity and 5#ality'
* 1oad tie &heet
* 1oad Port #llage report
* MasterFs re(eipt for (r#de oil saples
* &ealed and la2elled tins of 1oadport saples
* Cllage report pertaining to 1oad Port or Previo#s Port of (alling
and on42oard 5#antity when ship sailed fro Previo#s Port'
* After re(eipt of do(#ents (arry o#t the following alongwith
&#rveyors and Chief Offi(er of tan+er'
* "#antifi(ation of (r#de on42oard the tan+er 2y #llage
eas#reents'
* Water on42oard 2y physi(al dipping of ea(h tan+ on 2oard the
tan+er'
* Meas#reent of teperat#re and density of (r#de oil
.representative saples to 2e (olle(ted fro ea(h tan+/'
If the on42oard 5#antity assessed as a2ove falls short of ,-1 5#antity$ give
Protest letter' If water on 2oard e7(eeds >:: 81 give protest letter to Master
of tan+er'
8
Tanker Discarge Operation
* Conta(t IOC Control and ens#re that shore tan+ is lined #p for re(eipt of
(r#de oil fro the tan+er' .The tan+ is lined #p after ta+ing dips in
presen(e of C#stos as well as &#rveyorFs representatives/'
* After getting (learan(e fro IOC Control a2o#t lining #p of shore
tan+.s/$ iss#e letter to Chief Offi(er and infor hi to gear #p the
p#p' %is(#ss with hi a2o#t the dis(harge pattern'
* After getting (learan(e fro tan+er$ C#stos and &#rveyors$ infor IOC
Control as well as 8PT Control a2o#t starting of dis(harge
operation'
* Ens#re that all the valves on &PM$ and the floating hoses are +ept open'
* &tart dis(harge operation .2y opening of tan+er anifold valves/ and
infor 8PT as well as IOC (ontrol regarding starting of dis(harge
operation'
* Monitor the anifold dis(harge press#re and the flow rate aintained
2y the tan+er ho#rly'
* Infor IOC Control to (he(+ #p shore re(eipt and flow rate'
* If the flow rate is low$ +eep the senior IOC Offi(ers at Vadinar
infored and iss#e Protest letter to the Chief Offi(er'
* When the re5#ired 5#antity of (r#de is re(eived the tan+$ ens#re fro
IOC Control that the se(ond tan+ is lined #p for re(eipt of (r#de fro
the tan+er'

Post Discarge Operations
* On(e the dis(harge operation is (opleted infor IOC Control to (lose
the inlet valves of the tan+ #nder re(eipt'
* Inspe(t the tan+s on 2oard the tan+er to ens#re that the sae are
epty for iss#e of epty tan+ (ertifi(ate' In (ase$ the tan+er is #na2le
to p#p or otherwise and the (r#de oil is 2eing on4(arried to the
se(ond Port of Call$ re(ord the #llages$ water dips and (al(#late the
5#antity that is 2eing on4(arried' 8eep IOC senior offi(er at Vadinar
infored of the sit#ation' The 5#antity on4(arried sho#ld 2e Iointly
(ertified 2y the Master of the Tan+er$ &#rveyors and IOC representatives
and this sho#ld 2e in(orporated in tan+erFs #nloading report'
* Close the valves on &PM as well as floating hoses'
* %is(onne(t the floating hose strings'
* Iss#e Clearan(e Certifi(ate to the Master of the tan+er to fa(ilitate
release of tan+er'

De&ooring o0 tanker
* On(e tan+er dis(harge is (opleted$ infor the Pilot to deoor the
tan+er fro the ,#oy'
* %#ring (asting off of the tan+er$ (are sho#ld 2e ta+en to ens#re that
the floating hose strings do not (oe #nder the propeller of the
tan+er'
* On(e the tan+er is (ast off$ (olle(t the ooring gear fro the tan+er
at the o#ter an(horage'
9
* After allowing ?; ho#rs settling tie$ 5#antify the re(eipt of (r#de in
the shore tan+ in presen(e of &#rveyorFs and C#stoFs
representatives'
10
#INE "I## CA#C1#ATION "OR 'MP# (M/#5#/#5 'tn 6 T/")

MAIN#INE #INE"I## IN !#'

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TOTA# 78+789):.9
T/" PIPING
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1-6 O6 M-1$ 1-1 &TN' PIPING .I'E' PIPING CN%ER PRE&&CRI&E%
CON%ITION/
EHHH99'H?<
E = 4>D
TOTA# #/" TO 4E CON'IDERED "OR OI# ACCO1NTING
(INC#1DING M/# 6 'TN PIPING 1NDER PRE''1RI'ED
CONDITION >T/" PIPING)
7<89*<):<8
11
Docu&entation
%o(#ents as detailed 2elow are prepared and f#rnished 2y IOCFs ,oarding
Offi(e'
* 6ire fighting (he(+s .to 2e ens#red for safe operation of tan+er/'
* 1etter of Readiness to 2e iss#ed to the Master of the tan+er for starting
of dis(harging operation'
* Tan+er #llage report to 2e prepared and e7(hanged with s#rveyors and
tan+er personnel and ens#ring that the (argo 2ro#ght 2y the tan+er
is 5#antified properly'
* Protest 1etter to 2e given to Master of tan+er in (ase there is differen(e
in 5#antity assessed with respe(t to the ,ill of 1ading 5#antity and also
in (ase the water on 2oard the tan+er is in e7(ess of >:: 81s'
* Protest letter in (ase$ rate of tan+er dis(harge$ dis(harge press#re of
tan+er anifold is less than re5#ired'
* Epty Certifi(ate after (he(+ing the tan+s on the tan+er to 2e given to
&#rveyor and the tan+er Master'
41N!ERING O" '@IP' MOORED TO 'PM
The aIority of &PM Terinals (onsider that the 2#n+ering of ships 2y large
whilst dis(harging at &PMs sho#ld 2e dis(o#raged as it introd#(es #nne(essary
additional ris+' If peritted$ it sho#ld only 2e #nder stri(tly (ontrolled
(ondition and after the terinal operators have satisfied theselves that the
(ondition of the 2arge and pro(ed#re adopted are satisfa(tory' Indeed the
aIority of &PM terinals prohi2it the ooring of any (raft alongside whilst
the ship is on the 2#oy' All 2#n+ers-stores operations are norally re5#ired to
2e (arried o#t prior to 2erthing or after leaving the 2erth and ost Port
A#thorities or Terinal Reg#lations in(orporate e7pli(it provisions to this
effe(t' Aongst (onsiderations that #st 2e ta+en into a((o#nt at &PMs are)
>' Miniisation of fire 0 safety ris+s'
?' Need for #nipeded eva(#ation fro the 2erth in an eergen(y'
9' Possi2le in(rease in !awser loadings'

In (on(l#sion$ whilst 2#n+ering via the &PM is an a((epted safe pra(ti(e$ the
s#pply of 2#n+ers via ,arge (oaster d#ring (argo operations is not peritted
at any offshore terinal'
At o#r &PM Terinal$ IOC anageent stri(tly prohi2its the 2#n+ering of
ships oored to &PMs'
OCEAN #O''
De0inition an% 'cope
O(ean 1oss is the differen(e 2etween the 5#antity shipped as per the ,ill of
1ading and 5#antity re(eived in shore tan+s at the destinations' These losses
(an 2e f#rther (lassified into three spe(ial (ategories as #nder)
12
#oa%ing #ossA
These are losses whi(h o((#r d#ring loading operations of the tan+er'
$o-age #ossesA
These are losses that o((#r on 2oard the 2etween the Port of 1oading and Port
of %is(harges or 2etween two ports of dis(harge'
1nloa%ing #ossesA
These are losses whi(h o((#r at the dis(harge ports the (argo is 2eing
#nloaded' Th#s the ter O(ean 1oss (an 2e (orrelated with three spe(ial
(ategories as #nder)
O(ean 1oss L 1oading 1oss M Voyage 1oss M Cnloading 1oss
This (overs 2oth the physi(al loses d#e to vario#s fa(tors as well as the
operation losses arising fro errors in eas#reents$ sapling$ a((o#nting
et('
In the noral (o#rse$ the ,ill of 1ading is 2ased on the eas#reent of the
shore tan+s fro whi(h the (argo is loaded' In (ertain (ases$ however$ the
(argo ay 2e loaded at soe an(horage point 2y transhipent fro one
vessel to another' In s#(h (ases$ the ,ill of 1ading of the da#ghter vessel .i'e'
re(eiving vessel/ will 2e 2ased on #llages of the Mother vessel 2efore and
after the transhipent operation'
"ACTOR' A""ECTING #O''E'A
#OADING #O''E'A
(a) $esselBs E?perience "actorA

Every vessel has an e7perien(e fa(tor whi(h represents the noral variation
2etween the shore tan+ eas#reent and the shipFs eas#reent for a
parti(#lar level of (argo loading' As ost tan+ers are generally loaded to the
f#ll (apa(ity$ it is often e7pressed as a ratio of the 5#antity as per shipFs
eas#reents to the 5#antity as per the shore tan+ eas#reents' This is a
fair inde7 of the (orre(tness or otherwise of the loading of the vessel' In (ase$
a gain is re(orded on loading$ a (orresponding loss wo#ld 2e e7perien(ed
d#ring the #nloading operation$ or vi(e versa'
(3) Migration at 'ipBs / 'ore en%

At loading terinals$ n#2er of tan+s ay 2e si#ltaneo#sly involved in
loading of vessels at different Ietties' Cnless ea(h loading syste is positively
segregated$ the possi2ility of igration of prod#(t fro one syste to
another (annot 2e r#led o#t$ parti(#larly in view of the high press#re-flow
rates at whi(h the loading operations are (arried o#t' This applies e5#ally to
the pipeline anifolding at the shipFs end espe(ially when the vessel is
13
(arrying ore than one grade of (r#de or prod#(t whi(h re5#ire to 2e
segregated'
(c) #eaks in pipeline s-ste&

This (an give rise to s#2stantial variations parti(#larly in the (ase of #nder
gro#nd se(tions of the line$ in whi(h (ase the lea+s ay not 2e easily
identified'
(%) #ine 'lackness

In 2etween two s#((essive transfer operations$ it is possi2le that the loading
line fro the noinated tan+s #pto the tan+er Ietty ay 2e sla(+' The
assessent of the ,ill of 1ading wo#ld 2e erroneo#s to this e7tent'
(e) Pil0erage

This (an o((#r either at shore end or at shipFs end and re5#ires (onstant
alertness on the part of the &#pervisors at Terinal and tan+er ends' Trap
vessels plying #nder flags of (onvenien(e are ore prone to s#(h a(tivity'
(0) Gauging ErrorsA

This (o#ld o((#r either at the shore end or at the ship end and ay res#lt
fro one of the #nderentioned (a#ses)
i/ !#an errors'
ii/ E5#ipent errors'
iii/ Pro(ed#ral errors'

(g) Assess&ent o0 Water

1osses (an o((#r when water is re(orded as (argo d#e to one or ore of the
#nderentioned (a#ses)
i/ Inade5#ate settleent tie$ parti(#larly where loading operation
has 2een (arried o#t on fl#shing lines
ii/ !#an errors in re(ording of water parti(#larly in (argos of (r#de oil
and heavy f#el oils'
() Calculation Errors

This (o#ld o((#r at 2oth ship and shore ends on a((o#nt of one or ore of the
#nderentioned fa(tors)
i/ Cse of wrong Cali2ration (harts'
ii/ Cse of ina((#rate (onversion fa(tors .e'g' ,arrels to C#2i( Metres/
(i) 1se o0 "low Meters

Altho#gh ,ill of 1ading are norally 2ased on eas#reents of the shore
tan+s of the loading terinals$ there are (ertain terinals at whi(h loading is
14
2ased on vol#etri( deliveries thro#gh (ali2rated flow eters' &#(h loadings
ay give rise to erroneo#s res#lts and a2noral variations #nless the flow
eters are @provedA periodi(ally d#ring the loading operation' In s#(h (ases$
a#toati( inline saples are often #sed to deterine density and other
(hara(teristi(s s#(h as ,&0WB and it is iportant that these are also in proper
wor+ing (onditions$ if the ,ill of 1ading is to 2e (orre(tly assessed'
(C) Transip&ent o0 Cargo

As indi(ated earlier$ loading of tan+ers (an also 2e (arried o#t 2y eans of
transhipent fro one vessel to the other 2y 2ringing the two vessels to the
adIa(ent 2erths$ do#2le 2an+ing the vessels at the 2erth$ or do#2le 2an+ing
the vessels at an an(horage point' As already indi(ated$ the ,ill of 1ading in
s#(h (ases is generally 2ased on the #llage of the other vessel 2efore and
after transhipent #nless otherwise spe(ified in the (ontra(t'
This is prone to errorsB parti(#larly where transhipents are (arried o#t at
#nprote(ted an(horages at whi(h 2oth the vessels ay 2e rolling or pit(hing
on a((o#nt of prevailing weather (onditions'
$ODAGE #O''
(a) Nature o0 Cargo

Certain petrole# prod#(ts are highly volatile (opared to other
petrole# prod#(ts' !en(e$ Transit 1oss wo#ld to soe e7tent 2e
depending on the inherent nat#re of the prod#(t and the transit tie'
(3) Parcel 'iEe

At ties the voyage losses ay 2e higher than noral 2e(a#se of
saller par(el si3e' This wo#ld apply parti(#larly to volatile (argoes
whi(h are (arried in tan+s that reain sla(+ 2e(a#se of the 5#antity of
(argo vis4a4vis the (apa(ity of the tan+erFs tan+s'
(c) Inter tanks trans0er

Variations in voyage (o#ld o((#r d#e to inter tan+ transfers (arried o#t
2y the Master either for triing vessel or for ens#ring the safety of
the vessel d#ring the voyage'
The variations in 5#antities in s#(h (ases ay 2e related to the VesselFs
E7perien(e 6a(tor referred to in ite .a/ #nder the head @1oading
1ossesA a2ove' !owever$ it re5#ires to 2e investigated'
(%) Pil0erage

This (an o((#r d#ring the voyage and hen(e any a2noral variations
re5#ire investigation parti(#larly with referen(e to any variations in
2#n+er 5#antities 2etween the loading-dis(harge port'
15
(e) $o-age #oss
This (an also o((#r on a((o#nt of a((ident (ases in whi(h the vessel
ay 2e involved in a Mid4sea (ollision with soe other vessel or
o2Ie(t leading to r#pt#re of the wing tan+s'
(0) Gauging errors on 3oar% te ,essel at eiter #oa% Port or
Disport or 3ot

This ay 2e on a((o#nt of one of the #nderentioned (a#ses)
i/ !#an errors'
ii/ E5#ipent errors'
iii/ Pro(ed#ral errors'

(g) Calculation Errors

This ay arise fro one or ore of the #nderentioned (a#ses)
i/ Cse of wrong (ali2ration (harts'
ii/ Cse of ina((#rate (onversion fa(tors'
iii/ !#an errors'

1nloa%ing #oss
.a/ VesselFs E7perien(e 6a(tor ) A variation 2etween the 5#antity dis(harged
and the re(eipt in the shore tan+s (o#ld 2e d#e to the vesselFs e7perien(e
fa(tor and wo#ld 2e the reverse of the variations e7perien(ed at the Port
of 1oading'
.2/ Migration of prod#(t at either the ship or shore ends arising fro
inade5#ate fa(ilities for segregation'
.(/ 1ea+s in dis(harge line systes parti(#larly in #ndergro#nd se(tions'
.d/ Pilferage ) This (o#ld o((#r along the ro#te of the line or at inter4(hange
points #nless proper patrolling and (he(+ing systes are enfor(ed'
.e/ Ga#ging errors at ship and shore ends whi(h ay 2e on a((o#nt of one
or ore of the #nderentioned (a#ses)4
i/ !#an errors'
ii/ E5#ipent errors'
iii/ Pro(ed#ral errors'

Additionally at shore terinals where 5#i(+ dipping is resorted to for
release of the tan+s for other operations$ errors ay o((#r either on
a((o#nt of inade5#ate settleent tie or distortion in tan+ teperat#res
in shore tan+s in whi(h no (entre hat(h is availa2le for re(ording of tan+
teperat#res'
.f/ Assessent of water ) Any in(orre(t assessent of free water in the
shore tan+s either 2efore or after re(eipt of the (argo (an res#lt in
16
in(orre(t assessent of re(eived 5#antities and (onse5#ential a2noral
variations'

.g/ Cal(#lation Errors ) This ay 2e ainly on a((o#nt of referen(e to the
wrong (ali2ration (hart or d#e to errors in reading the Cali2ration
Charts-Conversion fa(tors'
General "actors a00ecting Ocean #osses
(a) Carriage in Centre tanks ,s) Wing tanks

The Centre tan+s on2oard are 2etter ins#lated fro the environent
than the wing tan+s' Th#s$ vessels in whi(h the wing tan+s are
designed only for segregated 2allast will not e7perien(e wide
teperat#re differen(es that are otherwise o2served where prod#(t is
(arried in wing tan+s'
(3) Inert Gas

On vessels fitted with inert gas$ I#di(io#s tiing and (ontrol of the tan+
press#risation (an help to iniise venting of the vapo#r to the
atosphere' 6or this advantage$ we wo#ld 2e solely dependent on the
e7pertise of the tan+er (rew'
(c) 1llage $olu&es

&la(+ tan+s will s#ffer larger treating losses in ters of vol#e than
f#ll tan+s' !en(e$ we sho#ld endeavo#r not to allow sla(+ tan+s d#ring
(arriage of volatile (argos'
(%) $o-age Duration

In volatile prod#(ts$ transit losses ro#ghly proportional to the n#2er of
2erthing (y(les' The total evaporation loss wo#ld th#s 2e proportional to
the voyage d#ration'
(e) Meto% o0 Con,ersion o0 $olu&es to Tonnage

There are different ethods eployed for (onversion of vol#e to
tonnage s#(h as A&TM-IP Method$ &oviet Method et(' %epending on the
density range of the (argo and the variation 2etween the A&TM-IP
Methods and those #sed 2y &oviet-East E#ropean (o#ntries (o#ld range
fro :':= to :'>EN of the ,ill of 1ading 5#antity'
(0) 'ingle/Multi Port Discarge

Generally losses on single port dis(harge are lesser as (opared to
losses on M#ltiPort dis(harge operations' This is ainly on a((o#nt of
the in(rease in the n#2er of ga#ging operations whi(h ay in(rease
the 5#ant# of loss' The sae theory wo#ld apply even when at a
single port$ (argo is re(eived into a large n#2er of tan+s'
17
Cnder ideal (ir(#stan(es$ the entire (argo fro a tan+er sho#ld 2e
re(eived into one or two tan+s only$ so that errors arising fro #ltiple
ga#ging operations (an 2e red#(ed'
IND1'TRD CE## ON OCEAN #O''
Ind#stry Cell on O(ean 1oss is a 2ody whi(h advises the e2ers of the Cell
ethods and te(hni5#es to (ontrol the O(ean 1oss' All #nits who are re(eiving
iported (r#de are the e2ers of Ind#stry Cell on O(ean 1oss' IOCFs
&hipping %epartent is the Co4ordinator of the Ind#stry Cell'
Tl L .>?'EMH9'EM..,ea of Tan+er/-?/ M .,ow to Manifold %istan(e/ M .6ree
,oard !eight/ M .Rail to Manifold %istan(e/ M .!eight of Manifold a2ove
the %e(+/
ACCEPTANCE CRITERIA O" TAN!ER' ON 'PM AT $ADINAR
%es(ription Of Tan+er Paraeter &PM4I &PM4II
%WT in MT 9$::$::: 9$>E$:::
1OA in M 9E: 9<?'E
,ea in M E< <:
,ow to (enter of anifold in M >H> >=:
Ma7i# free2oard #nder standard 2allast (ondition in M ?:'J ??
&tring length .&T,%/ in M 9>=':9 9?;'?9
C@ARACTERI'TIC' O" CR1DE OI# @AND#ED AT 'PM AT $ADINAR
Type of Cr#de oil Origin 1ordport &pe(ifi(ation
Ara2ian !eavy Rastan#ra
&a#di Ara2ia
Gravity API
&#lph#r Wt'N
Po#r Point 6
RVP P&I
8in' Vis'CstOH: 6
O >:: 6
?H'J
?'=E
?:
H'E
9H':
>J':
Ara2ian Rastan#ra Gravity API
&#lph#r Wt'N
Po#r Point 6
RVP P&I
8in' Vis'CstOH: 6
O >:: 6
99';
>'HJ
9:
9'<
>:'?
<'?E
Ara2ian Medi# Rastan#ra
&a#di Ara2ia
Gravity API
&#lph#r Wt'N
Po#r Point 6 M E
RVP P&I 9'?
8in' Vis'CstOH: 6
O >:: 6
9:'=
?';:
><'?
J';>
,asrah !eavy Persion
G#lf
Gravity API
&#lph#r Wt'N
Po#r Point C
8in'Vis'CstO >: C
C; 0 lighter wt N
?;'H
9'E
9:
=<'9
:':=
18
,asrah 1ight
Ira5
8her4alAaya
Piled str#(t#re
In G#lf Kand#
Gravity API
&l#lph#r wt'N
Po#r Point C
8in Vis'CstO >:C
C; 0 1ighter wt'N
99'H
>'JE
>E
>E':
>'9
,asrah Medi# Mina4al4,a+r
&ea terinal
Persian G#lf
Gravity API
&#lph#r Wt'N
Po#r Point C
8in Vis' Cst O >:C
C; 0 1ighter wt'N
9>'>
?'E=
9:
;>
>'<
%#2ai 6ateh$ CAE Gravity API
&#lph#r Wt'N
8in'Vis'Cst O ?:C
Car2on wt' N
Asphaltene wt N
RVP O ;:C
Po#r Point C
9>':E
?':
>?'=?
;'<?
>'H:
H':E
J
&#e3 Mi7 .Egypt/ Ras &h#+hair Gravity API
&#lph#r Wt'N
6VP psi
Po#r Point 6
Rans Car2on wtN
8in'Vis'Cst O>::6
C>4CE-vol yield
9>'J
;'E?
='9
9E
;';
='H;
E';=
!o#t &ea ,erth Off
Ras Al 8harIi
Gravity API
&#lph#r Wt'N
6VI psi
Po#r Point 6
8in'Vis Cst O =<6
Car2on (ontent wtN
Asphaltene wtN
Wa7 (ontent wtN
9?'=
>'J:
;'<
4>9':
J'==
E':>
>'<E
9'?
8#wait Mina Al Ahadi Gravity API
VI& &CV &e( at >::6
Po#r Point 6
&#lph#r wt'N
9>';
E='>
M E
?'E?
Oan ,lend Mina Al 6ahal Gravity
&#lph#r Wt'N
Po#r Point 6
RVP psi
8in' Vis'&#s'wt <:P6
Kield Vol#e N
9<'9
:'HJ
4 >E
;'?
<;'=
9'<9
Iranian !eavy 8harg Island Gravity
&#lph#r Wt'N
Po#r Point 6
8in' Vis'Cst H: 6
Kield Vol#e N
9>':
>'<E
4 E
><'=;
?'9=
Iranian 1ight 8harg Island Gravity
&#lph#r Wt'N
99'=
>'9E
4 ?:
19
Po#r Point 6
8in' Vis'Cst H:P6
>:'E=
&oviet ,lend Novorossys+
,la(+ &ea
Gravity
&#lph#r Wt'N
Po#r Point C
RVP psi
8in' Vis' at ?:PC
9?'E
>'9=
4?9
;J'?
>>'E
Nigerian "#a I2oe Gravity
&l#lph#r wt'N
Po#r Point C
RVP psi
8in' Vis' at EJPC
9E'=
:'>?
4;E
<':
<'H<
C@ARACTERI'TIC' O" 4OM4AD @IG@ CR1DE OI#
.A/ Physi(o4Chei(al Properties)
%ensity$ 8g-1itre at >EQC :'=?H=
&pe(ifi( gravity at <:-<:Q6 :'=?=?
API gravity at <:Q6 9J'9E
RVP 8g-(
?
at 9=QC :'9;
Po#r Point QC .Neat Cr#de/ M 9:
8ineati( vis(osity Cst at
9H'= QC .>::Q6/ 9'HE
;:':QC 9'?=
E:':QC ?'?;
Water Content$ N Vol' :'>E
&alt Content$ N wt :'::9?
12->::: 22l >>
&#lp#r total$ N wt' :'>H
Nitrogen$ total N wt' :':>E
Car2on Resid#e .Conradson/$ N wt' >'?
Asphaltene$ N wt' :'?=
Ash Content N wt :':>
Wa7 Content$ .E!/$ N wt' >;'H
Congealing point of wa7$ QC E=':
Water 0 &edient 2y Centrif#ge Nwt :'?
Total a(idity$ g-8O!-g :'>E
Inorgani( a(idity$ g-8O!-g Nil
Chara(terisation fa(tor 8.#op/ >>'H:
.,/ Theral properties)
&pe(ifi( heat :';H: 8(al-+g QC at ?:QC
6l#id (ond#(tivity :'>? 8(al-hr M QC
Vapo#r press#re at 9:QC 9'E psi
Theral e7pansion (oeffi(ient :':::=<: Per QC

.C/ Chara(teristi( of Panna-M#+ta Cr#de oil
Method Res#lts
a/ %ensity O >EQC-g-l .weighted average/ IP4<: :'=9:;
2/ API gravity O <:Q6 Psi Cal(#lated 9='=
20
(/ Reid vapo#r press#re O>:: Q6 Psi IP4<J ;':
.deterined for iddle saple of tan+/
d/ Water and &edient N vol' water (ontent Nvol IP4HE
e/ &alt Content as NAC1 loss->::: 22l IP4HH Not (he(+ed
f/ Po#r Point Q6 IP4>E H:
$IRAMGAM 2 C@A!'1 'ECTION
COM4INATION O" ENGINE' "OR DI""ERENT "#OW RATE
$GM 'ID@ A4R !OT RAFO 'EN RAM
"#OW RATE (!ls)/@r)) ((::
No' O6 ENGINE& > > > : : > :
RPM O6 ENGINE& H;< H9= H;< 444 444 H;H 444
%I&C!ARGE PR' 9H'E ;:'? ;< 444 444 ?J 444
&CCTION PR' E'; >;'? ??'< 444 444 ;'E 444
"#OW RATE (!ls)/@r)) (+7:
No' O6 ENGINE& > > > > > > >
RPM O6 ENGINE& H;< H9= H9: H9: H?E H;H 444
%I&C!ARGE PR' 9; E9'? 99 9: ?J'E 99'> ?:'<
&CCTION PR' E'? E'< 9'? E'E < J'E ?:'=
"#OW RATE (!ls)/@r)) (.7:
No' O6 ENGINE& > > > > > > >
RPM O6 ENGINE& H9= <J= H:< H9; H>< <=; <=>
%I&C!ARGE PR' 9;'H 9E'9 ?='E 9>'= 99'< 9;'E ;:'9
&CCTION PR' <'< J'9 9'E ;'E >>'; >>'; >E'<
"#OW RATE (!ls)/@r)) (7;:
No' O6 ENGINE& ? > > > > > >
RPM O6 ENGINE& <=E H?E H9: H>: H?E <=: H9E
%I&C!ARGE PR' E9'H ;H'> ;H'> ;E'J ;E'? ;9'? E?'E
&CCTION PR' H'; ??'H >H'= >='E ??'E ?>'< ?;'>
"#OW RATE (!ls)/@r)) (9::
No' O6 ENGINE& ? ? ? ? > ? ?
RPM O6 ENGINE& H?: H>E <HE H>E <J: <H: <<:
%I&C!ARGE PR' E:'E E>'? E:'? E>'E 9E 9J'< ;J'E
&CCTION PR' ; J >;'? J'H >E J ?:'E
"#OW RATE (!ls)/@r)) *:;:
No' O6 ENGINE& ? ? ? ? ? ? ?
RPM O6 ENGINE& H?J H>E <=H H>< <J< <<J <EJ
%I&C!ARGE PR' ;J'9 E9'; E;'= E>'E 9J'? 9='> ;9'9
&CCTION PR' 9'<E ='E< >;'? J'= H'>9 E'? 9'J
'A#ADA 2 $IRAMGAM 'ECTION
COM4INATION O" ENGINE' "OR DI""ERENT "#OW RATE
VA% GAM G%%' &FNAGAR
"#OW RATE (!ls)/@r)) +*::
No' O6 ENGINE& ? ? ? ?
RPM O6 ENGINE& E;E-<;: <HE-<HE =?:-<J9 <J:-<=E
21
%I&C!ARGE PR' ?;'E ;='9 ?='< 9H'E
&CCTION PR' 9'= >9'= H'9 >H'?
"#OW RATE (!ls)/@r)) +:::
No' O6 ENGINE& ? ? > >
RPM O6 ENGINE& E;E-<;: <=:-<=: H>: <J:
%I&C!ARGE PR' ?E'= ;J ?='< 9:'?
&CCTION PR' 9'= >E'E >E'J >J'<
"#OW RATE (!ls)/@r)) *<7:
No' O6 ENGINE& ? > > >
RPM O6 ENGINE& E;E-<;: H:: H?E <J:
%I&C!ARGE PR' ?E'= 9< ?9 ?H'E
&CCTION PR' 9'= >< ='H ><'E
"#OW RATE (!ls)/@r)) *7::
No' O6 ENGINE& ? > : >
RPM O6 ENGINE& E;E-<;: H:: : <J:
%I&C!ARGE PR' ?= ;9 >='E ?E'E
&CCTION PR' 9'= >='E >='E >9'?
"#OW RATE (!ls)/@r)) *+::
No' O6 ENGINE& ? > : :
RPM O6 ENGINE& E;E-<;: H:: : :
%I&C!ARGE PR' 9:'E ;<'? ?;'E >J'=
&CCTION PR' 9'= ?E'> ?;'E >J'=
$IRAMGAM 4DPA'' P1MPING IN $C 'ECTION
In (ase Viraga &tation in not availa2le for p#ping$ a flow rate of >>::
8l-!r (an 2e a(hieved 2y r#nning engines in the anner indi(ated 2elow'
If VC se(tion is to 2e r#n witho#t Viraga$ V8 side shall either 2e sh#t down
or ade e74Viraga tan+' Also &V flow rate shall 2e +ept (lose to a7i#
2y r#nning all the availa2le engines (lose to a7i# as far as possi2le'
VGM &I% A,R 8OT RAGO1A &EN%RA RAM&AR
ENG 444 > > > > > >
RPM 444 H:: H:: H:: H:: <J: <J:
&#('Pr' >?4>E ; 9'E 9'E 9'E 9'E 9'E
%ish'Pr' >?4>E 9:49E 9:49E 9:49E 9:49E 9: 9:
'TARTING PROCED1RE'

Mainline Pu&ping 1nits
%etailed 5#ality pro(ed#res is given in Pro(ed#re and Wor+ Instr#(tion Man#al
on @OperationsA.Pro(ed#re no' WI-OPN-?>/'

22
Noral operation of starting and stopping of the ainline p#ping #nits is
done thro#gh p#sh 2#tton (ontrollers provided on the station (ontrol panel
with light indi(ation for RAvaila2leF-R1o(+ed O#tF$ R&tartF and RR#nF (onditions'
Alar indi(ations are provided on the station (ontrol panel for vario#s engine
first stage fa#lts 2esides display of RPM$ s#(tion press#re$ dis(harge press#re$
flow rate et(' !owever$ all engine vi3'$ engine RPM$ e7ha#st gas teperat#res$
l#2e oil-Ia(+et water teperat#res$ l#2e oil-Ia(+et water-(harge air press#re
et(' are displayed in the #nit (ontrol panel of individ#al engines' The engine
(an 2e started only when all indi(ations are healthy and the engine availa2le is
displayed in the (ontrol panel'
The se5#en(e of operations of the ainline p#ping #nit$ in 2rief is as
follows)

When @&tartA (oand is given the (ontrol logi( (ir(#it shall deterine)

* &#(tion press#re is ade5#ate
* %is(harge press#re is not too high
* &tarting press#re is ade5#ate
* 6#el press#re is ade5#ate
* P#p s#(tion and dis(harge valves are (losed
* All sh#tdown-lo(+ed o#t devi(es are reset'

If all the a2ove (onditions are f#lfilled$ the s#(tion valve of the engine will
start opening' With this air otor driven l#2e oil p#p also startsB the starting
air valve opens and the engine starts (ran+ing when the engine speed pi(+s
#p$ f#el inIe(tion (oen(es and when the engine is firing and pi(+ing #p the
speed$ starting air is (#t off'
As engine speed pi(+s #p and (rosses ?:: RPM$ the dis(harge valve starts
opening' As the dis(harge valve starts opening$ the p#p starts pi(+ing #p the
load and the dis(harge press#re rises' Thereafter$ the engine RPM is adI#sted
as per the operational re5#ireent' The sae se5#en(e o((#rs when the
se(ond #nit is given starting (oand' Part of the load will then 2e ta+en 2y
the se(ond #nit' Ea(h p#ping #nit will then 2e r#n 2ased on the operational
paraeters re5#ired to 2e aintained to a(hieve the desired flow rates'
In (ase the p#ping #nit is not ta+ing start (oand fro the station (ontrol
panel on reote$ the sae (an 2e 2ypassed and the #nit started fro the
#nit (ontrol panel i'e' on lo(al' In this (ase$ the valves of p#ping #nit have to
2e operated Rlo(alF' !owever$ it ay 2e entioned here that all the Mainline
p#ping #nit prote(tion devi(es do not (oe in operation when the engine is
r#n on lo(al and hen(e the pro2le is to 2e investigated iediately and the
engine p#t on reote at the earliest'
Cecks 3e0ore starting
,ooster P#ps) .At Vadinar$ Viraga and Cha+s#/
* Che(+ that 2oosters are availa2le for RReoteF operation fro station
(ontrol panel' The s#(tion and dis(harge valves are to 2e p#t on reote
2oth at MCC and in the field'
23

Mainline Pu&ps
* Che(+ and (orre(t l#2e oil level for the %E-N%E 2earings'
* Prie the p#p 2y opening the vent valve and (lose the vent valve
tightly'

Mainline Engines
* Che(+ the starting air press#re in the re(eiver and ens#re that the sae
is ade5#ate'
* Che(+ instr#ent air press#re and ens#re that the sae is ade5#ate'
* Che(+ l#2e oil level in the engine-gear 2o7 and a+e it #pto the
re5#ired level'
* Che(+ f#el levels in the daily servi(e tan+s and fill #p the tan+s if
re5#ired'
* Che(+ Ia(+et water a+e#p tan+ level and fill #p if ne(essary'
* Che(+ that the overspeed trip is in RRCNF position'
* Che(+ Governor an#al speed (ontrol +no2 is at ini#'
* Move engine (ontrol handles as follows)
* Air lever to RONF position
* 6#el lever to RRCNF position
* 1OCA1-REMOTE sele(tor swit(h in AMOT panel on REMOTE
* Cr#de-%istillate f#el sele(tor swit(h on R%istillateF
* !eater RON-O66Fswit(h to heater RONF position'
* At MCC$ ens#re that engine a#7iliaries are swit(hed on to reote
position' These in(l#de radiator otors$ ITC1 heater-p#p otor'
* P#t the Gear ,o7 priing p#p to Rlo(alF'
* Che(+ that engine prote(tive devi(es are in order'

'tarting o0 Mainline Pu&ping 1nit
* &tart the Gear ,o7 priing p#p E in#tes 2efore starting the engine'
* &tart the ,ooster p#p fro (ontrol panel'
* &tart the engine fro station (ontrol panel
* Move air starting lever to RO66F position'
* On(e the engine pi(+s #p speed$ adI#st the sae to eet the
operational re5#ireent' The engine ta+es load a#toati(ally'
Cecks %uring running o0 te Engine
* &tarting air re(eiver)
Re(harge the re(eiver to the re5#ired wor+ing press#re'
* 1#2e Oil &yste)
Ens#re the teperat#re and press#re are aintained within liits'
* E7ha#st syste)
Ens#re that the variation in e7ha#st teperat#re 2etween different
(ylinders and the a(t#al e7ha#st teperat#re are within liits'
* Charge Air)
24
Ens#re that the press#re and teperat#re of (harge air are noral'
&hortfall in (harge air pres#re (an possi2ly 2e d#e to t#r2o(harger
pro2le' If the anifold teperat#res are high .possi2ly d#e to
2lo(+ing and fo#ling of (harge air radiator eleents/$ load #st 2e
red#(ed and engines sho#ld 2e sh#t down at the earliest'
'witcing o,er to Cru%e oil run (applica3le in case o0 ol% Allen
engines)
* Ens#re that the heater sele(tor swit(h is in RONF position
* P#t f#el sele(tor swit(h in (r#de position'

Now the (r#de p#p starts and (ir(#lates the (r#de in the 2#s rail od#le'
On(e the teperat#re of (r#de f#el attains the ini# set teperat#re .;<
C/ of AMOT teperat#re valve in(orporated in (r#de f#el (ir(#it$ the engine
a#toati(ally (hanges over to (r#de'
'topping o0 Engine
* Red#(e the speed-load of the engine slowly'
* &top the engine fro station (ontrol panel p#sh 2#tton .stop/ (ontrol'
'TARTING PROCED1RE "OR A##EN ENGINE' (G 2'eries)
Preparations 3e0ore 0irst start
&tarting Air Re(eiver)

>' %rain any oist#re fro the starting air re(eiver and (harge the
re(eiver to its (orre(t wor+ing press#re and (he(+ that there is no pipe
lea+age'

1#2ri(ating Oil &yste)
?' Reove the (ran+(ase doors and (he(+ that the engine s#p is (lean
and free fro water$ then fill the s#p with l#2ri(ating oil to the level
ar+ed on the dipsti(+'
9' Operate the priing p#p #ntil press#re is shown on the ga#ge
provided' Contin#e priing #ntil oil fro the (ooling oil dis(harge of
ea(h piston (an 2e seen draining 2a(+ into the s#p' The f#el p#p
and valve roller g#ides are press#re fed$ and oil lea+age fro the fills
the (ashaft oil 2aths' Che(+ that the oil 2aths are filled to the
(orre(t levelB this is indi(ated 2y overflow 2a(+ into the s#p'
;' E7aine all l#2ri(ating oil pipe Ioints for lea+s$ and a+e #p the s#p
level to (opensate for the initial filling of the l#2ri(ating oil syste' 6ill
the hydra#li( governor with oil to the level indi(ated on the ga#ge glass'
25
E' Re(he(+ all pipe Ioints and repla(e the (ran+(ase door' Open the
indi(ator (o(+s and 2ar the engine for at least two revol#tions to ens#re
that there are no o2str#(tions' Close the indi(ator (o(+s'
InIe(tor Teperat#re Control &yste)
<' 6ill the &eparate !eader Tan+ with %istillate f#el oil (oolant$ open the
s#pply and syste valves$ and open the vent to 2leed air fro the
syste' R#n the otor driven f#el oil (ir(#lating p#p for a few
in#tes to fl#sh all the air fro the syste and this sho#ld 2e done
with the vents (losed' Open the vents again to e7pel the reaining air'

H' Che(+ that the f#el inIe(tor teperat#re (ontrol p#p and inline heater
are in operation'

Cooling Water &yste)
=' The (ooling water syste sho#ld 2e filled and s#2se5#ently topped #p
with (lean$ soft water' If only hard water is availa2le$ it sho#ld 2e
treated with a softening agent to prevent the deposition of s(ale'
J' Open the air release (o(+s in the Ia(+et water syste and ens#re that
the syste is filled' The (o(+s are o#nted in the pipewor+ a2ove the
t#r2o(harger'
>:' Che(+ that all ne(essary valves are open in the se(ondary (ooling water
syste'
T#r2o Charger)
>>' If the engine has 2een o#t of operation for one or ore wee+s$ the
and t#r2ine o#tlet (asings of the t#r2o(harger #st 2e drained'
>?' After every ?E: !rs' r#nning of Engine$ the t#r2o (harger ay 2e
washed with hot water for sooth - effe(tive operation of the sae'
Charge Air Cooler)
>?' Condensate in the air anifold adIa(ent to the (harge air (ooler is
drained via the drilled pl#gs fitted in the anifold' Che(+ that no
air4lo(+ is present on the water side 2y eans of (o(+s or air release
pl#gs fitted to the headers'
PRE2'TARTING
Note )4 Prior to start4#p$ the following a(tions #st 2e ta+en to ens#re f#el is
2eing delivered to engine.s/ to 2e started'
26
() 4ulk Tank @eating Mo%ule Pre2'tart Ceck

.a/ Che(+ water s#pply is availa2le and tan+ is f#ll'
.2/ ,#l+ tan+ oil level reads a2ove o#tflow heater'
.(/ 6#el oil transfer p#p strainers are (lean'

*) 'tart 1p an% Operation

.a/ Close the s+id power s#pply isolator'
.2/ Ens#re the hot water (ir(#it water tan+ is f#ll'
.(/ T#rn the water heater swit(h to RONF position and this 2rings the
heater #nder the (ontrol of the tan+ therostat whi(h aintains
the teperat#re at =: C'
Note) 6ail#re of the therostat (a#ses the teperat#re to to J: C and
sh#ts down heater thro#gh the aster therostat and re5#ires
an#al reset'
.d/ Man#ally start the hot water p#p to (ir(#late hot water thro#gh
the 2#l+ tan+ o#tflow heater'
,#l+ tan+ heating od#le
.e/ &ele(t the (r#de f#el oil transfer p#ps to either)
P#p > d#ty - P#p ? &tand2y
or
P#p ? d#ty - P#p > &tand2y
The d#ty p#p will start and will p#p (r#de f#el fro the 2#l+ tan+
via the o#tflow heater to the pre4(entrif#ge tan+ of the f#el oil
treatent od#le' The delivery press#re is onitored 2y a press#re
swit(h P&>>.Ps->M>! dwg/ sho#ld press#re in the dis(harge anifold
not rea(h :'E +g-(? within the pre4set tie .tier T> ) :'9: se(/ then
the stand2y p#p will start' It will (ontin#e to r#n #ntil the d#ty-
stand2y sele(tion is (hanged' The d#ty p#p will 2e stopped$ as soon
as the stand2y p#p starter energises'
.f/ A press#re s#staining valve (ontrols the (r#de oil dis(harge
press#re and ret#rns e7(ess oil 2a(+ to the 2#l+ tan+'
.g/ The oil teperat#re is (ontrolled a#toati(ally 2y the thero
stati( valve at the 2#l+ tan+ o#tflow heater'

Note) In the event$ low water tan+ level o((#rs the water heater and
(ir(#lating p#ps stop and signal a reote alar'
+) "uel Treat&ent Mo%ule (Centri0uge)

.a/ Close the s+id power s#pply isolator'
.2/ &wit(h on the power s#pply to the (entrif#ge RVesaF (ontrol panel in the
(ontrol roo'
27
.(/ Ens#re the pre4(entrif#ge tan+ is f#ll and that the oil feed fro the 2#l+
tan+ forwarding #nit is availa2le' The tan+ level is aintained
a#toati(ally'
.d/ Ens#re the hot water tan+ is f#ll and water is availa2le and the tan+ level
is aintained a#toati(ally 2y a 2all valve'
.e/ &ele(t the hot water tan+ heater swit(h to RONF' !eater is now (ontrolled
2y the (ontrol therostat whi(h aintains the water teprat#re at =:C'
6ail#re of the (ontrol therostat allows a teperat#re rise to J:C 2efore
the heater is sh#tdown 2y the aster therostat whi(h then re5#ires
an#al reset'
.f/ &tart the hot water p#p at the lo(al panel effe(ting (ir(#lation thro#gh
the pre4(entrif#ge tan+ heating (oil' The oil teperat#re will 2e
a#toati(ally aintained at a ini# of 9:QC 2y the teperat#re
(ontrol valve in the pre4(entrif#ge tan+'
.g/ Man#ally start the Rd#tyF (entrif#ge fro the lo(al panel$ allow E in#tes
to rea(h f#ll speed' Oil will then 2e (ir(#lated 2y the (entrif#ge driven
feed p#p fro the pre4(entrif#ge tan+ thro#gh in4line heater and 2a(+
to the pre4(entrif#ge tan+'
.h/ Che(+ the air press#re to (entrif#ge is 2etween ?49 2ar and the hot water
and (old fed to (entrif#ge is ? 2ar with servi(e tan+ valvesopen'
.i/ when the (ir(#lated oil teperat#re rea(hes <E C press the RVesaF start
2#tton on the lo(al panel$ this a#toati(ally 2rings the (entrif#ge on line
and opens the oil feed into the (entrif#ge' AdI#st the (entrif#ge dis(harge
press#re to ? 2ar and oil flow to >EH: l-hr'
.I/ &#rpl#s oil overflowing 2a(+ to the pre4(entrif#ge tan+' The tan+ level is
aintained 2y a+e4#p fro the 2#l+ tan+ od#le as heated f#el is
passed to daily servi(e tan+s'
.+/ A#toati( desl#dging of the (entrif#ge is effe(ted at preset intervals with
sl#dge 2eing reoved to the sl#dge holding tan+ fro whi(h it is
periodi(ally reoved 2y an#ally starting the :'HE +w sl#dge p#p' A
sl#dge heater aintains the sl#dge at a p#pa2le teperat#re'

Note)4The following fa#lts will raise an alar and isolate the oil feed to
(entrif#ge)

1ow oil feed teperat#re)4 EE QC
!igh oil feed teperat#re)4 H: QC
1oss of oil feed4 &ensed 2y low oil dis(harge
1oss of 2owl seal4 Press#re swit(h

Note)4The following fa#lts will stop the (entrif#ges$ water p#ps and
heater)
28
Water tan+ low level'
Pre4(entrif#ge oil tan+ low level'
&l#dge tan+ high level'
.) "uel Oil "orwar%ing Mo%ule

.a/ Pre4start (he(+
Water s#pply availa2le 0 header tan+ f#ll'
Ele(tri(al s#pply availa2le'

.2/ &tart #p and operation

Note)4&in(e (r#de f#el teperat#re and oil press#re have to 2e (orre(t
2efore the engine (an 2e started$ it is advisa2le to ens#re that
the f#el oil forwarding od#le is operating well in advan(e of the
engine 2eing re5#ired to start' Close power s#pply isolator to
lo(al panel
Manual 'tart
* Close water heater on-off swit(h at lo(al panel'

Note)4!eater interlo(+ed to water (ir(#lating p#p and will not operate
witho#t water (ir(#lating p#p r#nning .A#to- Off- Man#al &tart
&wit(hes/
* &tart water (ir(#lating p#p at lo(al panel' This$ at the sae tie$ will
2ring water heater on load' !eater will a#toati(ally aintain water
teperat#re at =?QC' If the (ontrol therostat fails$ water teperat#re
will rise to J: QC and aster therostat on heater will sh#t the heater
down re5#iring an#al reset' .A#to- Off- Man#al &tart &wit(hes/'
* When water teperat#re rea(hes =?QC$ start f#el p#p at lo(al-
reote panel to (ir(#late engine 2#s rail' 6#el teperat#re will 2e
a#toati(ally aintained at <;QC ready for engine start'
Auto
4 &ele(t A#to-Off-Man#al swit(hes for f#el oil p#p and water p#p-
heater to SA#toS' ,oth #nits will start provided 2#s rail heating sele(tor
in CCP is at RONF'
* With engine r#nning$ engine driven f#el p#p will aintain press#re
on the 2#s rail and the ele(tri(ally driven f#el forward p#p will 2e
stopped'

7) Engine 1nit Control Panel (1CP)
To ens#re that (r#de f#el oil is at the (orre(t teperat#re and press#re
and that the f#el inIe(tors are wared thro#gh$ it is advisa2le to ens#re
that the CCP is in operation well in adan(e of an engine 2eing re5#ired
to r#n' The ini# re5#ireent is that the following a(tions have
29
2een #nderta+en)
.a/ Panel isolator valve t#rned to RONF position'
.2/ If the (r#de f#el whi(h is in #se re5#ires heating$ then sele(t @!eating
OnA at 2#s rail f#el oil heating sele(tor'
.(/ Ens#re f#el forwarding od#le is set #p as se(tion ;$ RA#toF'
.d/ Ens#re f#el inIe(tor tep' (ontrol p#p 0 heater starters are ready
for a#toati( operation at the otor (ontrol (entre$ i'e' Isolator RONF
Control sele(ted to RA#toF'
The following additional listed (he(+s sho#ld 2e ade 2efore start#p)
>' All se(ond stage fa#lts in the healthy position'
?' 6#el (ontrol lever in the RRCNF position'
9' Engine air start lever to start position'
;' Cr#de f#el teperat#re a2ove the noral set point when 2#s rail
heating sele(ted RONF'
E' 6#el inIe(tor teperat#re (ontrol p#p and heater in operation
.start when isolator in RONF position/'
;) Motor Control Centre (MCC)

.a/ Ma+e ne(essary pre4starting (he(+s in MCC'
.2/ &ele(t the following otor starters to r#n (ondition i'e$ isolator @ONA
and (ontrol sele(tor to @A#toA)

.>/ Engine l#2e oil priing p#p
.?/ Gear2o7 l#2e oil priing p#p'
.9/ 6#el inIe(tor tep (ontrol p#p'
.;/ 6#el inIe(tor tep (ontrol heater'
.E/ Radiator fan otors 9 off'

.(/ Close the following s#pply isolators at the MCC)
.>/ Interfa(e panel .Pne#ati(-Ele(tri( signal (onversion to CCP/
.?/ Oil Mist %ete(tor'
.9/ 6#el pipe tra(e heating'
.;/ 6#el forwarding od#le'
.E/ Charge air 2ypass a(t#ator'
Coon e5#ipent > off ea(h for station)
.</ ,#l+ tan+ heating od#le'
.H/ 6#el oil treatent od#le'
.=/ Centrif#ge (ontroller .VE&A >>/'

ENGINE 'TARTING G MAN1A#
1. Prie the gear2o7 l#2ri(ating with syste 2y #se of the otor driven
priing p#p on hand (ontrol fro the MCC.
30
?' Che(+ that the f#el forwarding od#le is operating (orre(tly and that
f#el at the (orre(t tep 0 press#re is availa2le at the engine' .Press#re
0 tep to s#it f#el in #se/'
9' Che(+ that all valves in the f#el inIe(tor tep$ (ontrol syste are open
and that the syste is operating (orre(tly$ i'e' Coolant tep' is sta2le
at aro#nd =: C'
;' Open the ain valve on the starting air re(eiver' Then ove the air
(ontrol and f#el (ontrol levers on the engine (ontrol 2o7 to the Rair onF 0
Rr#nF positions'
E' The CCP will indi(ate Rengine availa2leF provided f#el oil is at the
operating teperat#re' .If f#el heating is sele(ted to RO66F$ the f#el
tep' interlo(+ is disa2led/'
<' Operate the engine start valve on the CCP'
H' If it is desired to liit the engine rate of a((eleration on starting$ it is
now ne(essary to hold the f#el (ontrol lever to an interediate
position .after p#lling the start valve and 2efore the engine t#rns on
starting air/' To do this will entail ? operators$ one at the CCP and the
other at the engine hand (ontrols' When the engine is r#nning norally
the f#el lever ay 2e ret#rned to the Rr#nF position'
=' Provided that the engine priing has (orre(tly ta+en pla(e and the
gear2o7 l#2e oil press#re (oission tier has tied o#t the CCP will
initiate the following a(tions)4
.a/ The governor will 2e press#rised to allow the engine to r#n'
.2/ The starting air valve pilot will 2e press#rised to open the starting
air valve and t#rn the engine'
.(/ The fail to start ties will 2e initiated .:'9: se(/
J' If either the gear2o7 priing press#re valve or the engine l#2 oil
priing level valve do not operate to show that satisfa(tory priing has
2een a(hieved then the engine start at the CCP will 2e (an(elled and)
.a/ The horn will 2e so#nding'
.2/ The RFfail to prieA indi(ator will show red'

To attept to restart$ the following a(tions will 2e ne(essary)
.a/ &ilen(e the horn 0 (an(el the alar 2y p#lling the @fail to prieA
reset +no2'
.2/ P#ll the @engine startA +no2 again'

>:' If for any reason the engine fails to rea(h ?:: RPM 2efore the RfailedF to
start tier ties o#t$ the following will o((#r)4
31
.a/ The start se5#en(e will 2e (an(elled'
.2/ The horn will 2e so#nded'
.(/ The governor will 2e de4press#rised .;: l2-in
?
/ falling'
.d/ The starting air valve will 2e de4press#rised'
.e/ The failed to start tier will 2e (an(elled'
.f/ The lo(al failed to start indi(ation will 2e RONF'

To attept to restart the following a(tions will 2e ne(essary)
.a/ &ilen(e the horn and (an(el the alar 2y p#lling the @failed to
startA reset +no2'
.2/ P#ll the @engine startA +no2 again'
11. The air s#pply valve on the air re(eiver is to 2e +ept open while the
set is r#nning as an air s#pply is re5#ired on to the engine for
the(o2#stion air 2#tterfly valve and the (ran+(ase CO
?
inIe(tion
syste'
>?' After the engine has wared #p$ adI#st the speed setting +no2 on the
CCP to vary the engine speed setting to the desired engine speed'
&ho#ld the an#al (ontrol +no2 on the governor 2e #sed for speed
adI#stent$ 2e s#re to ret#rn it to the ini# speed position after
#se$ as otherwise$ f#ll (ontrol of speed fro the CCP or station
(ontrol panel will not 2e possi2le' .Csing the pne#ati( speed setting
devi(e in the governor 4 the an#al devi(e a(ts as a ini# speed
stop/'
>9' While the engine is idling$ pay (aref#l attention to l#2ri(ating oil and
(ooling water teperat#re and press#res' The t#r2o(harger will
a#toati(ally start r#nning when the engine is started and will (oe to
rest when the engine is stopped' The t#r2o (harger sho#ld a((elerate
and slow down grad#ally'

'TARTING A1TOMATIC G #OCA# (i) e) "ROM 1CP)
>' Ens#re that all the pre4starting (onditions have 2een set #p for the 6#el
6orwarding Mod#le$ Cnit Control Panel and Motor Control Centre .&e(tion
;$ E$ < Pre starting/'
?' If e7tended r#nning is envisaged ens#re that the ,#l+ Tan+ Mod#le and
6#el Treatent Mod#le have 2een set #p as well .&e(tion >$ ?$ 9 Pre4
starting/'
Note) @e7tended r#nningA eans longer than the 5#antity of f#el whi(h
the daily servi(e tan+ (an a((oodate'
9' &et the over speed trip in the RRCNF position$ then p#t the f#el p#p (#t4
o#t lever in the RRCNF Position$ and open all valves in the f#el s#pply
syste'
;' Ens#re all valves in the water s#pply syste are open'
32
E' P#t the engine air (ontrol lever to RONF position$ set the governor speed
setting +no2 to ini# speed'
<' Ens#re all valves in the inIe(tor syste are open'
H' The engine is now ready for a#toati( starting fro the #nit (ontrol
panel' CCP will now indi(ate engine availa2le'
=' When the engine has 2een r#nning for a s#ffi(ient length of tie$ and the
engine Ia(+et water rea(hes its noral operating teperat#re .H?QC/ the
following will o((#r )

.a/ The f#el forwarding water p#p and heater will stop'
.2/ The f#el forwarding water p#p r#nning indi(ation will deoperate'
.(/ The f#el forwarding water p#p heater r#nning indi(ation will de4
operate'
.d/ When the gear2o7 l#2ri(ating oil rea(hes its noral r#nning
teperat#re .<:QC/ the alar (hannel for the gear2o7 l#2ri(ating oil
filter differential high will 2e (oisssioned'
.e/ When the engine l#2ri(ating oil rea(hes its noral r#nning
teperat#re .<JQC/ the alar for engine l#2e oil filter differential
press#re high'
.f/ With all (he(+s (oplete$ the engine will r#n with all first and se(ond
stage alars and sh#tdowns (oissioned'

INTER#OC!'
#u3e Oil Pri&ing
.a/ If the engine l#2e oil and gear2o7 l#2e oil are not satisfa(torily pried$
then start will 2e prevented' &atisfa(tory priing is sensed 2y)4

Engine) 1evel sensing pne#ati( valve 1VJ positioned in (ha2er
a2ove (ran+shaft level' .Csed d#e to low press#re a(hieved
2y priing p#p when oil is hot/'
Gear2o7) Press#re valve PV< set to ?E l2-in
?
$ >'=+g-(
?
rising'
'tarting 'pee%
.2/ If speed of ?:: RPM not a(hieved in >: se(onds fro adission of
starting air valve .R&V;/ the start se5#en(e is 2lo(+ed' ?:: RPM (hosen
as a2ove (ran+ing speed of E:4<: RPM 2#t 2elow ini# r#nning
speed range' CCP alar 8A>'
'et A,aila3le to 'tart
.(/ This will not 2e given #nless f#el and air (ontrol levers are in R#n and
&tart positions as sensed 2y pne#ati( valves TV; 0 TVE' Warns
operator if set not properly prepared'
Cru%e "uel Te&perature Nor&al
33
.d/ &tarting will not 2e peritted #nless (r#de f#el is a2ove noral
teperat#re of >;E Q6$ <9 QC as sensed 2y teperat#re valve TV>H to
ens#re relia2le starting and satisfa(tory (o2#stion' This is 2e(a#se
(r#de is the only f#el on site and #st 2e at or a2ove this teperat#re
to prevent i7ing'
Facket Water Te&perature Nor&al
.e/ When engine Ia(+et water teperat#re e7(eeds >H?Q6$ H=QC it is
possi2le to swit(h off the ele(tri( water heating on the f#el forwarding
od#le' Engine Ia(+et water will now provide s#ffi(ient f#el heating'

A pne#ati( teperat#re valve TV>< will signal via CCP 0 interfa(e
Panel to heater (onta(tor'
'TOPPING2MAN1A#
>' If possi2le$ r#n the engine down on to light load for a few in#tes
2efore stopping to allow it to (ool'
?' P#t the f#el p#p (#t4o#t lever in the R&TOPF position'
9' Ens#re the inIe(tor teperat#re (ontrol syste is +ept r#nning'
;' Cran+(ase or inspe(tion doors sho#ld not 2e opened #ntil the engine
has (ooled$ parti(#larly if it is s#spe(ted that a part is serio#sly
overheating'
E' In the (ase of engines re5#ired for a#toati( starting$reset the
(ontrols as des(ri2ed in @&TARTING ACTOMATIC41OCA1A'

'TOPPING 2 A1TOMATIC
The following listed (onditions will (a#se an engine to stop'
.a/ Man#al operation of lo(al or reote stop 2#tton dependent #pon
lo(al-reote sele(tion'

.2/ ?nd stage sh#tdown fa#lt o((#ring'
.(/ Man#al operation of lo(al or reote eergen(y stop 2#tton'

RO1TINE ATTENTION W@I#E R1NNING
It is essential that the (orre(t (o2#stion (onditions are aintained in the
engine and the load is shared e5#ally 2etween (ylinders otherwise e7(essive
f#el (ons#ption$ high e7ha#st teperat#re or dirty e7ha#st gases will res#lt'
Co2#stion (onditions in ea(h (ylinder are (he(+ed 2y eas#ring the pea+
press#re and the e7ha#st gas teperat#re'
'tarting Air Recei,er
As soon as the engine has started$ the air re(eiver sho#ld 2e re4(harged and
wor+ing press#re aintained in (ase a f#rther start is re5#ired' The re(eiver
sho#ld 2e 2lown o#t daily 2y eans of the drain (onne(tion to reove any
oist#re whi(h ay have (olle(ted'
34

#u3ricating Oil '-ste&
The re(oended operating l#2ri(ating oil press#re into the engine fro the
(ooler and the a7i# teperat#re of the l#2ri(ating oil after the (ooler are
given in Maintenan(e Man#al' The l#2ri(ating oil press#re (an 2e adI#sted 2y
eans of the relieve valve fitted on the oil p#p dis(harge pipe at the free
end of the engine' The valve (ap #st 2e reoved and the lo(+ n#t loosened
in order to adI#st the position of the adI#sting s(rew' T#rning the s(rew
(lo(+wise will in(rease the oil press#re and t#rning the s(rew anti4(lo(+wise
will red#(e it'
In new or re(ently overha#led engines$ (aref#l note sho#ld 2e ta+en of the
press#re drop a(ross the filter eleents in #se' The filter eleents #st 2e
repla(ed when the press#re drop a(ross the filter rises to the val#e :'H
+g-(
?
' ,efore withdrawing a dirty eleent while the engine is r#nning$ the
(hange4over lever #st 2e oved to 2ring the other eleents into operation'
Csed eleents sho#ld 2e dis(arded and repla(ed 2y new$ (lean and #n#sed
eleents' The oil in the s#p sho#ld 2e aintained 2etween the levels
ar+ed on the dipsti(+'
It is re(oended that saples of oil are ta+en fro the engine and tested
at la2oratory for analysis and oil repla(eent is ta+en #p as per reIe(tion
liit'
"uel Oil '-ste&
The f#el oil filter (artridges sho#ld 2e repla(ed periodi(ally$ the intervals
depending on (onditions of servi(e and (leanliness of the f#el in #se' After
repla(ing the (artridge$ air sho#ld 2e released fro the filter thro#gh the vent
s(rew on top of the filter head (atering'
&l#dge and water (olle(ting at the 2otto of the f#el tan+ #st 2e drained off
at reg#lar intervals$ the period 2eing deterined 2y the 5#antity of f#el #sed'

I&portant
If the engine stops d#e to shortage of f#el (a#sed 2y the f#el tan+ 2eing
epty or a (ho+ed filter$ the f#el oil syste #st 2e re4pried 2efore
attepting to re4start the engine' .see @Engine &tarting4Man#alA paragraph/'
The heavy f#el oil filter (artridges sho#ld 2e repla(ed periodi(ally$ the intervals
depending on (onditions of servi(e and the effe(tiveness of the (entrif#ge in
(leaning the f#el'
After repla(ing the (artridges$ air sho#ld 2e released fro the filter thro#gh
the vent s(rew on top of the filter head (asting'
InCector Te&perature Control '-ste&
Che(+ sho#ld 2e ade periodi(ally of the level in the header tan+ to dete(t
lea+age'
35
O((asionally when the engine is not r#nning$ open the air vents to 2leed air
fro the syste'
Cooling Water '-ste&
The teperat#re of the water entering the (ylinder Ia(+et is aintained at a
parti(#lar teperat#re' A therostati(ally (ontrolled 2ypass valve is fitted to
ens#re that rapid war4#p and (orre(t r#nning teperat#res are a(hieved'
The standard valve is a#toati( and re5#ires no adI#stent'
A (ooling water o#tlet teperat#re valve is fitted' This operates a >st stage
alar in the event of an a2norally high water teperat#re$ and in the
se(ond stage this valve also sh#ts down the engine at the pre4deterined
a7i# water teperat#re'
E?aust '-ste&
A theroeter is fitted in the e7ha#st 2ran(h fro ea(h (ylinder' E7ha#st
teperat#res provide a #sef#l g#ide to the perforan(e of the engine and
sho#ld 2e re(orded reg#larly'
Variations of reading 2etween (ylinders sho#ld not e7(eed ?=C and while
teperat#res reain within that range$ the engine (ontrols re5#ire no
adI#stent'
Teperat#res sho#ld (opare (losely with those given in the engine test
sheets prod#(ed d#ring the wor+s test or site (oissioning trials' .The latter
e7ha#st teperat#res (o#ld 2e higher than those o2tained at the wor+s test
d#e to the infl#en(e of site (ondition$ a2ient teperat#res$ e7ha#st 2a(+
press#res et('/' The a7i# perissi2le e7ha#st teperat#re is ;9:QC' Any
(onsidera2le variation will pro2a2ly indi(ate a fa#lt in the inIe(tion e5#ipent'
This #st 2e investigated at on(e' The a((#ra(y of the theroeters sho#ld
2e (he(+ed reg#larly and if no relia2le (ali2rating instr#ent is availa2le$ their
(onsisten(y (an 2e (opared 2y r#nning the engine on a steady load and
inter(hanging the theroeters 2etween (ylinders'
A fall in engine effi(ien(y ay well (a#se heavy (ar2on deposits to 2#ild4#p in
the internal passages of the t#r2o (hargers' The operational (hara(teristi(s of
the t#r2o(hargers ay 2e referred fro tie to tie'
C-lin%er Pressures
To (he(+ the a7i# (ylinder press#res the engine #st 2e r#n steadily at
f#ll speed on f#ll load and the a7i# press#re eas#red for ea(h (ylinder
2y eans of a a7i# press#re indi(ator' These press#res and the
asso(iated (harge air press#re sho#ld 2e (opared with those given in the
test sheets' The inIe(tion e5#ipent$ valves$ or t#r2o(harger will re5#ire
aintenan(e if there are wide variations'
A low a7i# press#re indi(ates retarded 2#rning of the f#el and is #s#ally
asso(iated with a high e7ha#st teperat#re' !igh or noral press#res in
36
asso(iation with high e7ha#st teperat#res indi(ate e7(essive f#el delivery'
If it is ne(essary to alter the f#el p#p settings in order to e5#ali3e e7ha#st
teperat#res$ instr#(tions are given in @MAINTENANCE PROCE%CRE&A of
s#pplier an#al$ whi(h ay 2e (ons#lted'

O,erspee% trip
The overspeed trip sho#ld 2e tested every 9 onths' ,efore testing the trip$
the engine #st 2e dis(onne(ted fro the p#p set and with the engine
r#nning at noral speed$ operate the lever o#nted on the speed governor
o#tp#t shaft$ #sing a ?:$ open ended spanner$ in(reasing the engine
speed' The trip sho#ld operate when the engine speed is within >? to >E per
(ent a2ove noral r#nning speed' If the trip does not operate within this
range$ adI#stents ay 2e ne(essary as des(ri2ed in @MAIN4TENANCE
PROCE%CRE&A of &#pplierFs Man#al'
To set the overspeed trip gear in the RRCNF position$ lift the verti(al trip spindle
#pto the RRCNF position and ove the re4setting handle #ntil the trip spindle
held against the spring'
Engine Protection De,ices
These sho#ld 2e (he(+ed wee+ly for (orre(t operation'
Tur3o2Carger
Any (ondensate whi(h has a((##lated in the t#r2o(harger t#r2ine (asting
#st 2e drained off 2y eans of the drain (o(+ or s(rewed pl#g'
A re(ord sho#ld 2e +ept of the air delivery press#re d#ring the daily
inspe(tions of the engine' Any deterioration in perforan(e will indi(ate the
need for internal (leaning and overha#l' 6#ll aintenan(e instr#(tions are
given in the t#r2o(harger hand2oo+'
Water washing e5#ipent ay 2e provided for 2oth the (opressor and
t#r2ine ends and its reg#lar #se will aintain the t#r2o(harger perforan(e
near to the @as newA level' The fre5#en(y of the washing pro(ed#re depends
on the operating (onditions' After every ?E: hrs' r#nning of engine T#r2o4
Charger washing to 2e (arried o#t'
Carge Air '-ste&
A (harge air (ooler is fitted whi(h will ade5#ately (ool the (harge air #nder the
(onditions of f#ll load and (ontra(t a2ient air and water teperat#res'
Indi(ation of high air anifold teperat#re will show that the engine is
effe(tively operating at a theral overload and a((ordingly load #st 2e
red#(ed at the earliest opport#nity to a safe level' As soon as possi2le$ the
engine sho#ld 2e sh#tdown and an inspe(tion of the (harge air (ooler t#2es
sho#ld 2e ade to esta2lish whether t#2es are 2lo(+ed or the (ooling s#rfa(es
are fo#led'
37
E&ergenc- Operation
If a defe(t o((#rs in the t#r2o(harger that will prevent f#rther operation$ the
engine ay 2e r#n for a short period with the t#r2o(harger o#t of a(tion' A
Napier t#r2o(harger #st have the rotor reoved and the (entre (asting
apert#res 2lan+ed off' .Refer to the t#r2o(harger an#al/'
I&portant
When the engine is r#n with the t#r2o(harger inoperative$ the (oolant flow
#st 2e aintained'
As a g#ide to the load that the engine will (arry in this for$ the a7i#
e7ha#st teperat#res #st not e7(eed those o2tained when r#nning in the
press#re4(harged for'
A defe(tive t#r2o4(harger #st 2e reoved fro the engine and repla(ed 2y a
servi(ea2le #nit as soon as possi2le' If no repla(eent is availa2le$ and it is
ne(essary to (ontin#e r#nning the engine$ the e7ha#st gases #st 2e
disposed of 2y teporarily (onne(ting the engine e7ha#st pipes to the t#r2ine
o#tlet d#(ting'

@-%raulic Go,ernor
%isantling and aintenan(e instr#(tions for the governor are given in
separate hand2oo+s s#pplied with ea(h engine' The governor oil sho#ld 2e
(lean and free fro foreign parti(les' Always +eep the governor oil at the
(orre(t level in the oil ga#ge'
"A1#T "INDING

A) O3ser,e% Engine will not start
> Pro2a2ale Ca#ses Reedial A(tions
? 6#el p#p (#t4o#t lever not in RRCNF
position
9 Overspeed trip not reset
; 6#el tan+ epty
E 6#el s#pply valve not open
< 6#el syste not pried thro#gh to
no33les
H &tarting air distri2#tor valve not
ret#rning to seat
= &tarting air press#re too low Re(harge air re(eiver to (orre(t
press#re
J Poor (opression d#e to)
a Valve not seating Che(+ tappet (learan(es' Grind
in valves if ne(essary
2 Valves sti(+ing in g#ides Clean and apply l#2ri(ant
( A#toati( starting air valve in
(ylinder head not seating properly
Grind in with fine a2rasive
d Piston rings st#(+ or liners worn &ee Maintenan(e Pro(ed#res
38
J 6a#lt in f#el inIe(tion p#ps or
no33les
Che(+ flow fro ea(h p#p
#sing hand priing lever' &ee
that f#el p#p delivery valve is
not sti(+ing or the spring 2ro+en
>: Tiing of Cashaft or f#el inIe(tion
p#ps in(orre(t
6#el p#p tappets ay have
sla(+ened 2a(+
4) O3ser,e% Di00icult 'tarting
>> &ee E$ <$ H$ =$ J and >: a2ove
>? Water in f#el %rain pipes' Allow f#el to settle
or (entrif#ge
>9 Air inta+e filters (ho+ed Clean and servi(e eleents
>; Charge air (ooler .when fitted/ (ho+ed Che(+ and (lean
C) O3ser,e% Engine stops su%%enl-
>E 6#el filter (ho+ed Change to other eleent and
(lean dirty filter
>< 6#el tan+ epty
>H SOverspeedS trip tripped o#t d#e to
overspeed
D) O3ser,e% Engine runs unstea%il- or
HuntsB
>= 6#el p#p (ontrol rods or (ontrol
lin+age 2etween Governor and f#el
inIe(tion p#ps not free
Clean and l#2riate with engine
oil
>J 6#el inIe(tion p#p delivery valve
sti(+ing
?: %irt in f#el syste Clean filters$ p#ps and inIe(tor
filters' E7aine and (lan f#el
tan+
?> Air in f#el syste Prie syste
?? Water in f#el syste %rain f#el pipes and allow f#el to
settle or (entrif#ge
?9 Overload E7ha#st theroeters will show
an a2norally high reading
?; In(orre(t governor adI#stent$ Air in
Governor oil syste .hydra#li(
governor/ or sti(+ing governor parts
or levers
6lash oil in governor' &ee
governer Maint' 2oo+
E) O3ser,e% Engine %oes not sut%own
pro&ptl-
?E 6#el (ontrol lever not (#tting off
s#pply to all p#ps
AdI#st f#el p#p ra(+s and if
ne(essary$ governor lin+age
") O3ser,e% Engine will not carr- loa%
?< Engine overloaded Che(+ and red#(e load as
ne(essary
?H 6#el p#p (ontrol ra(+s sti(+ing Che(+ e7ha#st teperat#re to
see that all (ylinders are firing
?= 6a#lty t#r2o(harger Che(+ t#r2o(harger speed and
2oost press#re' &ee separate
hand2oo+
?J Air in f#el syste Prie syste
9: 6#el filter (ho+ed Change to other eleent and
39
(lean dirty filter
9> Air inta+e filters (ho+ed Clean and servi(e eleents
9? Charge air (ooler .if fitted/ (ho+ed or
airlo(+ed
Che(+ and (lean or 2leed air
fro water side
99 1ea+ing f#el (onne(tion
9; Cns#ita2le f#el Che(+ grade 0 &pe(ifi(ation
9E Poor (opression d#e to
a/ Valves not seating Che(+ tapped (learan(e' Grind
in valves if ne(essary
2/ Valves sti(+ing in g#ides Clean and apply l#2ri(ant
(/ A#toati( starting air valve in
(ylinder head not seating properly
Grind in with fine a2rasive
d/ Piston rings st#(+ or liners worn Inspe(t piston-liner
9< Ineffi(ient f#el p#ps and inIe(tors Reove$ (lean and test p#ps
and inIe(tors
9H !igh e7ha#st teperat#re d#e to low
raw water flow thro#gh inter(ooler
Che(+ pres#re
G) O3ser,e% Engine knocks
9= In(orre(t valve (learan(e Che(+ and reset
9J In(orre(t inIe(tion tiing Che(+ and reset
;: E7(essive e7ha#st teperat#re Che(+ water press#re 0 flow
;> E7(essive firing press#re Che(+ f#el delivery 0 e7ha#st
teperat#re
;? Main or (onne(ting rod 2earings worn
e7(essively
If possi2le$ identify ain or
(onne(ting rod 2earings' 6or
pre(a#tion against (ran+(ase
e7plosion
;9 Piston 2eginning to sei3e If possi2le$ identify piston' &ee
page for pre(a#tion against
(ran+(ase e7plosion
;; 6ail#re of water s#pply E7aine water p#p.s/$ pipes
and valves
;E !eavily s(aled water Ia(+ets %es(ale and (arry o#t
preventive treatent
@) O3ser,e% #ow #u3ricating oil pressure
Change over l#2ri(ating oil filters and if press#re is not restored$ stop
engine
;< Cho+ed s#(tion strainer Che(+ oil s#pply in s#p and
(lean strainer
;H Cho+ed filter or (ooler Che(+ for (leanliness
;= &pring loaded relief valve Che(+$ (lean and re4adI#st' 2y4
passing oil
;J &pring loaded reg#lating valve
2ypassing oil
Inspe(t reg#lating valve
E: 6ra(t#red pipe in l#2ri(ating oil
syste
Repla(e the fra(t#red pipe
E> Cran+shaft 2earings worn Carry o#t the inspe(tion as per
Maint' pro(ed#res
E? 1#2ri(ating oil p#p worn 4 do 4
E9 Press#re ga#ge line (ho+ed or valve
sh#t off
Repla(e
40
E; 6#el dil#tion of l#2ri(ating oil As 2elow
I) O3ser,e% "uel %ilution o0 #u3ricating
oil
EE 6a#lty f#el p#ps$ g#ides or Ioints Che(+ for lea+s and (orre(t as
ne(essary
E< 6a#lty inIe(tor Che(+ for lea+s and (orre(t as
ne(essary
EH &ti(+ing piston rings Inspe(t piston-piston rings
F) O3ser,e% E?cessi,e use o0 #u3ricating
Oil
E= &ti(+ing piston rings Inspe(t piston-piston rings
EJ Worn pistons$ rings or lines Inspe(t piston-piston rings-
liners
<: Oil lea+ to water side of (ooler %rain water and oil systes$
rea+e the Ioints and repla(e
seals
!) O3ser,e% @ig #u3ricating Oil
Te&perature
<> 1oss of l#2ri(ating oil Che(+ level in s#p and
press#re in syste
<? 1ow raw water flow Che(+ press#re and water
syste valves
<9 Oil (ooler (ho+ed Che(+ and (lean
<; !igh (ir(#lating water teperat#re in
engine Ia(+ets
Che(+ and (lean
#) O3ser,e% @ig Circulating Water
Te&perature
<E 1ow (ir(#lating water flow in engine
Ia(+ets
Che(+ press#re
<< !eat e7(hanger (ho+ed Che(+ and (lean
<H 1ow raw water flow Che(+ press#re and water
syste valves
M) O3ser,e% 1neIual or e?cessi,e
e?aust te&peratures
<= Engine overloaded Che(+ and red#(e load as
ne(essary
<J 6#el p#ps or governor in(orre(tly
adI#sted
Che(+ and reset
H: 1oads on no33le valve spring not
e5#al
Che(+ and reset
H> !oles in the no33le 2ody (ho+ed Che(+ and (lean
H? 6#el inIe(tion p#p delivery valve
sti(+ing
6ree valve
H9 1ea+ in the f#el inIe(tion syste
2etween the p#p and no33le
Che(+ and tighten all Ioints
H; Tappet s(rew #nder the inIe(tion
p#p ay have t#rned
Che(+ and re4set tappet
(learan(e
HE Air inta+e filter (ho+ed Clean and servi(e eleents
H< Inlet and e7ha#st valves sti(+ing Clean and l#2ri(ate' Che(+
tappet (learan(e
41
HH InIe(tion tiing retarded Che(+ and adI#st tiing
H= E7ha#st valve seats in (ondition Regrind e7ha#st valves
HJ !igh e7ha#st 2a(+ press#re pipewor+ Clear e7ha#st syste
=: 1ow (ir(#lating water flow Che(+ press#re 0 teperat#re
=> Cns#ita2le f#el Che(+ grade 0 spe(ifi(ation
=? T#r2o(harger (opresson diff#ser
fo#led
Clean diff#ser
=9 6a#lty e7ha#st theroeter Che(+ 0 repla(e if ne(essary
=; Charge air (ooler fo#led Che(+ and (lean
=E 1ow se(ondary (oolant flow Che(+ and re(tify
=< !igh se(ondary (oolant teperat#re Che(+ and re(tify
N) O3ser,e% '&ok- E?aust
=H Engine overloaded Che(+ and red#(e load as
ne(essary
== 6a#lty inIe(tion e5#ipent Che(+ inIe(tor 2low off press#re
2y eans of handp#p$ ens#re
that spring load is not e7(essive
=J The holes in the no33le 2ody (ho+ed
on one or ore (ylinders
Che(+ and (lean inIe(tion
J: E7(essive f#el delivered to one or
ore (ylinders d#e to in(orre(t
adI#stent of the governor (ontrol to
the f#el inIe(tor p#ps
AdI#st f#el p#ps
J> %ri22ling at no33le Reove no33le and thoro#ghly
(lean' Che(+ spray
J? In(orre(t f#el p#p tiing Che(+ f#el p#p tiing
J9 &ti(+ing piston rings Inspe(t piston-piston rings
J; Inlet and e7ha#st not seating
(orre(tly
Che(+ tappet (learan(e
JE Che(+ a7i# press#re and
e7ha#st teperat#re
J< Cns#ita2le f#el Che(+ grade 0 spe(ifi(ation
JH Ins#ffi(ient air (a#sed (ho+ed air
inta+e or filter
Che(+ and (lean
'
6a#lts J> and J? will also 2e indi(ated 2y a variation in the e7ha#st
teperat#re' !eavy 2l#e so+e in the e7ha#st is (a#sed 2y l#2ri(ating oil
getting past the piston rings$ possi2ly d#e to 2ro+en or worn rings or
alternatively d#e to worn grooves or (ylinder liners'
EJP#O'ION' IN DIE'E# ENGINE CRAN!CA'E'

The high standard of design and (onstr#(tion of %iesel Engines has
res#lted in a (orrespondingly high standard of safety' E7plosions in
(ran+(ase have$ therefore$ 2een relatively rare'
6ew e7plosions have 2een re(orded and (aref#l e7aination of the +nown
fa(ts shows that these have alost invaria2ly 2een d#e to overheating of an
internal part and the (onse5#ent ignition of a parti(#lar i7t#re of l#2ri(ating
oil ist and the air present in every (ran+(ase'

42
The ris+ of an e7plosion will 2e red#(ed if the following instr#(tions are stri(tly
(arried o#t 2y the Engineers in (harge of the engines)

WarningA
>' Early dete(tion of overheating and propt slowing down or stopping
of the engine as (ir(#stan(es perit will prevent the o((#rren(e of
(onditions favo#ra2le to fire or e7plosion'
?' Cran+(ase doors or inspe(tion doors &!OC1% NOT ,E OPENE%
and the engine sho#ld not 2e restarted or 2arred ro#nd #ntil it has
(ooled'
9' Overheated s#rfa(es sho#ld not 2e sprayed with oil li+ely to prod#(e
inflaa2le vapo#r$ the presen(e of whi(h in(reases the ris+ of fire'
;' Na+ed lights sho#ld never 2e #sed inside a (ran+(ase or other
en(losed (ha2er where an inflaa2le vapo#r or oil ist ay
2e present'

'OME GENERA# P1MP PRO4#EM' AND T@E REMEDIA# ACTION'
'DMPTOM PRO4A4#E "A1#T REMEDD
A) Pu&p %oes not %eli,er pro%uct
> Ipeller rotating in wrong
dire(tion
Reverse dire(tion of rotation
? P#p not properly priedB Air or
vapo#r lo(+ in s#(tion line
&top p#p and re4prie
9 Inlet of s#(tion pipe ins#ffi(iently
s#2erged
Ens#re ade5#ate s#pply of li5#id
; Air lea+s in s#(tion line or gland
arrangeent
Ma+e good any lea+s$ repa(+
glands or (he(+ e(hani(al seals
E P#p not #pto sti(+ing speed In(rease speed
4) Pu&p %oes not %eli,er rate% Iuantit-
> Air or vapo#r lo(+ s#(tion line &top p#p and reprie
? Inlet of s#(tion pipe ins#ffi(iently
s#2erged'
Ens#re ade5#ate s#pply of li5#id'
9 P#p not #ptp rated speed In(rease speed
; Air lea+s in s#(tion line or gland
arrangeent
Ma+e good any lea+s repa(+
glands$ or (he(+ e(hani(al
seals'
E 6oot valve or s#(tion strainer
2lo(+ed
Clean foot valve or strainer
< Restri(tion in delivery pipewor+
or pipewor+ in(orre(t
Clear o2str#(tion or re(tify error
in pipewor+'
H !ead #nderestiated Che(+ head losses in delivery
pipes$ 2ends and valves' Reading
losses as re5#ired'
= Cno2served lea+ in delivery
pipewor+
E7aine pipewor+ and repair
lea+
J ,lo(+age in ipeller.s/ or (asing %isantle p#p and (lear
43
o2str#(tion'
>: E7(essive (learan(e at wear rings
or wearing plates
%isantle p#p and restore
(learan(es to original diensions
>> Ipeller.s/ daaged' %isantle p#p and renew
ipeller.s/
>? P#p gas+ets lea+ing Renew defe(tive gas+ets'
C) Pu&p %oes not generate rate% %eli,er- pressure
> Ipeller rotating in wrong
dire(tion
Resverse dire(tion of rotation
? P#p not #pto rated speed In(rease speed
9 Ipeller wear rings or wearing
plates wor e7(essively'
%isantle p#p and restore
(learan(es to original diensions
; Ipeller .s/ daaged or 2lo(+ed %isantle p#p and renew
ipeller or (lear 2lo(+age
E P#p gas+ets lea+ing Renew defe(tive gas+ets
D) Pu&p losses liIui% a0ter starting
> &#(tion line not f#ly pried * Air
or vapo#r lo(+ in s#(tion
&top p#p and re4 prie
? Inlet of s#(tion pipe ins#ffi(iently
s#2erged
Ens#re ade5#ate s#pply of li5#id
at s#(tion pipe inlet
9 Air lea+s in s#(tion line or gland
arrangeent
Ma+e good any lea+s$ repa(+
glands or (he(+ e(hani(al seals
; 1i5#id seal to gland arrangeent
logging ring .if fitted/ 2lo(+ed
Clean o#t li5#id seal s#pply
E) Pu&p o,erloa%s
> P#p gas+ets driving #nit Renew defe(tive lea+ing gas+ets
? ,ad lea+ in delivery line$ p#p
delivering ore than its rated
5a#antity
Repaif lea+
9 E7(essive speed Red#(e speed
; Ipeller wear rings or wearing %isantle p#p and restore
(learan(e to original diensions
E Gland pa(+ing too tight &top p#p$ (lose delivery valve
to relieve internal press#re on
pa(+ing$ sla(+en 2a(+ the gland
n#ts and retighten to finger
tightness
< Me(hani(al seal fa#lt Che(+ and repair Me(hani(al seal
H Ipeller daaged %isantle p#p and renew
ipeller.s/
= Me(hani(al lightness at p#p
internal (oponents
%isental p#np$ (he(+ internal
(learan(e and adI#st as
ne(essary
") E?cessi,e ,i3ration
> Air or vapo#r lo(+ in s#(tion &top p#p and reprie
? Inlet of s#(tion pipe ins#ffi(iently
s#2erged
Ens#re ade5#ate s#pply of li5#id
at s#(tion pipe inlet
9 P#p and driving #nit in(orre(tly
aligned
%is(onne(t (o#pling and Realign
p#p and driving #nit
; Worn of loose 2earing %isantle and renew 2earings
E Ipeller.s/ 2lo(+ed or daaged %isantle p#p and (lear or
44
ipeller.s/ renew
< Rotation eleent shaft 2ent %isantle p#p and straighten
or renew shaft
H 6o#ndation not rigid Reove p#pB strengthen the
fo#ndation and reinstall p#p
= Co#pling daaged Renew (o#pling
J Pipewor+ e7erting strain on
p#p
%iss(onne(t pipewor+ and realign
to p#p
G) 4earing o,ereating
> Pp#p and driving #nit o#t of
alignent
%is(onne(t (o#pling and realign
p#p and driving #nit'
? Oil level too low or too high Replenish with (orre(t grade of
oil or drain down to (orre(t level
9 Wrong grade of oil %raining o#t 2earing thro#gh'
6l#sh 2earings$ refill with (orre(t
grade of oil'
; %irt in 2earings %isantle$ (lean o#t and fl#sh
thro#gh 2earingsB refill with
(orre(t grade of oil
E Moist#re in oil %rain o#t 2earing fl#sh thro#gh
and refill with (orre(t grade of
oil' %eterine (a#se of
(ontaination and re(tify
< ,earing too tight Ens#re that 2earings are
(orre(tly 2edded to their Io#rnals
with (orre(t ao#nt of oil and
(learness' Renew 2earings if
ne(essary
H Too #(h grease in 2earings Clean o#t old grease and repa(+
with (orre(t grade and ao#nt of
grease
= Pipewor+ e7erting strain on
p#p
%isantle pipe wor+ and realign
to p#p
@) 4earings wear rapi%l-
> P#p and driving #nit o#t of
alignent
%is(onne(t (o#pling and realign
p#p 0 driving #nit' Renew
2earings if ne(essary'
? Rotating eleent shaft 2ent %isental p#p' &traighten or
renew shaft' Renew 2earings if
ne(essary'
9 %irt in 2earings Ens#re that only (lean oil is #sed
to replenish 2earings' Renew
2earings' Renew 2earings if
ne(essary
; 1a(+ of l#2ri(ation Ens#re that oil is aintained at
its (orre(t level$ or that oil
syste is f#n(tioning (orre(tly'
Renew 2earings if ne(essary'
E ,earings 2adly installed Ens#re that 2earings are
(orre(tly 2edded to their Io#rnals
with (orre(t ao#nt of oil
45
(learan(e' Renew 2earings if
ne(essary'
< Pipewor+ e7erting strain on
p#p
Ens#re that pipewor+ is (orre(tly
aligned to p#p' Renew 2earings
if ne(essary
H E7(essive Vi2ration Refer to ."/
I) Irregular %eli,er-
> Air or vapo#r lo(+ in s#(tion line &top p#p and reprie
? 6a#lt in driving #nit E7aine driving #nit and a+e
good defe(ts
9 Airlea+s in s#(tion line or gland
arrangeent
Ma+e good any lea+s$ repa(+
gland or (he(+
; Inlet of s#(tion pipe ins#ffi(iently
iersed in li5#id
Ens#re ade5#ate s#pply of li5#id
at s#(tion pipe inlet
F) E?cessi,e noise le,el
> Air or vapo#r lo(+ in s#(tion line' &top p#p and reprie
? Inlet of s#(tion pipe ins#ffi(iently
s#2erged
Ens#re ade5#ate s#pply of li5#id
at s#(tion pipe inlet
9 Air lea+s in s#(tion line or gland
arrangeent
Ma+e good any lea+s$ repa(+
gland or (he(+ e(hani(al seals
; %is(onne(t (o#pling and realign
p#p and driving #nit
%is(onne(t (o#pling and realign
p#p and driving #nit
E Worn or loose 2earings %isantle and renew 2earings
< Rotating eleent shaft 2ent %isantle p#p straighten or
renew shft
H 6o#ndation not rigid Reove p#p and driving #nit$
strengthen fo#ndation
PROCE%CRE 6OR TCR,OC!ARGER WATER WA&!ING
i' R#n the Engine in f#ll load for >-? ho#r
ii' Red#(e the load to 9:N and r#n the engine for >: in' for sta2ili3ation'
iii' Pre heated water at a2o#t H: C inIe(t for >: in' +eeping 2oth the inlet
no33les and the drain valve open' Allow the (ar2on i7ed water to (oe
o#t thro#gh the drain valve'
iv' InI(ting hot water press#re will 2e >'? 8g'-&5$('
v' After the water washing r#n the engine for >: Min' in the sae (ondition'
vi' Grad#ally in(rease the load of the engine to f#ll load'
vii' Close the inlet no3els and the water draining valves'
GAC8ET WATER CON%ITION MONITORING
ROC8ER N, 1i5#id is #sed as (orrosion inhi2itor for M-1 Engine Ga(+et water
syste' It (ontrols (orrosion of piping$ valves$ p#ps and heat e7(hangers 2y
foring a prote(tive fil on all e7posed etal s#rfa(es4 iron$ steel$ (opper$
alloys$ al#in# and 2rass'
APP1ICATION)
46
6eed the re5#ired 5#antity of Ro(+er N, li5#id at (ir(#lating devi(e provided in
the (ooling syste of engine'
47
%O&AGE)
Con(entration level in the syste #st not 2e allowed to drop 2elow >E::
pp as nitrite.NO
?
/' 6or e(onoi(al reasons try to aintain nitrite level
2etween >E:: pp to ?::: pp altho#gh higher nitrite levels will not (a#se
operating diffi(#lties' Nitrite level is o2tained 2y #sing a siple (olo#rietri(
test for nitrite'
%O&E TA,1E)
Nitrite reading as pp No' ? Ro(or N, li5#id re5#ired in ltrs per >:::
ltrs of water in syste'
:49:: >;
9::4<:: >:
<::4J:: =
J::4>?:: E
>?::4>E:: ?
Over >E:: NONE
6RE"CENCK O6 TE&TING AN% GENERA1 POINT&
The details on vario#s tests of engine (ir(#lated water 0 feed water 2eing
(arried o#t$ its responsi2ility$ liits 0 periodi(ity are given 2elow)
.A/ Engine (ir(#lated water)
&l'
No
Type of Test 1iits to 2e
aintained
Periodi(ity
.>/ Nitrate Test A2ove >E:: PPM Wee+ly for ea(h engine
.?/ !ardness Test 1ess than E: PPM 6ortnightly for ea(h engine
.9/ Chloride Test 1ess than E: PPM 6ortnightly for ea(h engine
.;/ P! H'E to J'E 6ortnightly for ea(h engine
.,/ 6eed water . %M water M Raw water/ or .RO Plant o#t p#t water/)
&l'
No
Type of Test 1iits to 2e
aintained
Periodi(ity
.>/ !ardness Test 1ess than ?: PPM Whenever %M water is i7ed
with Raw water or wee+ly
on(e wherever RO Plant is
installed'
.?/ Chloride Test 1ess than ?: PPM 4do4
.9/ T%& 1ess than E: PPM 4do4
The test res#lts to 2e re(orded'
%istilled-%'M' Water)
Cpon re(eipt of distilled-%'M'water$ T%& .Total %issored &olids/ shall 2e
(he(+ed 2y T%& Meter 2y &hift Engineer 2efore #nloading and the sae
48
shall 2e less than >: PPM' If T%& is ore than >: PPM$ that parti(#lar
2at(h of distilled-%'M'water shall 2e reIe(ted'
6or aintaining the re5#ired 5#ality of feed water$ the distilled-%'M'water
shall 2e i7ed with raw water in the (orre(t proportion as re(oended
and stored in a (losed (ontainer' The proportion of distilled-%'M'water and
raw water shall vary fro site to site 2ased on the 5#ality of raw water
availa2le at that parti(#lar site' The (#rrent proportion of
distilled-%'M'water and raw water to 2e aintained shall 2e re(orded in a
register +ept #nder (#stody of &hift Engineer'
R)O)Water)
If R'O' Plant is availa2le at site$ the o#tp#t fro R'O' plant only shall 2e
#sed as a feed water for ainline engine (ooling'
Note)4 >::N distilled water shall not 2e #sed as a feed water for engine as
the sae is h#ngry for eating etal fro engine parts'
NITRITE TE'T .,ased on Ro(he test +it/
APPARATC&
>' Test T#2e
?' Titrator
9' &poon
REAGENT&
>' Nitrite Reagent No'>
?' Nitrite Reagent No'?
9' P! PAPER PAC8
PROCE%CRE
>' 6ill the Test T#2e to the El grad#ation ar+ with the water to 2e tested'
?' Add one spoonf#l of Nitrite Reagent No' > to the eas#red saple' Insert
the Test T#2e Cap and sha+e the i7t#re #ntil the powder has dissolved '
Please refer Note given 2elow'
9' The Titrator is filled with Nitrite Reagent No ? to the R3eroF ar+' Insert
the Titrator in the Centre hole of the Test T#2e Cap'
;' The Nitrite Reagent No ? is added drop 2y drop$ sha+ing gently$ #ntil a
pin+ (olo#r reains in the test i7t#re for 9: se(onds' The res#lt of the
test is read fro the s(ale on the side of the Titrator'
E' Res#lt is o2tained in pp nitrite 2y #ltiplying the Titrator reading 2y one
h#ndred'
Note)4 Ro(+er N, test is 2ased on the o7idation of sodi# nitrite 2y potassi#
per anganate)
This rea(tion only ta+es pla(e in an a(id environent * (reated 2y adding
Reagent No'> Norally one spoon is s#ffi(ient' In (ase a(id environent is
49
not a(hieved the first drop of Reagent No'? will res#lt in a (oloration of the
water saple$ s#ggesting the test is terinated$ res#lting in a 3ero reading
for Nitrite' In (ase of do#2t (he(+ p! of water saple with paper p! sho#ld
2e 2elow 9' If higher add e7tra regent No' > and pro(eed with test as #s#al'
@ARDNE'' TE'T .,ased on Ro(he test +it/

APPARTC&
>' Test T#2e
>' Titrator
REAGENT&
!ardness ,#ffer Reagent No'E
!ardness Indi(ating Reagent No'<
!ardness Titation Reagent No'H
PROCE%CRE
>' 6ill the Test T#2e to >: l level with the water saple to 2e tested'
?' Add E drops of the !ardness ,#ffer Reagent No'E to the water saple and
i7'
9' Add > spoon !ardness Indi(ator reagent No' < Insert the Test T#2e Cap
and sha+e to i7'
;' The Titrator is filled with the !ardness Titration Reagent No'H to the R3eroF
Mar+ Insert Titrator in the (entre hole of the Titration T#2e Cap'
E' The !ardness Test Reagent No'H is added drop 2y drop$ sha+ing gently
2etween drops$ #ntil red (olo#r (hanges to (lear 2l#e'
<' The res#lt is o2tained in pp Cal(i# Car2onate 2y #ltiplying the
Mi(ro2#rrette reading 2y >:'
C@#ORIDE TE'T .,ased on Ro(he test +it/
APPRATC&
>' Test T#2e
>' Titrator
REAGENT&
?El' Chloride Reagent No'>
E:l' Chloride Reagent No'?
>El' Phenolphthalein Reagent
>El' &#lph#ri( A(id Reagent .:'EN'/
PRO%E%CRE
>' 6ill Test T#2e to >El' 1evel with the water saple to 2e tested'
?' Add one drop of the Phenolphthalein Reagent to the saple' If the sol#tion
reains (olo#rless$ pro(eed dire(tly to step 9' If the saple t#rns red$ add
50
the &#lph#ri( A(id one drop at a tie #ntil the red (olo#r disappears then
pro(eed to step 9'
9' Add three drops of the Chloride Reagent No'> to the saple in the Test
T#2e$ insert the Test T#2e Cap and sha+e to i7' A yellow (olo#r will
res#lt'
;' 6ill Titrator with the Chloride Reagent No' ? to the R3eroF ar+' Then add to
the saple drop 2y drop$ sha+ing gently$ #ntil the Kellow (olo#r is
peranently (hanged to pin+-2rown'
Res#lt is o2tained in p'p'' Chloride 2y #ltiplying Titrator reading 2y ten'
EMERGENCD GENERATOR
%etailed 5#ality pro(ed#res is given in Pro(ed#re and Wor+ Instr#(tion Man#al
on @OperationsA.Pro(ed#re no' WI-OPN-></'

&TARTING O6 EMERGENCK GENERATOR
,efore start #p of eergen(y generator the following (he(+s are 2eing
(arried o#t'
.a/ Topping #p level in radiator fro water a+e #p tan+ or fro
dire(t water (onne(tion'
.2/ %raining o#t any oist#re fro starting air 2ottle and (harges
the re(eiver to its (orre(t wor+ing press#re'
.(/ Che(+ing the s#p l#2e oil level and (onfir that$ it is within the
liits on the dip sti(+'
.d/ Che(+ing s#ffi(ient diesel is there in the diesel tan+'
.e/ Ens#re that the ,C&4COCP1ER is in O66 position 2efore start #p
of Eergen(y Generator'
After ens#ring the a2ove (he(+s$ swit(h ON following)
.a/ Engine l#2e oil priing p#p$ tho#gh this p#p reains on
ACTO and starts-stops a#toati(ally periodi(ally to +eep the
engine l#2ri(ated all the tie'
i' Reset the signal .!igh l#2e oil$ !igh Ga(+et water teperat#re/ if any
fo#nd on AM6 panel'
ii' Open air 2ottle o#tlet valve'
iii' Give the starting (oand to E-G either fro AM6 panel 2y pressing
&TART 2#tton or fro (#t off valve installed on E-G in the air line'
iv' After the engine has started$ (loses (#t4off-5#i(+ly if the starting
(oand is given fro (#t4off valve and (loses the air 2ottle o#tlet
valve'
v' After the engine has started$ (he(+ the different press#re and
teperat#re readings e'g' 1#24oil press#re 2efore 0 after the filter$
raw water press#re$ Ia(+et water press#re$ (harge air press#re$
51
(ylinder teperat#re on the E-G paraeters display panel and a#to
start#p of raw water p#p'
vi' If vario#s paraeters are within liits as per Man#fa(t#rerUs an#al$
to r#n E-G on NO41OA% for a spe(ified period of trial r#n OR if
re5#ired p#t E-G ON41OA% 2y (losing E-G (ir(#it 2rea+er in the MCC
panel'
vii' If r#nning ON41OA%$ re(ord different paraeters on E-G data sheet'
Also re(ord the starting tie in shift 1og ,oo+ as well as in E-G data
sheet'
&TOPPING O6 EMERGENCK GENERATOR
i' If r#nning ON41OA%$ disengage .open/ E-G (ir(#it 2rea+er in MCC
panel'
ii' Give the stopping (oand 2y pressing the S&TOPS 2#tton on AM6
panel and the engine stops'
iii' Re(ord the stopping tie in &hift 1og ,oo+ and also re(ord in the E-G
log4sheet'
iv' Re(ord total r#nning period of E-G in E-G r#nning log4sheet'
Attention while r#nning

.i/ As soon as the engine has started$ air re(eiver sho#ld 2e re(harged
and re5#ired press#re aintained'
.ii/ Ens#re that the l#2e oil teperat#re and press#re are within liits'

.iii/ Che(+ the (ondition of e7ha#st' It shall 2e neither so+y white nor
sooty dar+

"IRE "IG@TING ENGINE
&TARTING O6 6IRE 6IG!TING ENGINE-PCMP
>'> ,efore starting of fire fighting engine-p#p$ (arry o#t following
(he(+s)
.a/ Che(+ water level in radiator and a+e #p the water if it is less'
.2/ Che(+ s#p l#2e oil level and that it is within liits on the dip
sti(+'
.(/ Che(+ diesel level in the diesel tan+ and (opensate if it is less'
.d/ ,ring the press#re in the (opressed air 2ottle to a2o#t >:':
8g-(
?
'
.e/ Ens#re that p#p in disengaged position'
.f/ Ens#re that an#al over ride sh#tdown +no2 is f#lly tightened'
>'? Open the o#tlet valve of (opressed air 2ottle'
52
>'9 Open the air starting valve and (lose it iediately the engine gets
start'
>'; Reg#late the a((elerator in s#(h a way that after the start #p of engine$
it r#ns at >::: RPM'
>'E Allows the engine to war #p for ;4E in#tes and 2rings the engine to
noral speed of >E:: RPM thro#gh a((elerator'
>'< Now he engages the p#p thro#gh (l#t(h handle'
>'H In (ase of eergen(y$ starts the engine iediately after the siren is
so#nded and adI#sts the p#p dis(harge press#re in s#(h a way that
ade5#ate press#re is availa2le at the farthest point of fire fighting water
line in p#p station'
?': &TOPPING O6 6IRE 6IG!TING ENGINE-PCMP
?'> In the noral ro#tine or after the eergen(y is over and long siren is
so#nded$ &hift Engineer- &hift !elper does the following a(tivities to
stop the 6ire 6ighting Engine-P#p'
.a/ %isengage p#p thro#gh (l#t(h handle'
.2/ Red#(e the speed of engine to >::: RPM thro#gh a((elerator'
.(/ &top the engine 2y rotating anti4(lo(+wise an#al over4ride
sh#tdown +no2 or ele(tri(ally'
?'? After the engine is stopped$ rotate (lo(+wise the an#al over ride
sh#tdown +no2 so that it is f#lly tightened'
?'9 Re(ords the d#ration of r#nning of 6ire 6ighting Engine in E5#ipent
R#nning Register- 1og2oo+'
9': &TARTING-&TOPPING O6 MOTOR %RIVEN 6IRE 6IG!TING PCMP
9'> Ens#re that ain swit(h of starter panel in the MCC Roo is in VONU
position'
9'? 1o(al- Reote sele(tor swit(h on MCC Panel is to 2e +ept in V1OCA1U
position'
9'9 Che(+ l#2e oil level of p#p 2earing (#p'
9'; Ens#re S&TOPS p#sh 2#tton in the field in #nlo(+ed position'
9'E Press SONS p#sh 2#tton in the field for starting the p#p'
9'< 6or stopping$ press SO66S p#sh 2#tton in the field and lo(+ it'
53
6or Ganagar$ &#rendranagar$ 8antalia$ Rasar$ Rewari 0 Viraga newly
installed engine driven p#ps are dire(tly (o#pled to engine' At Nagar also$
ele(tri( starting .witho#t air/ is #sed' The details are as #nder)
A) Pre start cecksA
>/ Ens#re diesel in f#el tan+ is topped #p'
?/ 1#2e oil level in engine s#p is till the level ar+ed on dip sti(+'
9/ Water level in the radiator is f#ll'
;/ &#(tion and dis(harge val#es of p#ps are open'
4) Air 'tartA
&tarting Pro(ed#re)
>/ Ens#re press#re in air 2ottle is H4>: +g-(
?
+no2'
?/ Open f#el solenoid valve 2y an#ally t#rning the over ride +no2'
9/ Open the air starting valve an#ally and hold it for 94; se(' and
(lose it'
;/ If the engine does not start repeat pro(ed#re .9/ on(e again'
E/ On(e the engine starts$ adI#st the speed to >E:: rp 2y
operating the speed (ontrol +no2'
</ AdI#st the header press#re 2y operating the tan+ ret#rn val#e to
H': 8g-(
?
'
&topping Pro(ed#re)
>/ Red#(e the speed to E:: rp 2y operating the speed (ontrol
+no2'
?/ Close the f#el solenoid valve 2y an#ally (losing the over ride
+no2'
C) 4atter- 'tartA
&tarting Pro(ed#re)
>/ T#rn the +ey on in the (ontrol panel'
?/ Press the start p#sh 2#tton on the (ontrol panel'
9/ On(e the engine starts$ adI#st the speed to >E:: rp 2y
operating the speed (ontrol +no2'
;/ AdI#st the header press#re 2y operating the tan+ ret#rn val#e to
H': 8g-(
?
'
&topping Pre(ed#re)
>/ Red#(e the speed to E:: rp 2y operating the speed (ontrol
+no2'
?/ T#rn the +ey off on the (ontrol panel'
Iportant

>' &top the engine iediately if any pro2le is noti(ed'
54
?' P#p sho#ld 2e engaged only when the engine has rea(hed >E:: RPM'
9' Grease the (l#t(h reg#larly'
;' If any a2noral so#nd is heard for the (l#t(h d#ring operation$
investigate the pro2le iediately'
Ro#tine operation

The fire fighting engine sho#ld 2e r#n daily for >E in#tes in the orning shift
and o2servation on its perforan(e sho#ld 2e re(orded in the log 2oo+'
The @Meas#ring and Monitoring of Eission Paraeters .&PM$ &O?$ CO$ NOT
et('/ will 2e done as per 5#ality pro(ed#re No'WRP1-EPM-;-J'9 of
Environental Pro(ed#re Man#al' 6#rther eas#ring and onitoring of Noise
level will 2e done done as per pro(ed#re No'WRP1-EPM-;-J'E of
Environental Pro(ed#re Man#al'
'CRAPPER (PIG) #A1NC@ING PROCED1RE

The following pro(ed#re is adopted for la#n(hing of s(raper 2arrel'

>' Epty the 2arrel 2y opening the drain valve'

?' Open the trap (los#re door$ insert the pig or s(raper and p#sh it till it
goes (opletely into the 2arrel'

9' Close the door (los#re and the drain vale
;' &et the pig signaler in position
E' Press#ring the 1a#n(hing ,arrel 2y A
a/ Opening the !OV of 2ypass line of &(rapper 1a#n(hing 2arrel
2/ Venting o#t the trapped air of the 2arrel 2y opening the air vent
valve
(/ Open the MOV of the &(rapper 1a#n(hing ,arrel f#lly
d/ Close the stn' o#tlet MOV to divert the flow thro#gh the 2arrel
e/ Note the tie 0 NRC of the other station at the tie the pig
alar (onfirs the la#n(hing of the Pig in the M-1 0 1-1 and re(ord
in the log 2oo+ and infored to the down station
<' Norali3e the flow dire(tion after the pig la#n(hing over 2y )
a/ Opening the &tn' o#tlet valve
2/ ,y (losing the MOV of the &(rapper la#n(hing 2arrel
(/ Close the !OV of 2y pass line of s(rapper la#n(hing 2arrel'
H' After ens#ring that pig is la#n(hed into the line$ open the drain valve
and the vent valve$ drain the 2arrel and then (lose the drain valve and
the vent valve'
55
'CRAPPER (PIG) RECEI$ING PROCED1RE
a) &hift4in4(harge (olle(ts e7a(t la#n(hing tie of the pig and the NRC of
the other &tn' at the tie of la#n(hing the pig fro the #pstrea stn'
3) Colle(ts fro Central %espat(h the ETA of pig
c) &hift4in4(harge verifies the ETA of pig 2y his own (al(#lation with the
data availa2le in the log 2oo+'
%) &hift4in4(harge diverts the flow thro#gh pig re(eiving 2arrel one ho#r
2efore as per the instr#(tion fro Central %espat(h and re(ords in the
log 2oo+' As per the instr#(tion des(ri2es in &l' No' E' .I/ to .IV/ for
&(rapper la#n(hing pro(ed#re a2ove'
e) &hift4in4(harge ta+es sh#t down and 2y4pass the &tn' half an ho#r
2efore the ETA of pig 2y (losing the respe(tive MOVs'
0) &hift4in4(harge re(eives the pig at the tie of pig sig gives alar $
notes down the pig arrival tie $ re(ords it in the 1og ,oo+ and infors
to Centarl %espat(h'
g/ &hift4in4(harge res#es p#ping after half an ho#r or as dire(ted 2y
Central %espat(h after opening the sts' 2y4pass valves$
&hift4in4(harge norali3e the flow dire(tion after the pig re(eiving over as per
instr#(tions given in &l'No'<' a/ to (/ for &(rapper la#n(hing pro(ed#re' Pig is
ta+en o#t fro the 2arrel 2y the &tation Me(hani( after draining o#t the (r#de
fro the 2arrel into the &#p tan+' Colle(ts the #(+ if any$ re(eived pig is
inspe(ted for any daages et(' and reports prepared'
&TATION
MAIN 1INE 1OOP 1INE
Total
vol#e
in 8ls
Appro7'
Travelling
Tie in
!rs'
%istan(e in
8'
Vol#e
in 8ls'
%istan(e
in 8'
Vol#e
in 8ls'
&V &e(tion 6low rate 9::: 8ls-hr'
Vadinar- The2a ;<'H >H=:< ;<'H >H=:< 9E<>? >?':>
The2a - Ga#ridad <H'J ?E=HJ >?'< ;=:9 9:<=? >:'9E
Ga#ridad - &UNagar >::'; 9=?=> >::'; 9=?=> H<E<? ?E'=9
&UNagar - Viraga EJ'; ??<E= 4444 4444 ??<E= H'<;
C 4 M se(' 6low rate >>E: 8ls-hr'
Cha+s# - Math#ra >JH'? E;=?H 444 444 E;=?H ;='?E
C 4 P se(' 6low rate J:: 8ls-hr'
Cha+s# - Rewari ?:E'H> EE>>9 444 444 EH??J <;'9<
Rewari - Panipath >;9'; 9J=?> 444 444 9J=?> ;;'H=
&TATION MAIN 1INE 1OOP 1INE
56
Total
vol#e
in 8ls
Appro7'
Travelling
Tie in
!rs'
%istan(e in
8'
Vol#e in
8ls'
%istan(e
in 8'
Vol#e
in 8ls'
V 4 C &e(' 6low rate 9::: 8ls-hr'

Viraga - &idhp#r J='9E ?H9<> 9='?:= >:<9: 9HJJ> >J'>=
&idhp#r - A2# Road >::'J? ?>JH= 99'J?> ;99= ?<9>< >9'9?
A2# Road - 8ot >::'J? ?=:H< 99'J?> J;9H 9HE>9 >='J=
8ot - RaIola =E'?9 ?99<9 444 444 ?99<9 >>'=?
RaIola - &endra E>'EE >;9;> 444 444 >;9;> H'?<
&endra - Rasar H<'JE ?>=9J 444 444 ?>=9J >>':E
Rasar - Cha+s# >>9'=: 9><EJ ?>'=E; <:=: 9HH9J >J'>:

V 4 8 &e(' 6low rate >>?E 8ls-hr'
Viraga - 8oyali >;='?< ?E<9E 444 444 E<E9E E:'=<


TERMINA# 'TATION OPERATION
%etailed 5#ality pro(ed#res are given in Pro(ed#re and Wor+ Instr#(tion
Man#al on @OperationsA'
8oyali$ Math#ra and Panipat are the re(eiving ends of the &alaya4Math#ra
Pipeline' The (r#de despat(hed fro (ha+s# in Cha+s#4Math#ra se(tion and
fro Viraga in Viraga48oyali &e(tion is re(eived at Math#ra and
8oyali Terinal &tations respe(tively$ and the (r#de p#ped in Cha+s#4
Panipat se(tion is re(eived at Panipat'
The terinals are e5#ipped with Inlet valves$ Press#re (ontrol valve$
&trainer$ 6low Meter$ %ensity Meter et(' The (r#de re(eived in the terinal
station is ro#ted thro#gh these e5#ipents 2efore going to anifold and
finally to tan+s in the refinery'
TAN! DETAI#' AT TERMINA# 'TATION'
Refinery Tan+
No'
Type of
Cr#de
&afe filling
!eight in CM
&afe filling
Cap' in 8ls'
%ead &to(+
in 8ls'
8oyali H:> 1& >?:: 9:::: H$:::
4do4 H:? 1& >?:: 9:::: H$:::
4do4 H:9 1&-,! >??: 9:::: H$:::
4do4 H:; 1&-,! >??: 9:::: H$:::
4do4 HH: 1& >??: <>$::: >?$:::
4do4 HH> 1&-,! >??: 9:$::: H$:::
4do4 HH? 1& >??: 9:::: H$:::
4do4 J:> !& >>=> ?JE:: H$:::
4do4 J:? !& >>=> ?JE:: H$:::
4do4 J:9 !& >>=> ?JE:: H$:::
57
4do J:; !& >>=E ?JE:: H$:::
Math#ra ::> !& ><:E ;<9JJ <$:::
4do4 ::? !& ><:E ;<9J; <$:::
4do4 ::H 1& >?E9 <>;?? >:$:::
4do4 ::= !& >?<? <>=:< >:$:::
4do4 ::9 ,! ><:= ;<E;: <$:::
4do4 ::; 1& ><:E ;<9H> <$:::
4do4 ::E !& ><:< ;<99< <$:::
4do4 ::< ,! ><:> ;<?=9 <$:::
Panipat 9:> 1& >>JE ;<$::: =$:::
4do4 9:? 1& >>JE ;<$::: =$:::
4do4 9:9 1& >>JE ;<$::: =$:::
4do4 9:; !& >>JE ;<$::: =$:::
Ter&inal Operation

8oyali$ Math#ra and Panipat Terinals have got the fa(ilities of re(eiving (r#de
oil #pto <'E MMPTA$ =': MMPTA and <': MMTPA respe(tively'
As per the line hydra#li(s$ a 2a(+ press#re of ;:-E: etres head is provided
at Terinal station' Therefore$ the press#re swit(h installed at terinal is set
for this head'

&tation is provided with a ainline 2lo(+ valve with ele(tri( a(t#ator at the
inlet side of terinal .MOV4?/' The p#rpose of the valve is for isolation of the
terinal station and lea+ dete(tion'

A station liit 2lo(+ valve$ an#ally operated is also provided for isolating the
entire station' In (ase$ a fire develops inside the station$ the station (an 2e
isolated fro ainline and fire (an 2e prevented'

The 2lo(+ valve .MOV4?/ is norally +ept open when the (r#de oil delivery is
ade to Refinery tan+s$ 2#t while re(eiving the s(raper$ this 2lo(+ valve is
+ept (losed' The valve is having p#sh 2#tton (ontrols and station indi(ating
laps are lo(ated in the (ontrol panel of the terinal station' &(raper
re(eiving fa(ilities with s(raper passage indi(ators are provided at the Terinal
&tation' &(raper passage indi(ator is also provided at the #pstrea end of the
2lo(+ valve'

A press#re transeter and a press#re ga#ge are also provided at the
#pstrea end of the 2lo(+ valve'

The press#re transeter is #sed to onitor the 2a(+ press#re and (ontrol the
lea+ dete(tion and eergen(y sh#tdown of the (oplete station'

At the down4strea end of the 2lo(+ valve .MOV4?/$ the following fa(ilities are
generally provided)

.>/ Control valve .PCP ,K4PA&&/ with ele(tro4hydra#li( Operator to (ontrol
2a(+ press#re and flow'
58
.?/ A press#re transeter$ press#re swit(h and press#re ga#ge are
provided for data gathering$ onitoring and (ontrol'
.9/ Inline strainer with 2lo(+ valves and a 2ypass line with a 2lo(+ valve are
provided' When the differential press#re a(ross the strainer e7(eeds a
val#e of :'= +g-(?$ the 2lo(+ valves are to 2e (losed$ the strainer is to
2e (leaned' %#ring this period$ the flow (an 2e diverted 2y opening the
2lo(+ valve provided on the 2ypas line$ so that interr#ption in the
p#ping operatin does not ta+e pla(e'
.;/ A f#ll flow .or &#rge/ relief valve has 2een installed for (ontrolling s#rge
pres#re' This s#rge relief valve has 2een provided as an additional
safety in (ase the (ontrol valve and press#re swit(h fails' %#ring this
period$ the flow is a#toati(ally diverted into the s#rge relief tan+' The
s#rge relief valve has got !i4!i level indi(ators and alars so that the
pipeline personnel availa2le in the (ontrol roo (an o2serve the
indi(ations and sh#t syste till the (ontrol valve and the press#re
transeter- swit(hes are re(tified' %#ring noral operation$ the 2lo(+
valve provided at the down strea of the s#rge relief valve sho#ld
always 2e +ept open'

.E/ %#al t#r2ine eter with isolating valves for eas#reent of total raw
flow and integrated flow of the station'

.</ Meter Prover with isolating valves and 2ypass valves for line integrity
(he(+s and (op#ting eter fa(tor'

.H/ The Terinal anifold with otor operated 2lo(+ valves and (he(+
valves' These 2lo(+ valves (an 2e operated 2y lo(ally or reote fro
the (ontrol roo'

.=/ A s#rge relief inIe(tor p#p is provided at the s#rge relief to epty o#t
the tan+ into the terinal anifold'

.J/ There will 2e an interlo(+ing arrangeent with the refinery tan+
anifold so that the ainline 2lo(+ valve (losed 2efore (losing the line
valve on the refinery anifold'

.>:/ %ensity Meter has 2een provided at the e7tree (orner of the
station o#tlet' This %ensity Meter is of radioa(tive type and gives an
appro7iate val#e of density and per(entage variation 2etween
,o2ay !igh (r#de to Iported (r#de varies ?: divisions'

.>>/ &#p p#p is to 2e operated when in the panel R!i4levelU alar
(oes' Power to 2e given to s#p p#p fro MCC Panel and starting
(oand to s#p p#p otor is to 2e given fro field' Appro7iate
tie ta+en to epty the s#p tan+ is 9: in#tes'

59
METER PRO$ER OPERATION
A/ At 8oyali$ Math#ra 0 Panipath

Meter Prover is provided for (ali2ration of flow eter to as(ertain
a((#ra(y of 5#antity delivered in the tan+'

Operation Proce%ure

.>/ 6irst (he(+ in the MCC PANE1 that the power s#pply for MOVs and Meter
Prover is RONF' P#t the lo(al-reote swit(h of MOV on reote ode in
the field' P#t also the Meter Prover swit(h on RReoteF in the field'

.?/ P#t the p#sh 2#tton swit(h 2ypass-on4line to ROnlineF in the (ontrol
panel' As soon as the swit(h is p#t ROnlineF MOV4>: 0 >> will start
opening' after MOV4>: 0 >> opened f#lly$ the MOV4J will start (losing'
Wait till MOV4J (losed f#lly'

.9/ P#sh the swit(h @In se5#en(e-ReadyA in Control Panel' It sho#ld show
@REA%KA position'

.;/ Then p#sh the yellow 2#tton RPROVEF' After a2o#t 9: se(onds
R1a#n(hedF lap will start flashing' This lap will 2e(oe steady after
few se(onds' The sphere has now start its Io#rney in the loop'
.E/ Then after a2o#t few se(onds Meter Prover (o#nter will start reading
a#toati(ally and will also stop a#toati(ally' Now the first (y(le is
over' Note down the Meter Prover reading' This reading is (alled the
first set of reading'

.</ To start another (y(le of operation$ there is a toggle swit(h inside the
3ener 2arrier 2o7' P#t it first in RONF position and 2ring 2a(+ to RO66F
position' The RREA%KF lap will glow'
.=/ 1i+e this ta+e < readings and average of those readings gives @AVERAGE
METER REA%INGA'
.J/ After proving is over press @,y Pass-ON 1ineA p#sh 2#tton to p#t the
prover in 2ypass' &wit(h O66 all the e5#ipents in the reverse order'

4) At $a%inar
>' 6ro MCC panel$ swit(h on the power s#pply for MOV49H$ 9= 0 9J and
eter prover otor' P#t the lo(al-reote swit(h of MOV4 9H$ 9= 0 9J
and the eter prover otor swit(h on reote ode in the field'
?' Ta+e perission fro Central %ispat(h for red#(ing the ain line flow
2elow ?;:: 81-!r for eter proving as the e7isting eter prover is
designed for a7 flow #p to ?;:: +l-!r' 8eep flow rate 2etween ?::: to
?;:: +l-!r'
60
9' %ivert the flow thro#gh Meter prover 2y opening MOV 9= 0 MOV 9J and
(losing MOV 9H'
;' Wait for >E in#tes for teperat#re sta2ilisation'
E' ,ring the eter prover s(reen on operator (onsole 2y (li(+ing @METER
PROVERA 2#tton provided in MAIN MENC %isplay'
<' Cli(+ METER 6ACTOR 2#tton on METER PROVING &(reen$ another
s(reen METER 6ACTOR REPORT will appear where online date 0 tie
s#(tion- dis(harge press#re$ flow rate et( will appear$ verify a2ove
paraeters with ii( panel paraeters'
H' Cli(+ METER PROVER %ATA ENTRK 2#tton on METER 6ACTOR REPORT
s(reen$ another s(reen will appear where paraeters li+e Meter Prover
No' R#nning Tan+$ Type of Cr#de$ A2ient Teperat#re$ %ensity of
(r#de at >E
o
C$ Chara(tristi( of (r#de$ last eter fa(tor et( to 2e filled
#p' 6ill #p all re5#ired data (orre(tly' Again press METER PROVER
6ACTOR ,#tton ain s(reen will appear with #pdated data and online
data'
=' &ele(t >
st
,at(h$ Reset Meter Proving 2y (li(+ing RE&ET METER
PROVING 2#tton' After 9: a2o#t se(onds @&phere la#n(hedA essage
will 2e displayed on the s(reen and sphere has now started its Io#rney'
J' After a few se(onds eter prover (o#nter will start reading
a#toati(ally and will also stop a#toati(ally' Now first (y(le is over
and no of p#lses will 2e stored for >
st
2at(h'
>:' Prover (oes to ready position a#toati(ally after (opletion of the
(y(le' 1i+ewise ta+e five readings 2y sele(ting the ?
nd
2at(h $9
rd
2at(h$
;
th
2at(h and E
th
2ath s#2se5#ently' The data sheet of METER 6ACTOR
REPORT will 2e #pdated for all E sets of readings'
>>' Average eter reading$ Net Meter Prover 6a(tor will a#toati(ally
displayed on the METER 6ACTOR REPORT' Ma+e ready the online printer
and ta+e the print 2y (li(+ing PRINT 2#tton on the s(reen'
>?' After proving is over$ divert the flow 2ypassing eter prover 2y opening
MOV 9H and (losing MOVs 9= 0 9J' &wit(h off all the e5#ipents in the
reverse order'
>9' After proving is (oplete and prover is isolated$ drain the prover to
depress#ri3e it and ta+e the (r#de in s#p tan+'
>;' R#n the s#p p#p to ta+e the (r#de of eter prover line in Main line'
In (ase of eter fa(tor is 2eyond a((epta2le liits .i'e :'JJ;E to >'::EE/ the
atter is 2ro#ght to the noti(e of T0I wing for (orre(tive a(tion

61
'@1TDOWN PROCED1RE

%etailed 5#ality pro(ed#res is given in Pro(ed#re and Wor+ Instr#(tion Man#al
on @OperationsA .Pro(ed#re no' WI-OPN->;/'

When the engine trips in prior P#ping &tation$ the line press#re and flow
rate falls grad#ally' To +eep the line press#rised and to 2e a2le to restart the
prior p#ping station engine .for a short sh#tdown/ and to dete(t any lea+
.for a long sh#tdown/ Terinal sh#tdown is ne(essary'
6or ta+ing sh#tdown$ (lose the PCV .for short sh#tdown/ and MOV4? .for long
sh#tdown/'
Proce%ure

6irst (lose the PCV and wat(h the press#re' When the press#re rea(hes to 9E
8g-(
?
as+ prior p#ping station to stop engines' Then (lose MOV4? .for
long sh#tdown/' Close only PCV when prior p#ping station as+ed or when
low flow alar (oes .6or short sh#tdown/'

E&ergenc- 'ut%own

Eergen(y &h#tdown is to 2e ta+en #nder the following o((asions)
.>/ In (ase of fire'
.?/ In (ase of line lea+ or 2#rst'
.9/ In (ase of any al4operation of MOVs when +ept in reote'

E&ergenc- 'ut%own 0ro& Control Panel

P#sh the eergen(y sh#tdown p#sh 2#tton in the Control Panel and infor
prior p#ping station as early as possi2le'
E&ergenc- 'ut%own 0ro& 0iel%

There are two E&% swit(hes$ one in front of (ontrol panel and the other in
front of 2ypass t#r2ine eter' Press either swit(h after 2rea+ing the glass to
ta+e eergen(y sh#t down and infor prior p#ping station as early as
possi2le line press#re within the spe(ified liits'
'TART 1P PROCED1RE

'tart 1p Proce%ure

%etailed 5#ality pro(ed#res is given in Pro(ed#re and Wor+ Instr#(tion Man#al
on @OperationsA.Pro(ed#re no' WI-OPN->9/'

A0ter a sort sut%own

Wait till prior p#ping station advises to start' If there is a (o#ni(ation
gap and if the press#re on the (ontrol panel in(reases$ then open the PCV
slowly and loo+ at the flow rate'
62

A0ter long sut%own

.>/ &ee whether the (orresponding tan+ in whi(h delivery is to 2e ta+en is
lined #p or not' Ma+e s#re it is to 2e lined #p'
.?/ The (orresponding MOV in tan+ far area is open and all other MOVs
(lose'

.9/ &ee whether all the in4line delivery valves are open in the Pipeline
Terinal'

.;/ Open MOV4? when prior P#ping &tation is ready to start p#ping'

.E/ Open PCV when prior p#ping station starts p#ping'

.</ Infor prior p#ping station and Refinery regarding the res#ption of
p#ping'

INTER"ACE C1TTING 6 TAN! C@ANGE O$ER
Three types of (r#de$ ,o2ay !igh$ Iported .low s#lph#r/ and Iported
.high s#lph#r/ are delivered to Refineries' The average density of ,! (r#de is
:'=?E and that of Iported is varies fro :'=;E to :'=<E' The (olo#r of ,!
(r#de is greenish 2la(+ and that of iported is 2la(+'
These two (hara(teristi(s help to dete(t the type of (r#de delivered to
Refineries'

Interfa(e is a proportionate i7t#re of two different types of (r#de oils whi(h
ta+es pla(e while travelling thro#gh the line' ,!-Iported (r#de .1&-!&/
interfa(e is to 2e ta+en in iported (r#de tan+s +eeping ,! (r#de as p#re as
possi2le' 1& and !& (r#de interfa(e is ta+en in !& (r#de oil tan+ to +eep 1&
neat' The noral tie ta+en 2y interfa(e 5#antity is apro7iately >E4?:
in#tes for 8oyali and ?E49: in#tes for Math#ra and Panipat refineries'

Inter0ace cutting

Interfa(e tiing to 2e (al(#lated depending #pon the flow rate and the 2at(h
length and the sae to 2e (onfored fro Central %espat(h'
>' Interfa(e tra(+ing started One !r' 2efore the arrival of
interfa(e with >E in' interval' After three saples$ fre5#en(y is
in(reased to every E in' and to sho#ld 2e in(reased to every in#te
as the interfa(e tie approa(hes nearer'

?' As soon as the density (hanges o((#r in the higher side
in (ase of ,!- Iported Cr#de interfa(e$ the tan+ (hange over is to 2e
ade +eeping ,! as p#re as possi2le'
9' In (ase of Iported-,! interfa(e$ tan+ (hange over is to 2e ade after
the interfa(e is over i'e' after getting the density of p#re ,!
63
;' In (ase of !&-1& interfa(e the interfa(e 5#antity is ta+en in !& tan+
+eeping 1& (r#de p#re'
E' Note down the tie of starting and (opletion of the interfa(e$ the
density variation o2served d#ring interfa(e tra(+ing and the tan+
(hange over tiing with NRC reading at the appropriate register'

Tank Cange O,er
Tan+ (hange over o((#rs when a parti(#lar tan+ whi(h is #nder delivery
happened to 2e topped #p i'e' .Iported-Iported or ,!-,!/$ or when the
,!-Iported or Iported-,! (hange over ta+es pla(e'

>/ Cal(#late the tan+ top #p tie as per the #llage and flow rate' 6inal
tie is to 2e (al(#lated as per the fo#r ho#rly dip and safe filling height
of the (orresponding tan+$ or the end of the parti(#lar par(el'

>/ After (al(#lating the tie of (hange over$ tan+ (hange over is
done 2y giving the OPEN- C1O&E (oand to the respe(tive MOVs
fro the P1C installed in (ontrol roo' In very rare (ase when there is
pro2le with the P1C the MOVs of respe(tive tan+s are operated 2y
giving the OPENING- C1O&ING (oand fro the Tan+ 6ar area itself
2y p#tting the MOVs RON 1OCA1F position'
Operating pro(ed#res of Tan+ 6ar MOVs fro P1C are as follows)
.a/ &ele(t the MOV to 2e operated$ on the P1C and do#2le (li(+ the
sae with the help of the o#se'
.2/ 6ro option en# give OPEN or C1O&E (oand depending
#pon the re5#ireent
.(/ GREEN or RE% light will start fli(+ering whi(h eans that
C1O&ING or OPENING operation respe(tively is in progress'
.d/ After soe ties the fli(+ering of light will stop whi(h eans
C1O&ING- OPENING operation of MOV is over and thereafter the
light will glow (ontin#o#sly' The (olo#r of the light will indi(ate
the stat#s of the position of the valve ieA RE% * OpenA 0 @GREEN
* CloseA'
'1MP P1MP R1NNING

&#p P#p is to 2e operated in the following sit#ation)

.>/ When the !i41evel s#p tan+ alar (oes in the Panel'
.?/ After Meter Prover Operation
.9/ After s(raper re(eiving'
.;/ %#ring any e(hani(al aintenan(e when the e5#ipents- ainline is
drained in s#p tan+'

6ollowing is the pro(ed#re for &#p P#p Operation)

64
.>/ Ens#re the availa2ility of power fro MCC Panel to the &#p p#p
otor'
.?/ Open the down4strea valve of s#p tan+ line to ens#re the delivery
(an 2e ade in ainline'

.9/ P#t RONF the s#p p#p otor fro the MCC Panel'
.;/ R#n it for a2o#t 9: in#tes to epty o#t'
Tan+ Capa(ity >E 81
P#p Capa(ity ?E 81-!r
Tie ta+en to epty the tan+ is >E-?E i'e' appro7' 9: Min'

.E/ P#t RO66F s#p p#p otor'

PC$ OPERATION
PCV is #sed to (ontrol the line press#re and flow rate' This is appli(a2le for
PCV at Math#ra Terinal'
Che(+ air s#pply is O8 .in' E 8g-s5'('/$ 1o(+ pin is reoved$ !andwheel is
in a7' open position$ Pr' E5#ali3ing valve is (losed prior to operate the
sae''
() A1TO OPERATION
PIC'4 ?-AM4? Cnit is #sed for setting 2a(+ press#re and A#to- Man#al
Control of PCV' 6IC 4 >; Cnit is #sed for setting 6low Rate'
Che(+ that internal p#sh 2#tton is pressed on 2oth PIC4?-AM 4 ? AN%
6IC 4 >; #nits'
&et 2a(+ press#re AN% 6low Rate re5#ired'
Press ACTOMATIC P#sh ,#tton of PIC 4 ?-AM 4? Cnit'
Wait AN% o2serve the pro(ess to settle to set valves'
?) MAN1A# OPERATION
Press SMANCA1S p#sh 2#tton on PIC4?-AM4? Cnit and (ontrol the
opening of PCV 2y SMANCA1S +no2'
+) A1TO/MAN1A# TRAN'"ERA
To avoid Ier+ to PCV d#ring transfer fro A#to to SMANCA1S ode$
press SMANCA1 8NO,S to see an#al valve on the s(ale a2ove'
E"CA1IDE the A#to 0 Man#al valves and press Man#al P#sh 2#tton'
It is advised to #se A#to ode in steady state (onditions only' 6or
transient (onditions of sh#tdown 0 start #p et(' It is 2etter to (hange to
65
an#al ode' 6or start #p$ align tan+age$ set re5#ired valves of
press#re and flow$ open MOV4? and then (hange to A#to ode'
.) "IE#D OPERATION
6ield operation sho#ld 2e resorted in (ase of power fail#re$ Air s#pply
fail#re or fail#re of (ontrol syste'
Go to PCV$ open e5#ali3ing valve$ rotate handwheel to at(h the holes$
insert lo(+ pin and then handwheel rotation will (ontrol PCV opening'
PC$ 4DPA'' OPERATION

PCV ,ypass syste is to 2e operated when

.>/ PCV aintenan(e is going on'
.?/ Power fail#re ta+es pla(e'

&pe(ially when the power fails$ the PCV 2ypass syste is to 2e opened
iediately$ otherwise it will 2e diffi(#lt to open the sae as the line press#re
in(reases d#e to a#toati( (loser of the PCV #pon power fail#re'
PCV 2ypass syste is to 2e (losed when the power s#pply res#es or the
PCV aintenan(e wor+ is over'

TAN! GA1GING

W Cr#de re(eived in the storage tan+ is re5#ired to 2e ga#ged to assess
the 5#antity of (r#de oil and water .if any/ re(eived in the tan+'

W The dip tape with the 2o2 is lowered into the storage tan+ (aref#lly
thro#gh the dip hat(h after lifting the lead and holding against the side
of the hat(h to prevent os(illation' 1t&ost ost (are is to 2e ta+en not
to dist#r2 the s#rfa(e of the oil while lowering the 2o2 #ntil the tip of
the sae I#st to#(hes the hat(h plate' Then the tape is rolled o#t and
the depth #pto$ whi(h the tape is wet$ is read to the nearest
grad#ation' The tape ay 2e wiped free fro oil thro#gh a short
distan(e 2elow the reading and the pro(ed#re repeated' The (lear oil
(#t on the tape is to 2e noted whi(h indi(ates the gross dip of oil and
water'

W To eas#re the 5#antity of water if any in the (r#de oil tan+s$ the lower
part of the dip tape in(l#ding the 2o2 is (oated #niforly with water
finding paste' Thereafter the dip tape is lowered thro#gh the dip hat(h
lo(ated at the (enter of the tan+ #ntil the 2otto of the 2o2 to#(hes the
dat# plate at the tan+ 2otto' The tape #st 2e held in this position
for s#ffi(ient tie to allow the water in the tan+ 2otto to (hange the
(olo#r of the water paste' The tape is then withdrawn and the reading
(orresponding to the #pper liit of (olo#r (hange of water paste is
noted$ whi(h gives water dip in the tan+'
66
W 6or eas#ring the Tan+ teperat#re a theroeter alongwith holder
(#p lowered thro#gh the dip hat(h of the tan+ with the help of dip tape
#pto the (enter height of the (r#de in the tan+ and hold it for s#ffi(ient
tie E*>: in' thereafter 5#i(+ly rise the theroeter holder (ap and
note the reading +eeping the eye in line with the theroeter'
6or the p#rpose of eas#ring the Cr#de density and ,&0W three
saples$ one fro the top layer$ se(ond fro the iddle layer and the
third fro the lower layer are ta+en and sent to the 1a2oratory'
E""#1ENT TREATMENT P#ANT

Effl#ent Treatent Plant at Vadinar$ Viraga and Cha+s# is provided to treat
the oily effl#ent generated fro P#p &tation tan+ far and the oily stor
water d#ring the onsoon for the reoval of free floating oil 2efore its
#ltiate disposal o#tside plant 2attery liits'
The oily effl#ent generated fro the P#ping &tation and tan+ far area is
(olle(ted in the re(eiving s#p and transferred to the oily effl#ent holding
pond' The oily effl#ent is treated in the s#2se5#ent treatent #nits$ and the
treated effl#ent is #ltiately (olle(ted in the treated effl#ent pond'

&tor water is separately treated 2y eans of 2ar s(reen and grit (hannel for
reoval of settlea2le solids$ gritty aterial and rags as a physi(al treatent'

Process Description

The oily wastewater is treated to reove free oil fro the waste water' The
treatent plant is designed to treat 9:: M
9
-hr effl#ent 5#antities' The oily
waste water is first ta+en in the re(eiving s#p fro where the water is
p#ped to the oily effl#ent holding pond' A 2ypass line is provided to ta+e the
oily effl#ent dire(tly to the API Oil &eparator' The oily effl#ent holding pond is
provided with oil s+ier$ for s+iing of free oil' The s+ied oil is
(olle(ted 2y this e(hanis and ta+en to the slop oil s#p thro#gh gravity$
while the effl#ent fro the holding pond is led to the API Oil &eparator'

The API Oil &eparator is provided to reove free4floating oil fro the top and
oily sl#dge fro the 2otto4(olle(ting 3one' &+ied oil is (onveyed to the
slop oil s#p while the sl#dge is ta+en to the sl#dge s#p 2y gravity' &l#dge
fro the sl#dge s#p is ta+en to the sl#dge lagoon for separation of oily
sl#dge' The treated effl#ent fro the API Oil &eparator is ta+en to the
inspe(tion (ha2er' If the oil is fo#nd present in the water$ then it is ta+en
2a(+ for repro(essing again to the re(eiving s#p of the treatent fa(ility' If
it is free of oil$ it is ta+en to treated effl#ent pond' A 2ypass line has 2een
provided fro oily effl#ent holding pond to the treated effl#ent holding pond'
The treated effl#ent in the holding pond is dis(harged to the o#tfall side of the
plant 2attery liit' At Cha+s#$ the treated effl#ent in the holding pond
.Poli(ing Pond/ is p#ped to 6ire Water Pond thro#gh 6ire water Networ+'

The stor water flowing in the stor water drain syste enters s(reen
(ha2er' The s(reen (ha2er is e5#ipped with an#ally (leaned s(reen$
in(lined at an angle'
67
The (oarse floating aterials in the stor water get arrested 2y the s(reen
and are reoved an#ally' The s(reened stor water flows to the grit
(hannel where the grit aterials settle 2y gravitational sedientation' The
settled grit is reoved interittently' The des(reened$ degritted stor water
flows to the stor water s#p and p#ped for disposal' In (ase stor water
2earing oil$ the stor water is p#ped to API Oil &eparator Cnit' Provision of
gates in s(reen (hannel$ grit (ha2er is ade for isolating these #nits and
stor water effl#ent flows into the oil effl#ent s#p thro#gh the
inter(onne(ting pipe'

The waste water treatent plant (onsists of the following #nits'

a/ Oily effl#ent s#p and p#p
2/ API Oil &eparator
(/ &lop Oil &#p 0 P#ps
d/ Treated effl#ent holding pond-Oily effl#ent holding pond
e/ &l#dge s#p and p#p
f/ &l#dge lagoon
g/ &(reen (hannel
h/ Grit Cha2er
i/ &tor water s#p 0 p#ps

Oil- E00luent 'u&p 6 Pu&ps

The oily effl#ent fro the tan+ far is re(eived in effl#ent s#p' The
s#pernatent oil layers fro holding ponds$ the sl#dge lagoons and
o((asionally stor water with tra(es of oil also flow to this s#p' The
a((##lated oil effl#ent is p#ped to API Oil &eparator with the help of
verti(al (entrif#gal p#ps' The s#p is provided with level swit(h interlo(+ed
with p#p for a#to start of p#p while the effl#ent level is high and a#to stop
when effl#ent level is low'
'u&p $a%inar $ira&ga& Caksu
Capa(ity E: M
9
?;'E M
9
E< M
9
1ength H M 9'E M ; M
Width ;'= M 9'E M ; M
1i5#id depth >'E M ? M 9'E M
'u&p Pu&p
No of P#ps 9 .?M>/ ?.>M>/ ? .>M>/
Type Verti(al
Centrif#gal
Verti(al Centrif#gal Verti(al
Centrif#gal
Ma+e 8hiline 8irlos+ar 8irlos+ar
Capa(ity >E: M
9
-!r >E: M
9
-!r >E: M
9
-!r
!ead >: M >: M >: M
'u&p Motor
Ma+e M-s
Cropton
Greaves
M-s 8irlos+ar M-s Cropton
Greaves
6lae proof$ 6lae proof$ &5#irrel 6lae proof$
68
&5#irrel (age
rotor
(age rotor &5#irrel (age
rotor
Ins#lation Class 6 6
!P >?'E >: >:
RPM >;;: >::: >;;:
API OI# 'EPARATOR

The Oil &eparator is provided to reove the free oil present in waste water'
The API Oil &eparator is a longit#dinal #nit$ (oprising of a pre4deoiler se(tion
followed 2y a Oil &eperator' The Oil &eparator se(tion is provided with a
e(hani(al s+iing (# s(raping e(hanis' The oil s+iing (#
s(raping e(hanis (oprises of wooden flights oving on an endless (hain
driven 2y a s#ita2le otor (o#pled to gear 2o7 and spro(+et asse2ly' %#e to
the (ontrolled (ondition of velo(ity in API Oil &eparator$ the aIor ao#nt of
oil gets separated and floats on the top s#rfa(e itself' The wooden flight a(ts
as a s+ier when it is oving in the dire(tion of flow whereas in (ase of
opposite dire(tion it wor+s as a s(raper' The sl#dge is (olle(ted in sl#dge pit
whi(h is drawn o#t 2y operation of flat seated #shroo valve' The s+ied
oil is (olle(ted in the s+ier pipe and finally slop oil s#p' The oil free
effl#ent fro oil separator$ fro the 2otto of the 2affle provided at the o#tlet
flows to the s#2se5#ent #nit'

Pre4deoiler
Channel
Vadinar Viraga Cha+s#
%esign flow rate
>E: M
9
-!r >E: M
9
-!r >E: M
9
-!r
No' of Cnits One One One
%iension .M/ >'? 7 :'E 7
:'?
?'9E 7 ?'E 7 >'? >?'9M7
;';7M>'9M
Oil &eparator
Channel
>= 7 9 7 >'? ?'9E 7 >< 7 >'?
Me(hani(al
E5#ipent
%riven 2y
flae proof
>;;: RPM 9
!P otor
throF do#2le
wor
red#(tion
gear2o7'
%riven 2y flae proof
?!P Motor$ thro#gh
do#2le wor
red#(tion gear2o7
%riven 2y flae
proof ?!P Motor$
thro#gh do#2le
wor red#(tion
gear2o7
Oil- e00luent ol%ing pon%

This #nit is provided to hold the oily effl#ent whi(h is transferred fro the
re(eiving s#p as well as for priary reoval oil' The (lear oil4free water is
dire(tly withdrawn and ta+en to the treated effl#ent pond whi(h the oily
effl#ent is ta+en 2y gravity flow to the API Oil &eparator Cnit' The oil s+ied
fro the top of holding pond is ta+en to slop oil s#p'

Treate% E00luent Pon%

69
This Cnit is provided to serve as a g#ard pond for the treated effl#ent re(eived
fro the hay filter or inspe(tion (ha2er of oily effl#ent holding pond' The
treated effl#ent fro this pond is ta+en 2y gravity for final disposal'
The 5#ality pro(ed#re for @Meas#ring and Monitoring of Effl#ent Paraeters
.oil (ontent and p!/ is given in Environental Pro(ed#re Man#al .Pro(ed#re
No' WRP1-EPM-;-J';/'
'lop Oil 'u&p 6 Pu&ps

The slop oil s#p is provided for (olle(ting the oil separated in API Oil
&eparator' The oil fro the holding ponds thro#gh the s(ooper pipes are also
a((##lated in the slop oil s#p' The (olle(ed oil fro the slop oil s#p is
p#ped to the slop oil tan+ 2y the slop oil p#ps provided' The s#p tan+ is
e5#ipped with level swit(h'
Pu&p $a%inar $ira&ga& Caksu
Nos' One ?.>M>/ One
Capa(ity M
9
-!r E: E: E:
!ead .M/ ;: ;: ;:
Ma+e 8hiline 8irlos+ar 8irlos+ar
Type Centrif#gal
Verti(al
Centrif#gal Verti(al Centrif#gal
Verti(al
Motor
Ma+e Cropton 8irlos+ar Cropton
!P 0 RPM ?E 7 >;;: >E 7 9::: >?'E7>;<:
Type 6laeproof 6laeproof 6rae proof

'lu%ge 'u&p 6 Pu&p

This Cnit is provided to (olle(t sl#dge fro API Oil &eparation Cnit and then it
is p#ped into sl#dge lagoon'

'u&p Di&ensions (M)
Vadinar ?'E 7 ? 7 >'E
Viraga ?'E 7 ?'E 7 ?'E
Cha+s# ;':7 ;': 7 ?':

'lu%ge #agoon

Two n#2ers sl#dge lagoons are provided for the storage of oily sl#dge'
&l#dge is p#ped to the lagoon 2y the sl#dge p#p provided' The pond is
provided with 9 Nos o#tlet at different levels for withdrawing the s#pernatent'
The s#pernatent is led to the API Oil &eparator' The renewal of sl#dge fro
lagoon is done an#ally'
The 5#ality pro(ed#re for @handling .Colle(tion$ &torage$ Treatent$
Transportation and disposal/ of ha3ardo#s waste .oily sl#dge/S is given in
Environental Pro(ed#re Man#al .Pro(ed#re No' WRP1-EPM-;-J'?/'
'creen Cannel
70

&(reen (hannel is provided in the stor water (hain syste to effe(tively
s(reen the large o2Ie(ts li+e ti2er$ rags et(' fro the stor water' The
s(reen is ade of M& Rod installed at ;EQ to the hori3ontal in dire(tion of flow'

Grit Cannel

Grit (ha2er is provided for (ontin#o#sly reoving grit parti(les fro the
stor water' The grit parti(les and ost atter d#e to higher spe(ifi( gravity
settle sele(tively in the grit (ha2er on the effl#ent flows thro#gh the #nit'
The settled grit gets (olle(ted in the hopper 2otto of the (ha2er and is
reoved an#ally'
71
'A"ETD C@EC!'

>' &tation 2y4pass otor operated valves are
a/ on strea$
2/ on reote and
(/ lin+ed to E&%'

?' P#p s#(tion and dis(harge valves are on reote'

9' Wor+ perit iss#ed and revalidated on every shift for any wor+ (arried
o#t in the station'

;' All drain valves are (losed after draining operation is over'

E' Eergen(y generator is on a#to ode'

<' Motor operated fire fighting #nit is on reote'

H' &ta#f (laps are provided on s#(tion and dis(harge valve of p#ps
whi(h are #nder aintenan(e'
=' 6#ses are reoved and +ept #nder (#stody for (riti(al e5#ipents
#nder aintenan(e'

J' Any safety interlo(+ 2y passed to 2e noted and 2ro#ght to the noti(e
of &IC and e7tra vigil to 2e aintained w'r't' the paraeter for whi(h
safety instr#entation is 2y passed'
MODA#ITIE' O" OPERATION O" #OOP #INE'
%etailed 5#ality pro(ed#res is given in Pro(ed#re and Wor+ Instr#(tion Man#al
on @OperationsA.Pro(ed#re no' "AP-OPN->H/'
Nor&al pipeline operationA
All the looplines valves shall always reain in f#lly open position'
A3nor&al con%itions
Closing of loop line se(tion ay 2e resorted to #nder very e7traordinary
(ir(#stan(es as en#erated 2elow)
A/ 1ea+age-pilferage where loop line and ain line r#nning parallel
In (ase of any lea+age- pilferage in any of the se(tions where M-1 or 1-1
are r#nning parallel$ the affe(ted se(tion of ain line or loop line ay 2e
isolated 2y (losing the re5#ired valves there2y ens#ring that pipeline
se(tion reains in operation altho#gh at lower thro#ghp#t till re(tifi(ation
is (arried o#t'
72
Precaution
While (losing the M-1 or 1-1 valve as far as possi2le it is to 2e ens#red that
only one type of (r#de vi3' ,! or 1& or !& is entrapped in the isolated se(tion
of ain line- loop line'
,/ Cllage (onstraints leading to detention of tan+ers
In order to a((oodate parti(#lar tan+er long 2at(hes of (r#des
introd#(ed in &V se(tion ay lead to sh#tdown of &V se(tion d#e to
ins#ffi(ient #llage at Viraga' This (oin(iding with non4availa2ility of
other type of (r#de ay (a#se disr#ption in p#ping in V8 and VC se(tion'
The sh#t down in &V se(tion ay (a#se the detention of s#2se5#ent tan+ers
at Vadinar'
In s#(h type of e7tra ordinary (ir(#stan(es we ay resort to 2lo(+ing of
(r#de in loop line in order to ens#re #ninterr#pted availa2ility of other (r#de at
Viraga and also avoiding the detention of other tan+ers at Vadinar'
In 2oth the a2ove (ir(#stan(es as entioned at A0, a2ove$ the (losed valve
shall only 2e opened after ens#ring that (r#de trapped and the oving (r#de
in parallel se(tion is sae thro#gh o#t the parallel length'
73
INTEGRITD TE'T O" MAIN#INE AND A''OCIATED "ACI#ITIE'
DETAI# PROCED1RE DE'CRIPTION
On(e in a year prefera2ly d#ring the tie when a7i# portion of ROW
reain (lear pipeline lea+ testing shall 2e (arried o#t se(tion wise$ for ?; hrs
at a spe(ified press#re as detailed in s#2se5#ent paras' The Central %espat(h
of &MP1 shall a+e the plan and intiate to Central Maint- 2ase stations in
advan(e for organi3ing the ROW s#rvey'
TE&T PRE&&CRE
&tep> ) Raise the press#re to HEN of Ma7i# &-d Press#re aintained in
the pre(eding >? Months'
&tep? ) !old Press#re for ; !o#rs'
&tep9 ) O2serve all (riti(al areas li+e valves$ flanges et( as well as f#n(tioning
of instr#ents And ga#ges within the stations' %#ring this period all
station paraeters shall 2e (losely Monitored'
&tep;) If no #n#s#al 2ehavio#r is o2served d#ring &tep?$ raise the press#re to
J:N of &-d press#re aintained in the pre(eding >? onths and hold
for ?; ho#rs'
&tep E) &#rvey)

&tarting fro the &-d period #p to H? hrs the entire ROW shall 2e
inspe(ted 2y line patrol en with additional reinfor(eent of
anpower- Offi(ers if re5#ired$ for any lea+age' The s#rvey shall 2e
planned in s#(h a way that sensitive lo(ations li+e River Crossings$
(ased and #n(ased Crossings$ M-1 2lo(+ valves$ Pop#lo#s areas$
s#(tion .inlet/ side of interediate stations .Where in noral
(ondition press#re reains low/ are (he(+ed on priority' The entire
se(tion to 2e s#rveyed within a7i# period of H? hrs'
In (ase of any s#spe(ted lea+age$ e7(avation shall 2e ade and presen(e of
hydro(ar2on shall 2e verified with e7plosive eter' If hydro(ar2on is dete(ted
the se(tion shall 2e isolated$ (orre(tive a(tion shall 2e ta+en'
&tep<) In (ase of lea+age$ after repair of the sae$ press#re sho#ld 2e raised
and steps ; 0 E a2ove shall 2e repeated'
All station paraeters shall 2e re(orded X ho#rly 2asis d#ring the entire
d#ration
Reporting of res#lts)

On (opletion of the lea+ s#rvey a report is to 2e generated indi(ating the
following as ini#)4
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Period of &#rvey
Tie of &#rvey
Test Press#re
%#ration of holding
&#rvey 1o(ation
O2servation in(l#ding dis(overy of lea+ $ if any
All &tation paraeters X ho#rly readings
Con(l#sion in(l#ding any &tation valves fo#nd passing
The (opiled report to 2e ade 2y Central %espat(h and p#t #p for
anageentFs aprisal'
YYYYYYYYYY
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