MEMPHIS REFINERY STANDARD PROCEDURES

Revision Date Annual Original Date: March 2001 Certification Date Flare (South) 2007 2007 2008 2008 2009 Manual Operation of Diesel 2009 2010 Pump 2010 2011 2011

PROCEDURE AND SIGN OFF

Note: The pump will normally be controlled by the Murphymatic Series 500 system. It will normally automatically start and stop based on the level in the flare knockout drum. The pump can however be started and stopped in Manual Mode regardless of the level in the flare knockout drum. If the pump was operating and shutdown due to a reason other than drum level, the cause of the shutdown will be displayed on the controller. Moving the Auto/Off/Manual selector switch to “Off” for two seconds then back to “Auto or Manual” resets the “faulted status”.

STARTUP PROCEDURE

Date Time Initials

1.______Ensure the Auto/Off/Manual switch is in the Off position.

2.______Ensure power is on to the control panel. If not, turn the power switch on.

3.______Ensure sufficient liquid is available in the flare knockout drum to provide the required NPSH to the pump (above pump low level shutdown).

4.______Ensure the 14” valve in suction line at drum and the 12” pump suction valves are open.

Note: To ensure minimum flow through the pump, either the discharge line must be lined up to the crude tanks or the pump must be lined up to circulate back to the flare knockout drum. This procedure assumes the re-circulation line to the drum is used to start the pump.

5.______Ensure the 4” valves in the re-circulation line at the pump and the drum is open.

Note: When the switch is placed in the Manual position the startup is initiated.

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6.______Place the Auto/Off/Manual switch in the Manual position.

Note: a) When the switch is placed in the Manual position, the Murphymatic control system will proceed through the startup logic programmed into it. Starting nitrogen will be sent to the engine starter, fuel will be sent to the engine and the engine will start to crank. If the engine does not start during the crank attempt, the crank and fuel outputs will turn off and the “rest delay” will begin timing. When the rest delay expires, the crank output will turn on and go through the same sequence. If the engine does not start within the number of cranks allowed, the engine will shutdown and the controller will display “Overcrank”. Moving the Auto/Off/Manual selector switch to “Off” for two seconds then back to “Auto or Manual” resets the “Overcrank faulted status”.

b) When the engine starts and the speed rises above the field-programmable Crank Disconnect speed setting, the Run Sequence for the Manual mode begins. The Warmup timer starts timing. The governor will slowly increase the engine speed to the warmup RPM. During engine warmup, the only shutdowns that are not bypassed are Overspeed, Underspeed and the Emergency Shutdown Switch. Internal

c) When the warmup time expires, the controller will send a target engine speed to the governor based on the pump discharge pressure. The controller will ramp up the RPM until the discharge pressure is within the deadband programmed into the system or the minimum or maximum RPM is reached.

7.______After the engine is operating, open the two 8” valves in the pump discharge and close the valves in the re-circulation line.

8.______Check flow meter, FI-426, to ensure the pump is pumping OK.

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SHUTDOWN PROCEDURE

Date Time Initials

1.______Place the Auto/Off/Manual selector switch in Off position or push the Stop Pushbutton to stop the engine. The following sequence will occur: 1.1 A signal will be sent to the engine governor to reduce the RPM’s to the “cooldown” RPM. The control panel will display the status: “Cooldown” 1.2 When the cool down RPM is reached the panel will display the status: “Cool Down Timing” 1.3 After the time programmed into the controller for cool down has elapsed, the engine will shut down. 1.4 The controller will return to Standby mode.

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PROCEDURE INFORMATION

PURPOSE: This procedure provides steps to manually startup the flare knockout drum diesel pump (41-15-148).

PREREQUISITES: The Murphymatic Series 500 control system must be operating properly and the diesel fuel tank must have sufficient diesel to startup and operate the pump.

RESPONSIBILITY: It is the responsibility of the Tank Farm Pumper Number 1 to manually startup the diesel pump.

MATERIAL AND EQUIPMENT: No special materials or equipment are required to carry out this procedure except fuel must be available in the diesel tank.

SAFETY: Special or Unique Hazards: None

Engineering Controls: N/A

Administrative Controls: This procedure is an administrative control to ensure that the pump is properly started.

Personal Protective Equipment (PPE): The standard refinery personnel protective equipment is required while performing this procedure.

SAFETY SYSTEMS: Shutdowns: There are several shutdowns associated with the diesel engine. These include the following: Low level in the drum, low engine oil pressure, low engine oil level, high engine oil temperature, high engine vibration, overspeed, overcrank, low suction pressure and high/low discharge pressure.

Other Safety: The diesel engine control panel, Murphymatic, has a common trouble alarm for the engine. Several alarms are provided on the control panel. These include the following: Low level in the drum, low engine oil pressure, low engine oil level, high engine oil temperature, high engine vibration, overspeed, overcrank, low suction pressure and high/low discharge pressure. High level alarms are also provided on the flare knockout drum. An Emergency Shutdown switch for the pump is also included on the panel.

QUALITY AND INVENTORY Inventory: There must be sufficient liquid in the flare drum to prevent cavitating the pump.

Quality: N/A

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OPERATING LIMITS Description Limits Consequences of Deviation Corrective and Avoidance Steps Flare knockout drum High: High: Liquid may be carried over to the If the level is high, action must be taken liquid level. Low: flare stack with potential safety and by the operators in the process units to environmental problems if liquid exits stop the flow of liquid to the flare and the flare tip. Could result in fires at the tank farm pumper must ensure the grade and unburned hydrocarbons and knockout drum pumps are operating smoke being released to the atmosphere. properly. Low: If the NPSH requirements of the If the level is low the pumper must knockout drum pumps are not meet the ensure the knockout drum pumps are pumps can be damaged. not operating.

CHEMICAL SAFETY General information is provided here. Additional information is available from the MSDS sheets for individual chemicals/materials Chemical Name Properties Hazards Actions if Exposed Flare Gas “Flare Gas” can be Hot fumes or mists can be irritating In case of skin contact, immediately Diesel liquid or vapor. Can to the skin eyes and respiratory tract wash with soap and water. Consult a contain H2S and can cause drowsiness, headache, physician if irritation develops. and nausea. Overexposure to vapors In case of eye contact, immediately can lead to unconsciousness or flush eyes with water for 15 minutes convulsions, bronchopneumonia, and including under the eyelids, and see a even brief inhalations of high physician. concentrations can cause fatal If swallowed see a physician, do not pulmonary edema. induce vomiting. Hydrocarbon vapors can burn or If inhaled, remove to fresh air. If not explode on contact with a source of breathing, give artificial respiration. ignition in the presence of air or See a physician. oxygen.

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