IMS-FM002-01

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DOCUMENT STATUS PAGE

Document Title: PUMPS OPERATION
Document Number: O01-WI053-03

Document History
AM # Issue Date Changes

N/A 01 11-06-01 N/A, First issue

AM001 02 05-08-11 Clause 4.2 deleted, Clause 4.6 added and whole procedure
reviewed.
AM002 03 14-04-14 Clause 2, 7.1.7, 7.1.8, 7.1.13, 7.2.12, 7.3.14, 7.4.11 & 7.5.10
amended, Clause 7.7 added.

Distribution
CCR
ARL Server

Prepared By: Engineer (Operations)

Reviewed By: Section Incharge

Approved By: Section Head

All information contained in this form is to be provided by the approving authority of the document.
 O01-WI053-03
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Pumps Operation
1 Purpose
The purpose of this work instruction is to ensure safe startup of pumps after
turnaround.
2 Scope
This work instruction applies to pumps at HCU plant i.e., HC-P-001, HC-P-002,
HC-P-003, P-004, HC-P-005 P-006, P-007, P-008, HC-P-009, HC-P-010, HC-P-011,
HC-P-014, HC-P-015, HC-P-016, HC-P-017, HC-P-020.
3 References
3.1 Pumps Operating Manual
4 Definitions
4.1 ARL Attock Refinery Limited
4.2 HCU Heavy Crude Unit
4.3 FC Flow Controller
4.4 PC Pressure Controller
4.5 P Pump
5 Responsibility
5.1 Plant Operator/Board Operator has the overall responsibility for the
implementation of this work instruction
5.2 The individual responsibilities of the users, as and if applicable, are given in
the following responsibility matrix.

Responsibility Matrix
Clause Responsibility
7.1-7.6.10 Plant Operator/Board Operator

6 Safety Precautions
6.1 Follow the same work instructions given in each pump startup for smooth
operation.
7 Work Instructions
7.1 Start Up of HC-P-001
7.1.1 Check the drain valves of the pump, these should be closed & suction
valve should be in open position.
7.1.2 Check the lube oil level of the pump, if the level is less than required,
then make up the oil level.
7.1.3 Check the discharge valve of the pump, it should be closed.
7.1.4 If the maintenance of the motor has been carried out before starting the
pump, rotation of the pump shaft is checked by giving it a jerk to check
that the rotation of the pump is in specified direction.
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Pumps Operation
7.1.5 Check the valves of the lines going to both the seals, these should be
opened.
7.1.6 Rotate the coupling manually to check for free rotation, then fit the
coupling guard before switching on the motor.
7.1.7 Open FC-048 (8)% & PC-004 (70)% on manual mode.
7.1.8 Prime the pump, ask shift electrician to switch on the breaker.
7.1.9 Switch on the motor.
7.1.10 Gradually fully open the discharge valve.
7.1.11 Check the discharge pressure; it should be as per specification.
7.1.12 Check the Amperes of the motor; it should be within design limit.
7.1.13 Check any abnormality in pump/motor.
7.2 Start Up of HC-P-002, HC-P-009
7.2.1 Check the drain valves of the pump, these should be closed & suction
valve should be in open position.
7.2.2 Check the lube oil level of the pump, if the level is less then required,
then make up the oil level.
7.2.3 Check the discharge valve of the pump, it should be closed.
7.2.4 Check the sealing steam that should be open.
7.2.5 If the maintenance of the motor is made then before starting the pump,
rotation of the pump shaft is checked by giving it a jerk to check that
the rotation of the pump is in specified direction.
7.2.6 Rotate the coupling manually to check for free rotation, then fit the
coupling guard before switching on the motor.
7.2.7 Prime the pump.
7.2.8 Switch on the motor.
7.2.9 Gradually fully open the discharge valve.
7.2.10 Check the discharge pressure, it should be as per specification.
7.2.11 Check the Amperes of the motor, it should be within design limit.
7.2.12 Check any abnormality in pump/motor.
7.3 Start Up of HC-P-003, P-004, P-006, P-007, P-008
7.3.1 Check the drain valves of the pump, these should be closed & suction
valve should be in open position.
7.3.2 Check the lube oil level of the pump, if the level is less then required,
then make up the oil level.
7.3.3 Check the discharge valve of the pump, it should be closed.
7.3.4 Check the sealing steam that should be open.
7.3.5 Check the cooling water system that circulates in pump support &
other parts, it should be on lined.
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Pumps Operation
7.3.6 If the maintenance of the motor is made then before starting the pump,
rotation of the pump shaft is checked by giving it a jerk to check that
the rotation of the pump is in specified direction.
7.3.7 Check the balancing valve, when the pump is to start, it should be
closed. When the pump is not in service it should be kept open to keep
the pump hot, so that the pump can be run at any time.
7.3.8 Rotate the coupling manually to check for free rotation, then fit the
coupling guard before switching on the motor.
7.3.9 Prime the pump.
7.3.10 Switch on the motor.
7.3.11 Gradually fully open the discharge valve.
7.3.12 Check the discharge pressure, it should be as per specification.
7.3.13 Check the Amperes of the motor, it should be within design limit.
7.3.14 Check any abnormality in pump/motor.
7.4 Start Up of HC-P-005, HC-P-016
7.4.1 Check the drain valves of the pump, these should be closed & suction
valve should be in open position.
7.4.2 Check the lube oil level of the pump, if the level is less than required,
and then make up the oil level.
7.4.3 Check the discharge valve of the pump, it should be closed.
7.4.4 If the maintenance of the motor is made then before starting the pump,
rotation of the pump shaft is checked by giving it a jerk to check that
the rotation of the pump is in specified direction.
7.4.5 Rotate the coupling manually to check for free rotation, then fit the
coupling guard before switching on the motor.
7.4.6 Prime the pump.
7.4.7 Switch on the motor.
7.4.8 Gradually fully open the discharge valve.
7.4.9 Check the discharge pressure, it should be as per specification.
7.4.10 Check the Amperes of the motor, it should be within design limit.
7.4.11 Check any abnormality in pump/motor.
7.5 Start Up of HC-P-015, HC-P-020
7.5.1 Check the drain valves of the pump, these should be closed & suction
valve should be in open position.
7.5.2 Check the lube oil level of the pump, if the level is less than required,
and then make up the oil level.
7.5.3 Check the discharge valve of the pump, it should be Opened
7.5.4 Instrument air supply of HC-P-020 should be opened.
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Pumps Operation
7.5.5 HC-P-015 stroke should be 100%.
7.5.6 Put both pumps on Auto mode.
7.5.7 Switch on the motor.
7.5.8 Check the discharge pressure, it should be as per specification.
7.5.9 Check the Amperes of the motor, it should be within design limit.
7.5.10 Check any abnormality in pump/motor.
7.6 Start Up of HC-P-017
7.6.1 Check the drain valves of the pump, these should be closed & suction
valve should be in open position.
7.6.2 Check the lube oil level of the pump, if the level is less than required,
and then make up the oil level.
7.6.3 Circulation line from discharge to Tank-001 should be crack opened.
7.6.4 Check the discharge valve of the pump, it should be crack opened.
7.6.5 Prime the pump.
7.6.6 Switch on the motor.
7.6.7 Gradually fully open the discharge valve.
7.6.8 Check the discharge pressure, it should be as per specification.
7.6.9 Check the Amperes of the motor, it should be within design limit.
7.6.10 Check any abnormality in pump/motor.
7.7 Start Up of HC-P-010, HC-P-011, HC-P-014, HC-P-021
7.7.1 Check the drain valves of the pump, these should be closed & suction
valve should be in open position.
7.7.2 Check the lube oil level of the pump, if the level is less than required,
then make up the oil level.
7.7.3 Check the lube oil level in HSD reservoir.
7.7.4 Check the discharge valve of the pump, it should be closed.
7.7.5 Check the sealing steam that should be open.
7.7.6 If the maintenance of the motor is made then before starting the
pump.Check the rotation of pump by giving it a jerk (Specified
direction).
7.7.7 Rotate the coupling manually to check for free rotation, and then fit the
coupling guard before switching on the motor.
7.7.8 Prime the pump.
7.7.9 Switch on the motor.
7.7.10 Gradually fully open the discharge valve.
7.7.11 Check the discharge pressure, it should be as per specification.
7.7.12 Check the Amperes of the motor, it should be within design limit.
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Pumps Operation
7.7.13 Check any abnormality in pump/motor.

8 Forms
None
9 Appendices
None