Au3.pdf 2v3iw

ATMOSPHERIC UNIT-III MANUAL-2016 GUJARAT REFINERY VOL-I

1

. Indian Oil Gujarat Refinery

Operating Manual for JR AU-III VOL-I: Addendum

Document No.: JR:PN:OM:HGU2-01 Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

PREFACE

This Operating Manual gives the operating guidelines for AU-III Unit of Gujarat Refinery, IOCL, Vadodara.

The Instruction and guidelines contained in this manual are for purpose of facilitating the start up and subsequent operation of the unit.

The operating procedure and conditions are indicative only and the modification may become necessary in due course of time as result of experience gained in actual operation of unit.

K Sarma Date: 01/09/2016

CHIEF PRODUCTION MANAGER

Gujarat Refinery- Eco-friendly Refinery Prepared By

Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 2


Document No.: JR:PN:OM:HGU2-01


Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Index List of contents Addendum list Sr No Date of change Existing system in brief Modification in brief Chapter/Page no. of manual Sr No.

DESCRIPTION

PAGE NO

Chapter-1

PRINCIPLE OF DISTILLATION

11-16

Chapter-2

INTRODUCTION OF THE UNIT

17-24

2.1

Chapter 1 FUNCTION OF PLANT

2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

Chapter 2 ONSTREAM FACTOR

Chapter-3

EQUIPMENT DATA

3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7. 3.8. 3.9.

PUMPS EXCHANGERS COOLERS / CONDENSERS VESSELS TANKS COLUMNS FURNACES/AIR PRE-HEATER TURBO BLOWERS PSV'S

18 18

DESIGN FEED RATE TURNDOWN RATIO FEED &PRODUCT DESCRIPTION FEED & PRODUCT BATTERY LIMIT CONDITIONS UTILITY SPECIFICATIONS MATERIAL BALANCE (% WT) UTILITY CONSUMPTION


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

18 19 19 22 22 23 24 25-40 25 27 29 30 30 31 32 32 33

Vol-I (Addendum)

Page 3




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

3.10. 3.10.1. 3.10.2. 3.10.3. 3.10.4. 3.11.

LIST OF CONTROL VALVES/CONTROLLERS FLOW CONTROLLERS LEVEL CONTROLLERS PRESSURE CONTROLLER TEMPERATURE CONTROLLERS LIST OF ALARMS AND TRIPS

Chapter-4

PROCESS FLOW DESCRIPTION

4.1. 4.2. 4.2.1 4.2.1.1 4.2.1.2 4.2.1.3 4.2.2. 4.2.3. 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.5 4.5.1 4.5.2 4.5.3 4.6 4.6.1 4.6.2 4.6.3 4.7 4.8 4.8.1. 4.8.2. 4.8.3. 4.8.4. 4.9

BRIEF DESCRIPTION OF THE PROCESS DETAILED DESCRIPTION OF THE PROCESS : CRUDE SUPPLY CRUDE STORAGE AND SETTLING SLOP PREPARATION AND SUPPLY CURDE BOOSTER PUMP FEED PREHEAT CIRCUIT CRUDE PRETTOPING FURNACES FURNACE F-1 FURNACE F-2 AIR PREHEATER (APH) SYSTEM FURNACE F-3 MAIN FRACTIONATING COLUMN OVERHEAD SYSTEM SIDE-CUT HEAVY NAPHTHA-II CIRCUIT KEROSENE-II CIRCUIT SRGO (HSD) CIRCUIT RCO CIRCUIT NAPHTHA STABILIZER DESIGN OPERATING CONDITIONS PRE-TOPPING COLUMN K-1 MAIN FRACTIONATING COLUMN K-2 NAPHTHA STABILIZER K-4 NORMAL OPERATING PARAMETRS COLUMNS FURNACES DESALTERS CRITICAL OPERATING PARMETERS CHEMICAL INJECTION SYSTEM DEMULSIFIER CAUSTIC INJECTION AMMONIA SOLUTION INJECTION CORRODION INHIBITOR INJECTION UNIT PERFORMANCE MONITORING


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

34 34 36 36 37 38 41-88 41 43 43 43 44 44 44 47 49 49 51 53 55 59 59 61 61 63 65 67 69 69 70 72 73 73 75 77 77 84 84 84 85 85 86

Vol-I (Addendum)

Page 4




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Chapter-5

UTILITIES SYSTEM

89-97

5.1. 5.2. 5.3. 5.4. 5.5. 5.6. 5.7. 5.8. 5.9. 5.9.1. 5.10. 5.11. 5.12. 5.13. 5.14 5.15

INSTRUMENT AIR PLANT AIR CIRCULATING WATER SYSTEM FIRE WATER DM WATER STEAM FUEL GAS SYSTEM FUEL OIL SYSTEM VR BURNING FACILITY ALTERNATE FUEL OIL SYSTEM FLARE SYSTEM FLUSHING OIL SLOP CLOSED BLOW DOWN SYSTEM OWS SYSTEM IVATION FACILITIES

Chapter-6

EQUIPMENT OPERATING PROCEDURE

6.1 6.1.1 6.1.2 6.1.3 6.1.3.1 6.1.3.2 6.1.3.3 6.1.3.4 6.1.3.5 6.1.3.6 6.1.3.7 6.1.3.8 6.1.3.9 6.1.3.10 6.1.3.11 6.1.3.12 6.1.4 6.1.4.1 6.1.4.2 6.1.4.3 6.1.5 6.1.6 6.1.7

DESALTER DESCRIPTION OF DESALTER DESALTER OPERATION OPERATING VARIABLES RAW CRUDE QUALITY SLOP ADDITION / OIL FEED RATE WATER INJECTION TEMPERATURE PRESSURE MIXING ENERGY INTERFACE LEVEL CHEMICAL AGENT AMPERAGE & VOLTAGE PH SOLIDS AT WATER OIL INTERFACE RETROFITTING OF DESALTER-1 PETRECO BIELCTRIC DESALTING PROCESS DESCRIPTION DESCRIPTION OF COMPONENTS COMMISSIONING OF DESALTER SHUTDOWN OF AND HANDING OVER OF DESALTER DESALTER DESLUDGING

89 89 90 90 91 92 94 94 94 96 96 96 97 97 97 97 98-204 98 100 101 101 102 102 102 102 103 103 103 104 104 105 105 106 106 106 107 110 115 116 116


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 5

. Indian Oil Gujarat Refinery 6.1.7.1 6.1.7.2 6.1.8 6.1.9 6.1.10 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.4.1 6.2.4.2 6.2.5 6.2.6 6.2.6.1 6.2.6.2 6.2.6.3 6.2.7 6.2.7.1 6.2.7.2



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CONTINUOUS DESLUDGING INTERMITTENT DESLUDGING TROUBLE SHOOTING INSTRUMENTATION LABORATORY TEST FURNACES F-1/F-2 AND AIR-PREHEATERS FURNACE F-1 FURNACE F-2 AIR PREHEATER FD & ID FAN GENERAL OPERATION BURNERS SOOT BLOWERS GENERAL SOOT BLOWER OPERATION FURNACE OPERATION BALANCED DRAFT OPERATION BALANCED DRAFT TO NATURAL DRAFT OPERATION COMBUSTION CONTROL SCHEME INTERLOCK SYSTEM FD FAN FAILURE ID FAN FAILURE FURNACE ARCH PRESSURE HIGH LOW FLOW IN F-1 LOW FLOW IN F-2 TOTAL FUEL CUT-OFF TO FURNACE F-1 TOTAL FUEL CUT-OFF TO FURNACE F-2 DOS AND DONTS OF INTERLOCK CIRCUIT EQUIPMENT RUN PERMITS FD FAN ID FAN DODs STACK DAMPERS PRECONDITIONS FOR OPENING F-1 SHUTDOWN VALVES (FO/FG)

6.2.8 6.2.9 6.2.9.1 6.2.9.2 6.2.9.3 6.2.9.4 6.2.9.5 6.2.9.6 6.2.9.7 6.2.9.8 6.2.10 6.2.10.1 6.2.10.2 6.2.10.3 6.2.10.4 6.2.10.5 6.2.10.6

PRECONDITIONS FOR OPENING F-2 SHUTDOWN VALVES (FO/FG) CLOSING OF SHUTDOWN VALVES EMERGENCY TRIP

6.2.10.7 6.2.10.8


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

116 117 117 120 121 122 123 124 125 126 126 126 127 128 129 129 130 131 131 133 134 136 136 137 137 138 138 139 139 139 141 141 142 142 144 145 147 148 149

Vol-I (Addendum)

Page 6




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.2.10.9 6.2.11 6.2.12 6.2.13 6.2.14 6.2.15 6.2.15.1 6.2.15.2 6.2.16 6.2.17 6.2.18 6.2.19 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 6.3.9 6.3.10 6.3.11 6.3.12

CRACK OPENING TEST OF DODs FURNACE DRY OUT OPERATION IVATION OF FURNACE STEAM AND AIR DECOKING PRE-COMMISSIONING ACTIVITIES NORMAL FURNACE START UP PREPARATION FOR START UP START UP OF THE FURNACE NORMAL FURNACE SHUT DOWN EMERGENCY PROCEDURES OPERATING INSTRUCTION TROUBLE SHOOTING FURNACE F-03 GENERAL DESCRIPTION OPERATING CONDITIONS FURNACE INSPECTION AND MECHANICAL CHECK PREPARING FOR INITIAL COMMISSIONING DRYING-OUT PROCEDURE START-UP NORMAL OPERATION SHUTDOWN EMERGENCY SHUTDOWN OF F-03 DECOKING INSTRUCTIONS INTERLOCK SYSTEM F-03 SOOT-BLOWING

149 150 151 152 155 155 155 156 158 160 161 162 165 165 167 174 175 177 183 192 195 196 198 198 200

Chapter-7

TASK TO BE PERFORMED BY OPERATORS

7.1

PUMP OPERATOR

205

7.2

FIELD OPERATOR

207

7.3 7.4

FURNACE OPARETOR OPERATOR

210 213

Chapter-8

NORMAL SHUT-DOWN PROCEDURE

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9

INTRODUCTION PRELIMINARY PREPARATION DECOMMISSIONING OF DESALTERS THROUGHPUT REDUCTION

205-221

222-232 222 222 223 224 225 226 227 228

COOLING SHUTDOWN OF NAPHTHA STABLISER PUMPING OUT GAS OIL FLUSHING DEPRESSURISATION AND STEAMING

229


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 7




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

8.10

IVATION OF F1/F2/F3

Chapter-9

NORMAL START UP PROCEDURE

9.1 9.2 9.3 9.4 9.5 9.6

PRELIMINARY PREPARATION AIR REMOVAL & PRESSURE TEST GAS BACKUP COLD CIRCULATION HOT CIRCULATION BRINGING UNIT ON STREAM

Chapter-10

EMERGENCY PROCEDURES

10.1 10.2 10.2.1 10.2.2 10.2.3 10.3 10.4 10.5 10.6 10.7 10.8 10.8.1 10.8.2 10.9 10.9.1 10.9.2 10.9.3 10.9.4 10.9.5 10.10 10.11 10.12

GENERAL GUIDELINES POWER FAILURE PARTIAL POWER FAILURE TOTAL POWER FAILURE TOTAL POWER FAILURE FOR SHORT LONG DURA FAILURE OF ALL UTILITIES TOGETHER STEAM FAILURE WATER FAILURE INSTRUMENT AIR FAILURE CRUDE FEED FAILURE FAILURE OF HEATER TUBES IN F-1, F-2 & F-3 SMALL LEAK MAJOR LEAK CONTROL SYSTEM FAILURE 24V DC FAILURE 110V AC FAILURE 110V DC FAILURE 440V AC FAILURE DCS/PLC FAILURE/FREEZING FIRE IN THE PLANT FAILURE OF CRITICAL EQUIPMENTS FURNACE OIL FAILURE

Chapter-11

STANDARD OPERATING PROCEDURE

11.1 11.2 11.3 11.3.1 11.3.1(A) 11.3.1(B) 11.3.1(C) 11.3.2

EQUIPMENT HANDING OVER TO MAINTANANCE: EQUIPMENT TAKING OVER FROM MAINTENANCE EQUIPMENT HANDLING PROCEDURE : PUMPS CENTRIFUGAL PUMP RECIPROCATING PUMP ROTARY/GEAR PUMP ID/FD FANS

232 233-242 233 234 237 238 239 241 243-258


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

243 244 244 245 246 246 248 249 250 251 252 252 253 254 254 254 255 255 255 256 256 258 259-283 259 264 267 267 267 269 270 270

Vol-I (Addendum)

Page 8

. Indian Oil Gujarat Refinery 11.3.3 11.3.4 11.3.5 11.3.6 11.3.7 11.4 11.4.1 11.4.2



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

11.4.3 11.4.4

HEAT EXCHANGERS COOLERS CONDENSERS DESALTER FURNANCES TANK OPERATIONS TANK HANDING OVER FOR MAINTENANCE: CHECK LIST FOR TAKING OVER STORAGE TANK AFTER MAINT AND INSPECTION COMMISSIONING OF TANK DO'S AND DO NOTS OF TANK OPERATION

271 272 272 274 275 280 280

Chapter-12

INTRODUCTION TO DCS

12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.8.1 12.8.2 12.8.3 12.9 12.9.1 12.9.2 12.9.3 12.9.3.1 12.9.3.2 12.9.3.3

INTRODUCTION ADVANCED MULTIFUNCTION CONTROL CRITICAL PROCESS CONTROLLER INDUSTRIAL PROGRAMMABLE CONTROLLER UNIVERSAL STATION HISTORY MODULE APPLICATION M MODULE COMMUNICATION SYSTEM LOCAL CONTROL NETWORK DATA HIGHWAY HIGHWAY GATEWAY UPS SYSTEM INTRODUCTION TO UPS SUPPLY DISTRIBUTION TO DCS SYSTEM TYPES OF UPS FAILURES ANY INCOMING 440V AC SUPPLY OR ANY MODULE FAILURE TOTAL FAILURE OF 110V AC TO NODES PARTIAL FAILURE OF 110V AC TO NODES

Chapter-13

LINE-UP OF CIRCUIT

289-297

1

FEED CIRCUIT A) PRE HEAT TRAIN-1 B) PRE HEAT TRAIN-2 C) PRE HEAT TRAIN-3

2 3 4 5 6

STABILIZED NAPH. CIRCUIT SIDE CUT NAPHTHA -1 CIRCUIT KERO-1 CIRCUIT CR-1 CIRCUIT NAPHTHA-2 CIRCUIT

289 289 290 291 291 292 293 293 293

281 283 283 284-288


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

284 285 285 285 285 285 285 286 286 286 286 287 287 287 287 287 288 288

Vol-I (Addendum)

Page 9




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

7 8 9 10 11 12 13

HEAVY NAPHTHA CIRCUIT KERO-II CIRCUIT SRGO (HSD) CIRCUIT RCO CIRCUIT CR-II CIRCUIT CR-III CIRCUIT LPG CIRCUIT

293 294 294 295 296 296 297

Chapter-14

FIRE FIGHTING FACILITIES

298-327

Chapter-15

SAFETY SYSTEM & PROCEDURE FOR ACCESSING ROOF OF FLOATING AND FIXED ROOF STORAGE TANKS

328-332

Chapter-16

SAMPLING SCHEDULE

Chapter-17

MASTER BLIND LIST

334-339

Chapter-18

MATERIAL SAFETY DATA SHEET

340-359

333

CORROSION INHIBITOR /AHURALAN AMMONIA CAUSTIC SODA DEMULSIFIER CONTROL OF HAZARDOUS CHEMICAL INVENTORY LEVEL

340 345 350 354 359

Chapter-19

AU3 CONTROL VALVE DATA

360-369

Chapter-20

LIST OF INTERLOCKS

370-374

Chapter-21

HSD COALESCER

375-377

Chapter-22

Annexures

378-424

1. Checklist for handing over and taking over of equipments 2. AU-3 M&I-2009 jobs 3. K-2 Flash zone replacement 4. RUP Hook up jobs 5. Procedure for dechoking of equipment drain line 6. Flare KOD draining procedure 7. General Safety Instructions 8. Routine check by operator 9. AU-3 M&I-2013 jobs 10. Columns, vessels, furnace blind list 11. Limit for Skin thermocouples in AU3


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

378 389 391 392 393 394 396 398 400 411 421

Vol-I (Addendum)

Page 10




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Chapter-23

12. List of work instructions DRAWINGS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

CRUDE PREHEAT CIRCUIT (I&II) DESALTERS CRUDE PREHEAT CIRCUIT(TRAIN III&IV) PRETIOPPING COLUMN K-1 F-1 FURNACE CIRCUIT F-2 FURNACE CIRCUIT AIR PREHEAT SYSTEM FOR F-1 & F-2 FURNACE F-3 F-3 BALANCE & COT NAPHTHA & KERO-I STRIPPER MAIN FRACTIONATING COLUMN K-2 HEAVY NAPHTHA CIRCUIT CR-III & DIESEL R/D CIRCUIT KERO C/R & R/D CIRCUIT NAPHTHA STABILIZER K-4 NAPHTHA R/D CIRCUIT FUEL OIL SYSTEM FUEL OIL PUMPING SYSTEM VR SURGE DRUM' VR BURNING SYSTEM VR BURNING FACILITY CR/ RFO CONNECTION FUEL GAS SYSTEM DM WATER SYSTEM DEEMULSIFIER INJECTION CAUSTIC INJECTION AMMONIA INJECTION AHURALAN INJECTION SYSTEM DESALTER DETAILS FLUSHIN OIL / FO FACILITY STEAM SYSTEM PESSIVATION FACILIYT FLARE KO DRUM FLARE SYSTEM GENERAL ARRANGEMENT OF FURNACE F-1 GENERAL ARRANGEMENT OF FURNACE F-2 DETAILS OF APH BURNER DETAILS FURNACE DRYOUT INTERMEDIATE TANK SYSTEM

422 425


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 11

. Indian Oil Gujarat Refinery 41 42



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

OWS SYSTEM INTERLOCK SYSTEM


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 12




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Addendum List


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 13


Operating Manual for JR AU-III


VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

REVISION HISTORY

AMENDMENT RECORD

MANUAL NO: JR: PN: OM: HGU-2- 01/02

Revision No.

Date

Description

Approved By

1

01/09/2016

Design Feed & Product yield

NM


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 14




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ADDENDUM LIST:

THE ADDENDUM LIST IS BEING PREPARED BASED ON THE NEW CHAPTER / TOPIC ADDITION IN THIS MANUAL AS PER RTF (RELIABILITY TASK FORCE) GUIDELINES.

THE DETAILS OF THE CHANGES MADE IN THIS MANUAL ARE AS PER BELOW TABLE:

S No

Date of Change

Existing system in brief

Modification in brief

1.

01.10.2016

New Topics

EFFLUENT SUMMARY: Gaseous & Aqueous effluent data

Chapter / Page no of manual Chapter No-2

2.

01.10.2016

New Chapter

JOB RESPONSIBILITY: Job description of shift engineers/ Engineers and field operators

Chapter No-5

3.

01.10.2016

New Chapter

Commissioning and precommissioning

6.

01.10.2016

New Topic

SOPs

7.

01.10.2016

New Chapter

8.

01.10.2016

New Chapter

9.

01.10.2016

New Topic

SAMPLING, LABORATORY ANALYSIS AND QUALITY CONTROL: Sampling and testing frequency of respective streams, test methods and PLANT PERFORMANCE MONITORING: Detailed methods for various calculation, monitoring, troubleshooting etc List of Safety equipments like safety showers, Communication facilities such as pagers system, field telephones, walkie-talkie etc UOP Catalyst MSDS

Chapter no.-6 Chapter No-20 Chapter –10

10.

01.10.2016

New Chapter

INSPECTION REQUIREMENTS: Frequency of Inspection requirements for various equipments and M&I. Tabulate metallurgical limits with respect to pressure, temperature and corrosive conditions etc.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Chapter –11 Chapter –12

Chapter –14

Vol-I (Addendum)

Page 15




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

11.

01.10.2016

New Chapter

DCS, PLC, ADVANCE PROCESS CONTROL, CCTV AND ONLINE ANALYZERS:

Chapter –16

12.

01.10.2016

New Topic

Complete description of Electrical power substation facilities

Chapter –17

13

01.10.2016

New Chapter

Respective unit PFD along with detailed material balance sheets

Chapter –21

14

01.10.2016

New Topic

Accident Reporting Procedures

Chapter –22


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 16




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Volume -1


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 17




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER - 1 PRINCIPLES OF DISTILLATION


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 18




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Distillation is a technique by which two or more substances with different boiling points can be separated from one other. For example, fresh water can be obtained from seawater (water that contains salts) by distillation. When seawater is heated, water turns into a vapor that can be condensed and captured. The salts in the seawater remain behind. In contrast to the preceding example, distillation is most commonly used to separate two or more liquids from each other. General Principles: Separation of components from a liquid mixture via distillation depends on the differences in the boiling points of the individual components. Depending on the concentrations of the components present, the liquid mixture will have different boiling point characteristics. Distillation processes therefore depends on the vapor pressure characteristics of liquid mixtures. The vapor pressure of a liquid at a particular temperature is the equilibrium pressure exerted by molecules leaving and entering the liquid surface. A liquid is said to ‘boil’ when its vapor pressure equals the surrounding pressure. Liquids with high vapor pressures (volatile liquids) will boil at lower temperatures. The vapor pressure and hence the boiling point of a liquid mixture depends on the relative amounts of the components in the mixture. The ease with which a liquid boils depends on its volatility. Distillation occurs because of the differences in the volatility of the components in the liquid mixture. Dew-point is the temperature at which the saturated vapor starts to condense. Bubble-point is the temperature at which the liquid starts to boil.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 19




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Boiling Point Diagram

The boiling point diagram shows how the equilibrium compositions of the components in a liquid mixture vary with temperature at a fixed pressure. Consider an example of a liquid mixture containing 2 components (A and B) - a binary mixture. The boiling point of A is that at which the mole fraction of A is 1. The boiling point of B is that at which the mole fraction of A is 0. In this example, A is the more volatile component and therefore has a lower boiling point than B. The upper curve in the diagram is called the dew-point curve. The lower one is called the bubble-point curve. The dew-point is the temperature at which the saturated vapor starts to condense. The bubble-point is the temperature at which the liquid starts to boil. The region above the dew-point curve shows the equilibrium composition of the superheated vapor.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 20




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The region below the bubble-point curve shows the equilibrium composition of the subcooled liquid. For example, when a subcooled liquid with mole fraction of A=0.4 (point A) is heated, its concentration remains constant until it reaches the bubble-point (point B), when it starts to boil. The vapors evolved during the boiling have the equilibrium composition given by point C, approximately 0.8 mole fraction A. This is approximately 50% richer in A than the original liquid. This difference between liquid and vapor compositions in equilibrium is the basis for distillation operations. Relative Volatility •

Relative volatility is a measure of the differences in volatility between two components, and hence their boiling points.

•

The relative volatility of component ‘i’ with respect to component ‘j’ is defined as

yi = mole fraction of component ‘i’ in the vapor xi = mole fraction of component ‘i’ in the liquid


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 21




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Example Imagine a mixture of three liquids, A, B, and C. A has a boiling point of 86°F (30°C); B has a boiling point of 104°F (40°C); and C has a boiling point of 122°F (50°C). Ordinary gasoline is such a mixture, except that it consists of many more than three components. The three-liquid mixture described above is added to a distillation flask. The mixture in the flask is heated by a Bunsen burner or some other apparatus. The temperature of the liquid mixture rises until it reaches the boiling point of any one liquid in the flask. In our example, that liquid is A, which boils at 86°F. Liquid A begins to boil when the temperature in the flask reaches 86°F. It turns into a vapor at that temperature, rises in the distilling flask, and es out of the flask arm into the condenser. The condenser consists of a long tube surrounded by a larger tube. The outer tube contains water, which enters near the bottom of the condenser and leaves near the top. The water ing through the outer jacket of the condenser cools the vapor ing through the inner tube. The vapor loses heat and condenses (meaning it changes back to a liquid). It flows out of the condenser and into a receiving container—a flask or beaker placed in position to capture the liquid. The liquid (liquid A) is now known as the distillate, or the product of the distillation. Meanwhile, the temperature in the distilling flask has not changed, as indicated by the thermometer in the mouth of the flask. Heat added to the liquid mixture is used to vaporize liquid A, not to raise the temperature of the mixture. That temperature will begin to rise only when liquid A has completely boiled away. By watching the thermometer, therefore, an observer can know when liquid A has been completely removed from the liquid mixture. At that point, the receiver containing pure liquid A can be removed and replaced by a new receiver.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 22




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Once liquid A has boiled away, the temperature in the distilling flask begins to rise again. When it reaches 104°F, liquid B begins to boil away, and the sequence of events observed with liquid A is repeated. Eventually, pure samples of A, B, and C can be collected. Some liquids decompose (break apart) at or below

A typical laboratory distillation setup. their boiling points. Vacuum distillation is used for such liquids. In vacuum distillation, air is pumped out of the distilling flask. Under reduced pressure in the flask, liquids boil away at temperatures less than their boiling points (below the point at which they would otherwise decompose). Applications Distillation is among the most important and widely used industrial operations today. About 95 percent of all separation processes today are carried out in industry with more than 40,000 distillation systems. Those systems generally consist of structures that look very different from the one shown in the distillation setup figure. For example, a petroleum refining plant is usually distinguished by a group of distilling towers that rise more than 100 feet (30 meters) into the air. The principle on which such towers operate, though, is no different from the one described above.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 23




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

In petroleum refineries, crude oil is heated at the bottom of the refining tower. The hundreds of compounds that make up crude oil each boil off at their own characteristic boiling point. They rise in the refining tower, are cooled, and condense to liquids. Collectors at various heights in the tower are used to draw off those liquids into various fractions known by designations such as gasoline, diesel oil, heating oil, and lubricating oil. To vaporize heavier components at a prescribed temperature, stripping steam is provided in some distillation column at the bottom to reduce partial pressure of heavier components.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 24




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER-2 INTRODUCTION OF THE UNIT


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 25




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Atmospheric Distillation Unit-III was originally designed by Russians to process 1.0 MMTPA of 50:50 mix of Ankleshwar and North Gujarat Crudes. It was commissioned on 28.09.1967. The Unit has been revamped to process North Gujarat as well as Imported (Low Sulphur) / Bombay High crudes.

The Unit was debottlenecked in four stages: 

In first stage, the processing capacity was raised to 1.4 MMTPA in year 1974 - 1975.



In second stage, the processing capacity was raised to 1.6 MMTPA.



In third phase, the heaters were replaced and unit was revamped to increase the processing capacity to 2.0 MMTPA in 1987.



In fourth stage, the Unit was revamped in May-June 2000, to augment its processing capacity to 3.0 MMTPA.



In June-July’06 Planned shutdown, K-2 and E-2 vessel hook-up job to LP flare header executed and commissioned.



HSD Coalescer commissioned in HSD rundown line in October 2005.



HSD salt dryer has been installed in May ’11. It was commissioned in jan’13



In June-2009 M&I, K-2 flashzone section of 6 meters height was replaced by SS cladded CS plate.

Atmospheric Unit-3 consists of two Electrostatic Desalters, Pre-topping Column K-1, Main Fractionating Column K-2, Hy Naphtha-I — Kero-I Stripper K-6A/B, Hy Naphtha-II— SRGO Stripper K-3A/B, Kero-II Stripper K-3C, Naphtha Stabilizer K-4 and three Furnaces F-1/ F-2/F-3.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 26






Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

In 2013 M&I 14 new heat exchangers (7*2 RCO/CRUDE) installed and 9 new pumps installed. Details given in ANNEXURE.

2.1

FUNCTION OF PLANT After the last revamp in May-June, 2000, the plant can process 3.0 MMTPA North Gujarat and Imported (Low Sulphur) / Bombay High crude in a recommended proportion of 55%NG and 45% Imported (Low Sulphur) / Bombay High. The Unit can also process 100%NG crude. At times of requirement, the Unit can also process slop at a slow rate together with the in-going crude. LPG, Naphtha, SKO, HSD (SRGO) and RCO/LSHS are normal products obtained from this Unit. On demand from UDEX, Hot Oil is produced here.

2.2

ONSTREAM FACTOR

No of Onstream hours in a year considered for design is 8200 hrs (344 days)

2.3

DESIGN FEED RATE Case I: NG55% + Imp45% Case II: NG55% + BH45% Case III: NG100%


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 27



Sr No.

VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

DESIGN CAPACITY (MT/Hr) Case-I Case-II Case-III (NG55% + (NG55% + (NG100%) Imp45%) BH45%)

FEED

1 2*

Crude a) Total feed to F-1 b) Total feed to F-2 c) Total feed to F-3

375.0 77.0 141.0 107.0

375.0 76.0 139.5 106.0

375.0 83.0 153.0 116.5

3

Feed to K-2

325.0

321.5

353.0

4

Un-stbalised Naphtha (E1Gasoline) to K-4

27.3

31.6

8.5

*Note: Feed rates to F-1, F-2 & F-3 are given on the basis that the stripper K-6A/B is in operation.

2.4

TURNDOWN RATIO 50% of the design feed rate


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 28




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

2.5 FEED &PRODUCT DESCRIPTION

A.

CRUDE

Sr. No.

Specifications

1 Density @ 15°C. 2

TBP Distillation IBP to 75 ° C. 75 to 100 ° C. 100 to 125 ° C. 125 to 150 ° C. 150 to 175 ° C. 175 to 200 ° C. 200 to 225 ° C. 225 to 250 ° C. 250 to 275 ° C. 275 to 300 ° C. 300 to 325° C. 325 to 350°C. 350 to 370° C.

UNIT

N/G

B/H

gm/cc

0.8927

0.8278

% Vol.

0.88 1.17 1.76 1.76 2.22 2.22 1.23 2.40 4.54 4.68 4.51 4.19 3.25

6.3 5.1 5.9 5.5 6.8 4.2 3.7 4.6 5.9 4.3 4.8 4.6 3.7

5.12 3.51 3.11 3.51 3.80 3.60 4.56 3.53 4.01 3.16 3.84 4.59 3.26

63.82

31.0

49.4

CSt

1.37 -

3.6 -

°C Kg/cm2 % wt. % Wt.

68.0 42.5 + 24 0.02 0.16 5.43

3.75 3.28 2.24 + 30 0.38 0.17 1.20

1.00 19.5 13.8 +36 2.49 6.20

Residue at 370 °C Gas & Loss 3 Viscosity @ 20°C 30 °C 37.8°C 40°C 50°C 4 Pour Point 5 RVP @ 380°C. 6 Sulphur 7 CCR (Conradson)

IMP (Kuwait) 0.8723


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 29




VOL-I: Addendum

8 Acidicity (i) Total

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

MgKOH/gm

3.88

,,

0.002

-

11.95

(ii)Inorganic 9 KUOP

0.15

0.13 -

11.70

-

B. PRODUCTS SR PRODUCTS PARTICULARS NO 1 LPG TBP Distln 95% vol RVP/TVP 2 E-1 Gasoline Density at 450C ( Unstabilised TBP Distln 5% vol Naphtha) 98% vol 3 E2Gasoline Density at 450C (Naphtha-II) TBP Distln 5% vol (Light 98% vol Naphtha) 4 K-4 bottoms TBP Distln 5% vol (Naphtha-I) 98% vol Density at 166.8 0C 5 SKO Density at 50 OC (KeroI + TBP Distln 5% vol KeroII) 95% vol Flash Point 6 HSD Density at 299.3 0C TBP Distln 5% vol 70% vol 90% vol 95% vol

DESIGN VALUE + 2.36 °C 5.6/7.8 kg/cm2 0.673 gm/cc -19.3 0C 151 0C 0.721 gm/cc 60.2 OC 162.5 0C

Density at 43.80C : 552.8 kg/m3

TBP cut : IBP—120OC RVP : 0.55 kg/cm2(a)

28.85 0C 152.6 0C 0.693 gm/cc 0.804 gm/cc 143 0C 308 0C 39.67 OC 0.856 gm/cc 234.6 oC

TBP cut : 140—270OC

TBP cut : 270—340/370OC SRGO only No Naphtha Injection

344 OC 375 OC 388.3oC

ASTM D86 Distillation : 1% vol : 194.5 OC 5% vol : 250.7 OC 90% vol : 359.4 OC 95% vol : 369.9 OC

92.4 OC Flash Point

7

RCO

Density at 359.5 OC TBP Distln 1% vol 5% vol

REMARKS

0.948 gm/cc 238.2OC 336.9OC

TBP cut : 370OC(+)


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 30


Operating Manual for JR AU-III VOL-I: Addendum 10% vol

8


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

373.8OC 11.95 102.9 OC 197.04 OC 0.757 gm/cc

Watson K Heavy TBP Distln 5% vol Naphtha 98% vol ( Hy Naph-I + Density at 50 OC Hy Naph-II )

TBP cut : 120—140OC

2.6 FEED & PRODUCT BATTERY LIMIT CONDITIONS

SR. NO.

1 2 3 4 5 6 7

8

FEED/ PROD

Crude Fuel Gas LPG SKO HSD RCO Naphtha-I (Stabilised Naphtha) (K-4 bot.) Naphtha-II (Light Naphta) (E-2 gasoline)

PRESSURE (kg/cm²) (abs) 3.5 to 5.0 1.5 to 2.0 12.5 4.5 6.0 5.0 6.0

10.0

TEMP

SOURCE / DESTINATION

°C 32 to 40 35 to 40 45 45 45 80

Offsite Crude pump discharge at GRE Fuel gas bullet at CRU/GRE AU-I/GRE Caustic Wash OM & S / LAB feed stock OM & S FPU-I, FPU-II, OM&S,GRE, Job-50 To General Naphtha pool (OM&S) via 45 AU-1. To AU-IV for Caustic Wash. To AU-I/II for reprocessing. 45

- DO -

Provision have been made to route SKO &HSD to DHDT feed tank. As on June’11, it is yet to be commissioned.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 31




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

2.7 UTILITY SPECIFICATIONS SR. NO 1

2.

3 4 5 6

2.8

UTILITY

High Pressure Steam Medium Pressure Steam Instrument Air Plant Air Recirculating Water DM water

7

Fuel Oil (RCO)/ Slop Distillate (IFO)

8

VR

9

Fuel Gas

PRESSURE kg/cm²(g)

TEMP (° C)

OTHER SPECIFICATION

39.0(max) 35.0(max) 32.0(max) 13.0 (max) 8.5 (nor) 7.5 (min) 6.5 6.5 2.8 to 3.5

440 435 420 325 230 200 Ambient Ambient Ambient

6.0

Ambient

2.0 to 4.0 (at burner)

80 to 95

4.0

120 to 140

2.0 to 2.52

35 to 40

-15° C dew point Free from Oil Hardness 0.5ppm (max) as CaCO3. pH = 6.5 to 8.0 Viscosity at Burner = 25.30 cSt Calorific Value = 9600 kCals/kg. Sulphur = 0.3% Calorific Value = 13,000 KCals/Kg

MATERIAL BALANCE (% WT) The design yield pattern is as follows. (Actual yield pattern obtained from Test Run on 12th October, 2000 compared) Feed : 375 MT/Hr ( NG100% )

SR PRODUCT NO 1 LPG 2 Naphtha-I

TEST RUN (MT/Hr) 0.75 10.21

DESIGN (% Wt)

TEST RUN ( % Wt) 0.20 2.07


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

0.02 2.73

Vol-I (Addendum)

Page 32


3

4 5 6 7 8



(Stb Naphtha)(K4 Bottom) Naphtha-II (Lt Naphtha i.e. E2 Gasoline) Hy Naphtha-I (K-6A Naphtha) Hy Naphtha-II (K-3A Naphtha) Kero-I Kero-II SRGO

9 RCO 10 Gas + Loss

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

8.10

0.80

2.17

4.10

0.93

-

5.23

0.80

1.4

11.90 32.31 54.26

2.87 9.94 11.88

-8.64 14.51

262.25 0.0095

70.71 0.0025

70.12 -

* The above have changed after introduction of Advance Process Control. To be modified after test run.

2.8 UTILITY CONSUMPTION

SR. NO

UTILITIES

1

M.P. Steam

2

Instrument Air Plant Air Circulating Water

3 4 5

CONSUMPTION

18.3 Kg/MT of crude 655 M3/MT of crude

Service Water

6

DM Water

7

Fuel Oil/Fuel Gas

8

HP Steam

5 to 6 M3/Hr 3-4 MT/Hr (IFO)

USES Atomising, Soot blowing, Stripping in K1, K2, K3 & K6, Hose stations, Steam air decoking Instruments Service stations, decoking Coolers, Condensers And Pumps Utility stations at heat exchangers and decoking pot Desalter-I, Desalter-II Furnaces F-1, F-2 and F-3

VR Heating


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 33




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER - 3 EQUIPMENT DATA


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 34




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

3.1 PUMPS

Sr No

EQPT NO

SERVICE

DISCH P PRESS (kgf/cm2) (kgf/cm²)

FLOW (M³/Hr) Rated

kW

Normal

1

H-2/2A

CRUDE

175

150

21.0

2 3 4

H-2B H-2C H-4/5A

CRUDE CRUDE SRGO

175 175 110

150 150

21.0 22.0

5

H-6

75

65

9

K-1 TOP REFLUX H-8 K-2 TOP REFLUX/ NAPHTHA-2 R/D H-8A K-1 TOP REFLUX H-9 K-2 TOP REFLUX / NAPHTHA-2 R/D H-10/ 10A KERO-II

113

10

H-11/ 11A RCO (K-2 BOT)

200

11

H-14

K-4 BOT

40

12

56

17

H-15/ 15A K-4 REFLUX / LPG R/D H-18 SLOP/CBD H-19 SLOP/CBD H-20/ IFO/E6-E7 pump 20A H-21A/ AHURALAN /B/C/D Injection H-25 CAUSTIC Injection

18

H-26

6 7 8

13 14 15 16

CAUSTIC Injection

50

LUBE OIL

Rated Amp

18.0

220

23

SS46

18.0 19.0 137 (H in m) 8.0 5.0

260 260

27 27 180

,, ,, SS68

22

37.8

SS46

18.5

32

,,

22

38

,,

18.5

32

80 (H in m) 12

75

MOTOR

50

80 (H in m)

,,

78 (H in m) 147 (H in m) 14.5 47.4

15.0

6.2

SS68 ,, 18.5

45

SS46

30

50

,,

80 60 18

6.0 6.0 7.3

8 11 8

16 20 18

,, ,, ,,

5 LPH 150 LPH 150

6.0

0.37

0.9

,,

20

0.37

1.1

,,

20

0.37

1.1

,,


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 35


Sr No

EQPT NO

VOL-I: Addendum

SERVICE

H-28/ 28A H-29/ 29A H-30 /31

DM Water Injection Pump DEMULSIFIER

23

H-41 A /B / C H-42

K-1 BOT (K-1 RESIDUE) RCO (K-2 BOT)

24

H-101

25

H-102

26

H-103

27

45-PM002 A/B P-231 A/ B P-231C

SUCTION FROM TK-212/213/214 SPARE FOR (Slop) H-101 / H-103 SUCTION FROM TK-209/210/211 VR/IFO PUMP DESALTER DESLUDGING DM WATER Injection K-1 CR-I (KERO-I) K-2 CR-II (KERO-II) Hy Naphtha (K-6A & K-3A bottoms) KERO-I Product (K-6B bottoms)

20 21 22

28 29 30

P-301 A/ B 31 P-302 A/ B 32 P-304 A/ B/C 33

P-305 A/ B

AMMONIA SOLUTION

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


FLOW (M³/Hr) Rated

19



MOTOR

kW

Normal

LUBE OIL

Rated Amp

LPH 20

40

35

52

,,

8

21

0.37

1.1

SS46

20 LPH 220

8

0.37

1.1

,,

12

160

268

SS68

200 60

147 (H in m) 5.5

15

27.5

50

-

4.3

11

20

,,

52

-

5.2

15

28

,,

10

9

15

27.5

SS68

22

16

5.5

10.5

,,

30

52

SS46 SS68

3.25

,, SS46

28

23.2

6.6

4.0

7.5

13.5

250

225

6.5

5.1

45

74

,,

23

18

8.5

6.0

15

25.1

,,

28

17.5

9.0

6.0

15

26.5

,,


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 36


Sr No

EQPT NO

VOL-I: Addendum

SERVICE

35 36 37

P-306 A/ B P-307 A/ B P-5A/B

K-4 Feed (E-1 to K-4) K-2 CR-III (SRGO) Hot Oil/FO to UDEX Sucn. ex TK-212/213 2115P119 Diesel boostr pump A/B

3.2

Sr NO

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


FLOW (M³/Hr) Rated

34



MOTOR

kW

Normal 15

LUBE OIL

Rated Amp

37

61

SS46

270

238

7.5

6.1

67

105

SS68

-

-

-

-

11

19.9

SS46

127.6

55.46 (H in m)

53

EXCHANGERS

EQUIPMENT NO

FLUID Temp, °C (in/out)

SERVICE

SHELL

TUBE SRGO+HNI+HN-II 150/70 CRUDE 70/102 CR-II 192/133

1

E-102 A/B

CRUDE PREHEAT

CRUDE 35/70

2

E-103 A/B

CRUDE PREHEAT

3

HM3A/B

CRUDE PREHEAT

4

E-106

K-4 BOTTOM REBOILER

5 6

E-231 A/B/C E-301A/B

DM WATER HEATER CRUDE PREHEAT

RCO 155/110 CRUDE 102/147.2 CR-III 288/268 DM WATER 40/65 CRUDE 35/65

7

E-302A/B/C

CRUDE PREHEAT

8

E-303

CRUDE PREHEAT

RCO 215/110 CRUDE 106/123


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

K-4 BOT 165/180 BRINE 13.5/75 KERO1+ KERO2 132/70 CRUDE 65/114 KERO-II 177/132

Vol-I (Addendum)

Page 37


Sr NO


EQUIPMENT NO


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

FLUID Temp, °C (in/out)

SERVICE

SHELL

9

E-305

CRUDE PREHEAT

10

E-306A/B

CRUDE PREHEAT

11

E-307

CRUDE PREHEAT

12

E-308A/B/C

CRUDE PREHEAT

13

E-309A/B/C

14

E-310A/B

15

E-311

16

E-313A/B

17

E-315

18

E-317A/B

19

E-318

K-1 RESIDUE HEATING K4 FEED (E1 Gasoline) PREHEAT K4 FEED (E1 Gasoline) PREHEAT DM WATER HEATER SRGO(HSD) COOLING K1 RESIDUE HEATING BRINE COOLER

20

E-320A/B

CRUDE PREHEAT

21

E104A /B

CRUDE PREHEAT

22

HME/F

CRUDE PREHEAT

23

HMC/D

CRUDE PREHEAT

24

HMA/B

CRUDE PREHEAT

25

45-EE-003-A/B/C/D

VR/IFO HEATING

CRUDE 123/142 CRUDE 142/190 CRUDE 202/220 RCO 325/235 K-1 BOT 229/265 K-4 FEED 45/129 K-4 FEED 40/129 CR-I/CR-III 100/127 SRGO(HSD) 70/45 K-1 BOT 204/231 C.WATER 33/42 RCO 182/168 RCO 184/167 RCO 347/184 RCO 347/184 RCO 347/184 VR 120/235


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

TUBE SRGO 189/150 SRGO 284/189 CR-III 241/224 CRUDE 213/256 RCO 339/284 K-4 BOT 172/85 SRGO 147/60 D M Water 108/140 Cooling Water 33/42 CR-III 285/232 Desalter Brine 72/43 CRUDE 140/150 CRUDE 126/138 CRUDE 138/178 CRUDE 178/218 CRUDE 218/260 HP STEAM 430/239

Vol-I (Addendum)

Page 38

. Indian Oil Gujarat Refinery 3.3



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

COOLERS / CONDENSERS

FLUID Temp, °C (in/out) SNO

EQUIPMENT NO

SERVICE

1

T-7A/B

2

T-8A/8B/8C

3

T-8D

4

T-9 A/B

5

T-14A

K-1 O/H VAPOURS CONDENSING K-2 O/H VAPOURS CONDENSING K-2 O/H VAPOURS CONDENSING K-4 O/H VAPOURS CONDENSING KERO R/D

6

T-16 A/B/C/D

RCO R/D

3.4

SHELL

TUBE

K-1 TOP 132/45 K-2 TOP 125/45 K-2 TOP 125/45 K-4 TOP 61/35

WATER 33/42 WATER 33/45

KERO-I+ KERO-II 72/42 RCO 110/90

WATER 33/42

WATER 33/45 WATER 33/45

WATER 33/45

VESSELS

PRESSURE (kg/cm2) SNO

EQUIPMENT

SERVICE

CAPACITY

NO

OPERATING

DESIGN

(M) 3

1

E-1

K1 REFLUX

42

2.7

3.5

DRUM 2

E-2

K-2 REFLUX DRUM

20

0.25

3

E-4

K-4 REFLUX DRUM

18.3

8.0

4

E-8

UGT/CBD

20

ATM

-

5

E-9

AHURALAN

1.199

ATM

-

6

E-11

INSTRUMENT AIR

20

6.0

7

E-12

DM WATER

16.7

ATM


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

10.5

-

Vol-I (Addendum)

Page 39




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

8

E-13

DEMULSIFIER

2.033

ATM

9

E-19

BRINE FLASH DRUM

10

-

DESALTER-I (OLD)

13.5

19 at 300 0F

11

-

DESALTER-II (NEW)

13.5

19 at 300 0F

12

45-VV- 003

VR SURGE DRUM

31

2.4

13

45-VV-004

FLARE KO DRUM

3

2.2

14

3.5

03-V-107

LP FLARE KO DRUM

48

-

0.3

3.5

Op Temp : 801000C

Des. Temp : 1800C

TANKS REFERENCE

SNO

TANK NO

SERVICE

CAPACITY

HEIGHT

SFH

(M)

(cm)

(cm)

FACTOR (MT/CM)

3

1

209

UDEX RAFFINATE

300

608.8

0.238

2

210

UDEX RAFFINATE

300

608.8

0.238

3

211

UDEX RAFFINATE

300

608.8

0.238

4

212

DIESEL

300

670

0.370

5

213

HOT OIL

300

670

0.370

6

214

SLOP / PDF R/S

300

670

0.370

7

E-6

FUEL OIL

60

585

--

--

8

E-7

FUEL OIL

60

587

--

--

3.6

COLUMNS TRAY

SNO 1 2

EQUIPMENT NO K-1 K-2

SERVICE

Nos

TYPE

PRE TOPPING

1 to 8

SIEVE

COLUMN

9 to 29

VALVE

MAIN

1 to 6

SIEVE

7 to 41

VALVE

FEED

TOP

TOP

ENTRY

TEMP

PRESSURE

TRAY

(°C)

(kg/cm2)

8

110 to 129

2.2 to 2.9

6

111 to 125

0.6

FRACTIONATING COLUMN


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 40

. Indian Oil Gujarat Refinery 3

K-3A


Operating Manual for JR AU-III VOL-I: Addendum HYNAPHTHA-II STRIPPER

6

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

175 to

-

SIEVE

6

180

4

K-3B

SRGO STRIPPER

6

SIEVE

6

333

-

5

K-3C

KERO-II

6

SIEVE

6

-

-

NAPHTHA STABILIZER

34

VALVE

11,15,

60

8.0 to 8.3

HY NAPHTHA-I

6

SIEVE

6

-

-

6

SIEVE

6

-

-

STRIPPER 6 7

K-4 K-6A

17

STRIPPER 8

K-6B

KERO-I STRIPPER

3.7 FURNACES/AIR PRE-HEATER EQUIPMENT SR NO 1

SERVICE

NO F-1

HEAT DUTY (ABSORBED) MMKCal/Hr

CRUDE HEATER

8.63

90% WITH

FOR K-2 FEED 2 3

F-2

CRUDE HEATER FOR K-2 FEED

APH

COMBUSTION AIR

APH

PREHEATING

4

F-3

CRUDE HEATER FOR K8.0 2 FEED

5

F-3 APH COMBUSTION AIR PREHEATING

90% WITH

16.02

F-1/F-2

3.8

APH

2.55

0.825 (oil fired norm)

10

6

90%

1.5 ( oil fired design)

6

-

-

-

-

TURBO BLOWERS CAPACITY CAPACITY

SR NO

NO. OF BURNERS

EFFICIENCY

TAG NO

NO

SERVICE

(NM3/HR)

(NM3/HR)

MAX

MIN


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

DIFFL PR. (MMWC )

MOTOR kW

RATED Amp

Vol-I (Addendum)

Page 41



VOL-I: Addendum

C-1 (FDFAN)

COMBUSTION AIR BLOWER

1


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

10,000

316

66,000

(FOR F1/F2) 2

90

190

110

224

37

63

45

76

(3099 Pa)

C-2

1

FLUE GASES

88,200

15,700

204

(ID FAN) (FOR F1/F2) 3

(2000 Pa)

410-FD-01 A/B

2

COMBUSTION AIR BLOWER

(FD FANS)

25,300

-

(FOR F3) 4

333.45 (3270 Pa)

410-ID-02

1

FLUE GASES

38,160

-

250.85

(ID FAN) (FOR F3)

(2460 Pa)

3.9 PSV'S SNO

TAG

Nos

LOCATION

SERVICE

NO 1

RELEASE

(kgf/cm )

TO

3.7

FLARE

3.15

FLARE

1.5

L.P Flare

1.2

L.P Flare

9.4

FLARE

9.4

FLARE

19.34

K-1

18.7

K-1

2

3PSV-3201

2

A/B 2

SET PR

3PSV-05

1

K-1O/H

To vent

(On Condensers Platform)

Naphtha

On E-1 Vessel

To vent LPG

3

3PSV-3501 A/B/C/D 3PSV3502

.

3PSV-3503

5

K-2 TOP

&

To vent Naphtha

1

On E-2 Vessel

To vent Naphtha

5

3PSV-3601

2

K-4 TOP

A/B 6

3PSV-3601

To vent LPG

1

On E-4 Vessel

To vent LPG

7

8

3PSV-901

3PSV-902

1

1

Desalter -I

To vent

O/H line on K-1 8th Platform

Crude

Desalter -I

To vent

O/H line on K-1 8th Platform

Crude


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 42

. Indian Oil Gujarat Refinery SNO

TAG

Operating Manual for JR AU-III VOL-I: Addendum Nos

LOCATION


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

SERVICE

NO 9 10 11

3PSV-3101A 3PSV-3101B 3PSV-4501

SET PR

RELEASE

(kgf/cm )

TO

20.3

K-1

20.3

K-1

3.15

Flare

2

1 1 1

Desalter-II O/H

To vent

On K-1 Platform

Crude

Desalter-II O/H

To vent

On K-1 Platform

Crude

On VR surge

To vent FG

Drum 12

3PSV-4504 1

On disch of VR pump

K.O. Drum 10 To vent VR

45-PM-002B 13

3PSV-4505 1

On disch of VR pump

3TSV-4501

1

VR O/L of Exch

To vent VR

3TSV-4502

1

VR O/L of Exch

To vent VR

17

3TSV-4503

3TSV-4504

1

1

Temp=

10

CBD

Temp=235 C 0

To vent VR

45-EE-003C/D 16

Suction of the

120 to 1700C same pump

45-EE-003A/B 15

Temp=120 to 1700C same pump 10

45-PM-002A 14

Suction of the

10

CBD

Temp=2350C

On VR/FO Supply lines to AU3/Udex furnaces before supplyreturn by

To vent VR/FO

On VR/FO Supply

To vent VR/FO

10

Surface Drain

10

Surface

Line to Udex 18

19

3TSV-4505

3TSV-4506

1

1

Drain

On VR/IFO Return line (to VR Drum) near E-7

To vent VR/FO

On IFO line ex E6/E-7 to VR Drum near VR pumps

To vent FO

10

Surface

Temp=2350C

Drain

10

CBD

Temp=1700C


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 43




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

LIST OF CONTROL VALVES/CONTROLLERS

3.10.1 FLOW CONTROLLERS SR

TAG NO

NO

SERVICE

CONTROLLER

1

3FV3003

F-3 -1 FEED FLOW

3FC3003

2

3FV3005

F-3 -2 FEED FLOW

3FC3005

3

-

TOTAL AIR TO F-3

3FC3012

4

3FV3110

CRUDE FLOW TO K-1

3FC3110

5

3FV3111

KERO-II TO KERO R/D

3FC3111

6

3FV3112

RCO TO OM&S

3FC3112

7

3FV3113

COLD RCO TO OM&S (LV Grade)

3FC3113

8

3FV3114

SKO TO RCO TO VR (HV)

3FC3114

9

3FV3115A

HOT RCO TO FPU-1

3FC3115A

10 3FV3115B

HOT RCO TO FPU-2

3FC3115B

11 3FV3116

RCO TO OM&S /VR

12 3FV3117

RCO VBU TANKS

3FC3117

13 3FV3118

SK TO RCO (LV Grade)

3FC3118

14 3FV3119

SKO TO RCO TO OM&S (LV)

3FC3119

15 3FV3120

COLD RCO TO FPU-2

3FC3120

16 3FV3135

SRGO R/D (TO HSD) FLOW

3FC3135

17 3FV3203

FEED (E1 GASOLINE) TO K-4

3FC3203

18 3FV3205

STRIPPING STEAM TO K-1

3FC3205

19 3FV3208

KERO-I FLOW TO KERO R/D

3FC3208

20 3FV3211

KERO-I CR TO K-1(CR-I)

3FC3211

21 3FV3301

FEED TO F-1

3FC3301`

22 3FV3303

FUEL GAS TO F-1

3FC3302

23 3FV3402

-1 OF F-2 FEED FLOW

3FC3402

24 3FV3403B

-2 OF F-2 FEED FLOW

3FC3403

25 3FV3411

FUEL GAS TO F-2

3FC3411

26 3FV3501

STRIPPING STEAM

27 3FV3502

KERO CR TO K-2

28 3FV3508

STRIPPING STEAM

29 3FV3509

STRIPPING STEAM TO

(HV Grade)

(HV Grade)

3FC3116

TO K-2

3FC3501

(CR-II)

3FC3502

TO K-3B

3FC3508 3FC3509

K-3A(Hy Naphtha-II Stripper) 30 3FV3510

NAPHTHA-II R/D FLOW

3FC3510

31 3FV3517

STRIPPING STEAM TO K-3C

3FC3517

32 3FV3519

CR-II (SRGO) TO K-2

3FC3519


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 44




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

33 3FV3602

DRAG STREAM EX CRU

3FC3602

34 3FV3604

LPG EX E-4 TO AU-4/AU-1

3FC3604

35 3FV3209

HY NAPHTHA TO SRGO (HSD)

3FC3209

36 3FV3210

HY NAPHTH TO SRGO (HSD)

3FC3210

37 3FV3801

F1/F2 FD FAN COLD AIR FLOW

3FC3801

38 Damper

HOT AIR FLOW TO F-2

3FC3802

39 Damper

HOT AIR FLOW TO F-1

3FC3803

40 3FV3906

DM WATER TO DESALTER-I

3FC3906

41 3FV3907

DM WATER TO DESALTER-II

3FC3907

42 3FV5905R

HSD to blending (EURO-3)

3FC5905R

43 3FV5903R

Kero to DHDT feed tank

3FC5903R

44 3FV3112A

Kero to LABFS tank

3FC3112A

45 3FV5911R

P119A/B MIN CIRC FLOW

3FC5911R

3.10.2 LEVEL CONTROLLERS SR NO

TAG NO

SERVICE

CONTROLLER

1

3LV3109

DM WATER TO TANK( E-12) LEVEL

3LC3109

2

3LV3201

K-1 BOTTOM

3LC3201

3

-

E-1 HYDROCARBON

3LIC3202

4

3LV3203

E-1 BOOT WATER

3LDIC3203

5

3LV3205

K-6A (Hy NAPHTHA-I)

6

3LV3206

K-6B (KERO-I) BOTTOM

3LC3206

7

3LV3501A

K-2 BOTTOM

3LC3501A

8

3LV3502

K-3A BOTTOM

3LC3502

9

3LV3503

K-3B (SRGO STRIPPER) BOTTOM

3LC3503

10

-

E-2 HYDROCARBON

3LDIC3504

11

3LV3505

E-2 BOOT WATER

3LDIC3505

12

3LV3516

K-3C (KERO-II) BOTTOM

3LC3516

13

3LV3601

K-4 BOTTOM

3LC3601

14

3LV3602

E-4 HYDROCARBON (LPG) LEVEL

3LDIC3602

15

-

E-4 BOOT-WATER

3LDIC3601

16

3LV3901

VR SURGE DRUM LEVEL

3LC3901

17

3LV3902A/B

DESALTER-I INTERFACE

3LDIC3902A/B

18

3LV3903A/B

DESALTER-II INTERFACE

3LDIC3903A/B

19

3LI1110

LP FLARE KOD LEVEL

BOTTOM


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

3LC3205

Vol-I (Addendum)

Page 45




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

3.10.3 CONTROLLER SR NO

TAG NO

SERVICE

CONTROLLER

1

VANES

F-3 HIP ARCH PR. (ID FAN IGV CONTROL)

3PC3001

2

3PV3003

F.G. TO F3 PRESSURE

3PC3003

3

3PV3005

F.G. TO F3 PRESSURE

3PC3005

4

3DPV3006

DIFFL. PRESSURE BETWEEN

3DPC3006

FO & ATM STEAM TO F3 5

3PV3101

DESALTER PRESSURE CONTROL

3PC3101

6

3PV3201

K-1 TOP PRESSURE

3PC3201

7

3PV3205

STRIPPING STEAM TO K1

3PC3205

8

3PV3301

FO PRESSURE TO F-1

3PC3301

9

3DPV3302

DIFFL. PR. BETWEEN

3DPC3302

FO & ATM STEAM IN F-1 10

3PV3417

FO PRESSURE TO F-2

3PC3417

11

3DPV3419

DIFF PR BETWEEN

3DPC3419

FO & ATM STEAM TO F-2 12

3DPV3503

K-2 TOP PRESSURE

3PC3503A/B

A/B 13

3PV3601

K-4 TOP PRESSURE

3PC3601

14

3PV3701

STRIPPING STEAM PRESSURE

3PC3701

TO K-2 & K-3 15

3PV3702

STEAM TO UNIT PRESSURE

3PC3702

16

3PV3704

FUEL GAS SUPPLY PRESSURE TO UNIT

3PC3704

17

3PV3705

INSTRUMENT AIR VESSEL PRESSURE

3PC3705

18

3PV3706

FUEL OIL BPC

3PC3704

19

DAMPER

F-1 HIP ARCH PRESSURE

3PC3801

20

DAMPER

F-2 HIP ARCH PRESSURE

3PC3820

21

3PV3901A/B

VR SURGE DRUM PRESSURE

3PC3901A/B

22

3PC5905R

SRGO TO DHDT

3PV5905R

23

3PC5903R

KERO TO RUNDOWN

3PV5903R


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 46




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

3.10.4 TEMPERATURE CONTROLLERS SR NO

TAG NO

SERVICE

CONTROLLER

1

3TV040

CRUDE PREHEAT TEMP

3TC040

2

-

F-3 COT

3TC3013

3

DAMPER

FLUE GASES (EX F-3 APH) TEMP CONTROL

3TC3028

4

3TV3102A

CRUDE TEMP. CONTROL

3TC3102A

5

3TV3102B

CRUDE TEMP. CONTROL

3TC3102B

6

3TV3125A

CRUDE TEMP CONTROL

3TC3125A

7

3TV3125B

CRUDE TEMP CONTROL

3TC3125B

8

3TV3129

CR-I(KERO-I) RETURN TEMP CONTROL

3TC3129

9

3TV3130

CR-II (KERO-II) RETURN TEMP CONTROL

3TC3130

10

3TV3131

K-4 FEED TEMPERATURE CONTROL

3TC3131

11

3TV3135

CR-III(SRGO) RETURN TEMP CONTROL

3TC3135

12

3TV3201

K-1 TOP TEMPERATURE

3TC3201

13

-

F-1 COT

3TC3312

14

-

F-2 COT

3TC3418

15

3TV3505

SRGO WITHDRAWAL EX K-2 TO K-3 B

3TC3505

16

3TV3506

Hy NAPHTHA WITHDRAWAL EX K-2 TO K-3 A 3TC3506

17

3TV3507

K-2 TOP TEMPERATURE

3TC3507

18

3TV3603

K-4 TOP TEMPERATURE CONTROL

3TC3603

(PREVIOUSLY 3FV3601) 19

3TV3605

K-4 REBOILER(E-106) TEMP CONTROL

3TC3605

20

3TV3901

VR/IFO (TO F1/F2/F3) TEMP CONTROL

3TC3901

(HP STEAM C/V)

3.11

LIST OF ALARMS AND TRIPS:

Following alarms and trips are provided in the unit : SR NO

TAG NO

SERVICE A

ALARM/ TRIP

SET VALUE

UTILITIES

1

3PL3303

Fuel Oil Pressure Low

ALARM

2.0kg/cm2(g)

2 3 4

3PSL3702 3PSL3705 3PL3704

Unit Steam Pressure Low Instrument Air Pressure Low Fuel Gas To Unit Pressure Low

ALARM ALARM ALARM

6.0 Kg/cm2(g) 3.0 Kg/cm2(g) 1.0 Kg/cm2(g)


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 47

. Indian Oil Gujarat Refinery SR TAG NO NO 5 3PAL3901 6 3PAH3902 7 3LAH3901A

VOL-I: Addendum

3LI3201A 3LI3203 3LAL3501 3LAH3505 3LAL3505 3LSL3601 3LAH3701 3LI3904 3LI3905

3PAL3303A 3PSL3303B 3PAL3304A 3PSL3304B 3PAL3305 3FAL33O7A 3FAL3307B 3FCL3307 3TAH3303 3TAH3315 3PSH3706 3PAH3801 3PAH3802 3LAL3902 3LAL3903 3FL3402 3FL3403B 3FL3401A 3TAH3403 3PAL3411A 3PSL3411B 3PAL3412A

Rev. Date

1st Sep,2016

0

1st Sep,2016

ALARM/ TRIP

SET VALUE

ALARM ALARM ALARM

30% 30% 50%

ALARM ALARM ALARM ALARM ALARM ALARM ALARM ALARM ALARM

30% 20% 20% 80% 20% 20% 75% 75% 75%

ALARM TRIP ALARM TRIP ALARM TRIP ALARM TRIP ALARM TRIP ALARM ALARM TRIP ALARM ALARM

2.0 kg/cm2 1.0 kg/cm2 0.2 kg/cm2 0.1 kg/cm2 0.25 kg/cm2 60 M3/Hr 80 M3/Hr 60 M3/Hr 450 0C 390 0C 7.5 kg/cm2 +1mm WC +5mmWC 20% 20%

TRIP TRIP TRIP ALARM ALARM TRIP ALARM

90 M3/Hr 90 M3/Hr 90 M3/Hr 450 0C 2.0 kg/cm2 1.0 kg/cm2 0.2 kg/cm2

COLUMNS & VESSELS

K-1 Level Low E-1 Boot Water Level K-2 Bottom Level Low E-2 Boot Water Level High E-2 Boot Water Level Low K-4 Bottom Low E-8 Level High E-6 Level High E-7 Level High FURNACE F-1

F-1 Fuel Oil Pr.Low F-1 Fuel Oil Pr. Very Low F-1 Fuel Gas Pr. Low F-1 Fuel Gas Pr. Very Low F-1 Pilot Gas Pr. Low Flow Very Low (F-1) Flow Low (F-1) Flow Very Low (F-1) F-1 Stack Temp High F-1 Coil Outlet Tmp High Fuel Oil BPC High F-1 Arch Pressure High F-1 Arch Pressure Very High Desalter-I Level Low Desalter-II Level Low D

1 2 3 4 5 6 7

Rev. No.

VR Discharge Pressure Low VR Surge Drum Pressure High VR Level In KO Drum High

C 1 2 3 4 5 6 7 8 9 10 15 11 12 13 14

Issue Date

SERVICE

B 1 2 3 4 5 6 7 8 9



FURNACE F-2

F2 -1 Flow Low F2 -2 Flow Low F2 Combined Flow Very Low F2 Stack Temp High F2 Fuel Oil Pr Low F2 Fuel Oil Pr Very Low F2 Fuel Gas Pr Low


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 48

. Indian Oil Gujarat Refinery SR NO 8 9 10 11 12 13

TAG NO 3PAL3412B 3PAL3413 3TAH3413 3TAH3422 3PAH3820 3PAH3821



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

SERVICE

ALARM/ TRIP

F2 Fuel Gas Pr Very Low F2 Pilot Gas Pr Low F2 Coil Outlet Temp High -1 F2 Coil Outlet Temp High -2 F2 Arch Pressure High F2 Arch Pressure Very High

TRIP ALARM TRIP TRIP ALARM TRIP

SET VALUE 0.1 kg/cm2 0.25 kg/cm2 390 0C 390 0C +1.0 mmWC +5.0 mm WC

E. F-1 & F-2 AIR PREHEATER 1 2 3 4 5 6 7 8

3TAL3805 3TAH3806 3TAH3807 3TAH3810 3PL3811 3PL3811A 3PH3819 3PH3819A

Flue Gases After APH Temp Low Flue Gases After APH Temp High Flue Gases Before APH Temp High Hot Air After APH Temp High FD Fan Discharge Pr Low FD Fan Discharge Pr Very Low ID Fan Suction Pr High ID Fan Suction Pr Very High

ALARM ALARM ALARM ALARM ALARM ALARM ALARM TRIP

170 0C 230 0C 420 0C 200 0C +30mmWC +20mmWC -30mmWC -20mmWC

TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP TRIP

10.0 T/Hr 10.0 T/Hr 0.4 kg/cm2 1.6 kg/cm2 16 mmWC +10 mmWC +10 mmWC +10 mmWC 4000C 4000C

-20 mmWC -20 mmWC 0.2ACount Ratio 0.2ACount Ratio 0.2ACount Ratio -60 mmWC 285 0C

F. FURNACE F-3 1 2 3 4 5 6 7 8 9 10

3FT3002 3FT3004 3PT3004 3PT3013 3PT3015 3PT3016A 3PT3016B 3PT3016C 3TT3023A 3TT3023B

F-3 -I Feed Flow Low F-3 -II Feed Flow Low F-3 Fuel Gas Pressure Low F-3 Fuel Oil Pressure Low Combustion Air Presure Low F-3 Arch Pressure High F-3 Arch Pressure High F-3 Arch Pressure High F-3 -I COT High F-3 -II COT High G. F-3 AIR PREHEATER

1 2

3FT3011A 3FT3011B

FD-A Suction Flow Low FD-B Suction Flow Low

TRIP TRIP

3

3IT3001A

FD-A Current Low

TRIP

4

3IT3001B

FD-B Current Low

TRIP

5

3PT3003

ID Fan Current Low

TRIP

6 7

3PT3011 3TT3027

ID Fan Suction Pr High ID Fan Suction Temp High

TRIP TRIP


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 49




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER-4 PROCESS FLOW DESCRIPTION


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 50




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

4. 1 BRIEF DESCRIPTION OF THE PROCESS

Crude from OM&S is received through booster pumps located at GR/GRE Crude Control. Crude is charged at a temperature of 350C by feed pumps H-2, H-2A, 2B, 2C for processing. These are actually crude booster pumps, which take suction from discharge of offsite pumps at GR/GRE Crude Control. It is pumped and preheated by successive heat exchange with Hy Naphtha-I, Hy NaphthaII, Kero-I, Kero-II, SRGO (HSD), and RCO and received in desalters. Salts, water and BS&W are removed from crude by applying high voltage across the electrode grids in the desalters. Crude is further heated by successive heat exchange with RCO, SRGO and then it enters the pre-topping column K-1. K-1 top gasoline vapours are condensed in two sets of condensers (T-7A/B) and received in reflux drum E-1. A part of this liquid is sent as reflux back to column and the remaining quantity is sent to stabilizer column K-4 after ing through heat exchangers where LPG is removed & naphtha is sent to R/D. K-1 bottom residue is further preheated in RCO and SRGO exchangers and then heated up in three furnaces running in parallel. Hot residue crude from the furnaces is combined and is sent to flash zone of the main fractionating column K-2. Column K-1 has two side cut products. Heavy Naphtha-I is the first side cut product, which goes to K-6A for stripping, and Kerosene-I is the second side cut which is sent to stripper K-6B. Later Hy Naphtha-I combines with Hy Naphtha-II and SRGO of K-2 and goes to HSD rundown. Kerosene-I combines with Kerosene-II of K-2 and exchanges heat with crude and then it is cooled in cooler and sent as Kero R/D. In flash zone of K-2 all products except RCO go in vapour form in upper section whereas RCO drops in stripping section of K-2. Vapours rise through the upper section of the column and are fractionated and withdrawn as a side product. Gasoline comes out as vapours from K-2 top whereas Hy Naphtha-II, Kerosene and SRGO are withdrawn as side cuts from column K-2. From the top of K-2, Gasoline vapours enter into four sets of condensers (T-8A/B/C/D) and after condensing are collected in reflux drum E-2. A part of E-2 gasoline is put back into the column as a reflux and balance is sent to Naphtha-2 rundown.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 51




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Hy Naphtha-II is drawn as first side cut from column K-2. This Hy Naphtha enters the top section of K-3 stripper. After stripping, Hy Naphtha-II together with Hy Naphtha-I of K-6A and SRGO exchanges heat with crude and circulating water and is sent to HSD rundown. Kerosene-II is withdrawn as 2nd draw-off from column K-2. After withdrawing it is fed to K-3C for steam stripping. Product pumps H-10/10A deliver kero-II from K-3C to crude exchangers where it exchanges heat with crude. T-14A cooler is used to cool down the final rundown product (Kero-I and Kero-II). A part of Kero-II is taken from the same draw-off line and sent to crude exchanger where it exchanges heat with crude. From crude exchanger it returns to column K-2 as CR-II. SRGO is withdrawn as 3rd side cut from column K-2. SRGO enters the bottom section of K-3 stripper. SRGO from stripper is pumped to storage after exchanging heat with crude, K-4 feed and circulating water (in cooler E-315). After K-4 feed preheat exchanger E-311, Hy Naphtha-I and Hy Naphtha-II together combine with SRGO. These three streams in combination through another crude exchanger E-102A/B as HSD. Cooler E-315 is used to cool down this HSD to rundown temperature. A part of SRGO upstream of stripper is pumped through K-4 bottom reboiler; K-1 residue exchanger, crude exchanger and DM water heat exchanger and then returns to main column K-2 as circulating reflux (CR-III). There is interconnection between discharge lines of P-307A/B and H4/5A to facilitate SRGO C/R through stripper K-3B instead of upstream of SRGO withdrawal. RCO from K-2 bottom is routed to FPU-I, II and OM&S after exchanging heat with crude in different crude heat exchangers and with circulating water in coolers T-16/16A/B/C/D/E.

4.2

DETAILED DESCRIPTION OF THE PROCESS

For convenience of understanding, the unit is divided in various circuits viz. crude supply, feed preheating, crude pre-topping, furnace, main fractionating column, overhead system, Hy Naphtha, Kerosene, SRGO, RCO, Stabiliser, Naphtha Stripper, Utilities etc. The drawings of the respective


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 52




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

circuits are given in Annexure. These drawings show the arrangement of the process equipment and major controls.

4.2.1

CRUDE SUPPLY

4.2.1.1 CRUDE STORAGE AND SETTLING AU-III processes NG crude Imported crude/ BH crude and Slop.

These are stored in

respective tanks earmarked for them. NG CRUDE TANKS OF GRE CRUDE CONTROL

TANK NO

781 782 783 911

SERVICE

NG NG NG NG

CAPACITY

REFERENCE HEIGHT

SAFE FILLING HEIGHT

(kL) 20,000 20,000 20,000 20,000

(cm) 1769.0 1700.5 1694.0 1667.5

(cm) 1250 1230 1230 1360

CRITICAL ZONE

(cm) 220 to 250 150 to 186 150 to 186 180 to 218.5

FACTOR

KL/CM 14.1 14.1 14.1 14.1

Adequate settling time, 12 hours or more after completion of receipt is required for each tank to settle down water/sludge. The water is thoroughly drained before feeding to the unit. The sludge from the tank is drained to melting pit. A crude tank prepared as above, is first fed at slow rate by crack opening of outlet valve (bleeding), along with the already feeding tank. After minimum of 4 hours bleeding, this may be made a complete feed tank. This procedure is adopted to avoid unit upsets due to possible sudden influx of water or abrupt feeding of different quality crude from the fresh tank. Feeding from the crude tank to the unit crude feed pump may be either by gravity, as in the case of low feed requirement, or via crude booster pump as in the case of higher throughput requirement.

4.2.1.2 SLOP PREPARATION AND SUPPLY


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 53




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Slop is injected in the crude line Ex GRE crude. There is a CV (51FC100A) to control the slop rate to crude depending on the unit condition whose indication is given in Au-3 DCS but the control is in the hand of GRE. Slop is taken to unit initially at a slow rate, which can be slowly increased up to 800 TPD, max.

4.2.1.3 CRUDE BOOSTER PUMP 5 Crude pumps are provided at GRE Crude Control for supplying crude to AU-3. Part of this supply goes to other GR Units also. Out of these 3 pumps are in N/G crude service and 1 pump each in SG & B/H crude service.

SR NO 1 2 3 4 5 6

PUMP NO 751-P-11A 751-P-11B 751-P-11C P-101B 751-P-01 751-P-06C

SERVICE NG NG NG SG

CRUDE CRUDE CRUDE CRUDE SLOP BH/IMP

CAPACITY (M3/Hr) 375 375 375 400 360 237

DISCH PR. (kgf/cm2) 7.5 7.5 7.5 7.5 -

MOTOR (kW) 110 110 110 300 67

4.2.2 FEED PREHEAT CIRCUIT Crude is supplied to the Unit by GRE Crude Controls. Through the crude booster pumps as mentioned in the above tables provided at GRE Crude Controls, crude enters AU-3. Downstream of the crude battery limit valve, demulsifier is injected. On crude line to pump suction start up (circulation) line hook up is provided. One line is hooked up with UGT pumping line for reprocessing UGT material through H18 and H19. Crude through the crude feed line reaches the crude feed pump H2, H2A, H2B and H-2C. Out of 4 pumps, 3 pumps are running while operating at maximum throughput (9000 + MT/Day) level. Usually two 2 crude pump suffice the need. On crude pump discharge header steam connection is provided to facilitate flushing. FLO connection is also provided on these pumps suction for flushing. Slop oil (of Tank- 213 & Tank- 214) line hook-up is provided at suction of H-2B via H-101/H-102. H-2C can also be used for same slop processing by diverting slop from H-2B to H-2C through FLO line.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 54




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

With the help of crude feed pumps, crude is pumped to a number of heat exchangers to recover heat from run-down products. Crude is charged to two parallel preheat series branched by 3TV3125A and 3TV3125B.

These two series of exchangers constitute pre-desalter section of

preheat circuit, Preheat Train-I,

which

impart a large quantity of heat to crude.

The crude

preheat circuit is divided into three sections viz. pre-desalter (Preheat Train-I), post-desalter (Preheat Train-II) & post-pretopping column (Preheat Train-III).

PREHEAT TRAIN-I The first exchanger of one series of this train is E-102A/B (Crude/SRGO). Crude ex E-102 A/B is divided into two parts and es through tube side of E-103A and E-103B through flow indicators 3FI3101 and 3FI3102. Crude flow through heat exchangers is adjusted to optimize heat recovery from RCO stream for which 3TI3107 and 3TI3109 have been provided on the outlets of E-103A and E-103B respectively. Crude ex E-103A and E-103B mixes and es through tube side of HM3A/B and takes heat from RCO flowing through shell side. Crude ex HM3A/B es through the shell side of CR-II (SRGO) heat exchanger E-104A/B (mounted one above another). Desalting temperature is achieved in E-104A/B. Crude outlet of E-104A/B is the end of first series where the end of other series combines. The second part of this train consists of exchangers no. E-301A/B (Crude/Kero-I+II), E302A/B/C (Crude/RCO), E-303 (Crude/Kero-II) and E-305 (Crude/SRGO) respectively. While ing through these exchangers crude takes heat from Kero-I, RCO, Kero-II and SRGO. In this circuit, desalting temperature is achieved in E-305. Crude from both circuits mixes and proceeds towards Desalter-I (old) and Desalter-II (new), which operate in parallel. Crude oil is heated from 35°C to 130°C in the pre-desalter section i.e., Preheat Train-I. Crude enters for removal of salt and water at bottom section of both desalters through inlet distributors. Crude is initially mixed with adequate amount of DM Water (3%) with the help of mixing valve. Recommended pressure drop across mixing valve is 0.7 to 1 kg/cm2. Adequate settling time is allowed to break the oil-water emulsion and salt-water to settle down in desalter. The crude desalting operation is carried out at 145° C and 12.0 kg/cm2(g). The pressure in the desalters is


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 55




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

controlled by 3PC3101 located on discharge of feed pumps H-2, H-2A, H-2B and H-2C. DM water (and stripped sour water) is injected to crude at desalter inlets through flow controllers 3FC3906 and 3FC3907. The DMW exchange heat with brine in E-231A/B/C and with CR-I/III in E-313A/B and is heated to 120- 140° C. The desalted crude is withdrawn with the help of outlet crude collector mounted on the top most part inside the desalter. The separated effluent water with dissolved salt is drawn from each desalter through interface level controllers 3LC3902A/B (for Desalter-I) and 3LC3903A/B (for Desalter-II) and after combining exchanges heat with DM water in E-231A/B/C. Effluent water is then drained through a flash drum, E-19.

Interface level is

maintained around 25%. The exact interface level for efficient desalting will depend upon the salt content and appearance of effluent water. To physically check the interface level, tri-lines are provided to each desalter and sample from these tri-lines is checked through a sample cooler. Desalted crude from the two desalters combines in a common outlet on which 3PI3101 is located. Corresponding control valve, as mentioned above, 3PV3101 is located on the common discharge header of crude feed pumps. A small slipstream is withdrawn from desalter common inlet and es through a vortex mixer where it is mixed with caustic solution at a regulated rate and injected to desalter common outlet. PREHEAT TRAIN-II Crude from desalters is sent to Preheat Train-II. The crude flow is again divided into two parallel branches of heat exchangers by 3TV3102A and 3TV3102B. On one part ing through 3TV3102A, flow indicator 3FI3127 is provided to measure crude flow so that crude can be adjusted to optimize heat recovery. In this branch of Preheat Train-II, crude oil is heated successively by SRGO, CR-III and RCO in exchangers no. E-306A/B (Crude/SRGO), E-307 (Crude/CR-III) and E308 A/B/C (Crude/RCO) respectively. In another branch of this train, crude oil es through the tube side of E-320 (RCO/Crude) and crude is then divided into two parts and successively heated by RCO in newly installed HME/F. HMC/D,HMA/B. Both the branches of Preheat Train-II combine before entering the flash zone of pre-topping column K-1. In this preheat section crude oil is heated to around 230OC. The preheat temperature of feed to K-1 is indicated by 3TC040 and 3TI3203.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 56




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

4.2.3 CRUDE PRETTOPLING The crude after getting preheated enters the pre-topping column K-1 (I.D. = 2400 mm; Ht = 23750 mm, TL to TL) above tray No.8 at around 230° C. This column is meant for removal of the lighter ends from the crude and has 8 sieve trays below flash zone and 21 valve trays above 8th tray. The column operates at top pressure of 1.9--2.7 kg/cm2 (g) and a top temperature in the range of 110OC to 129OC. Light naphtha boiling up to about 110 to 129OC is recovered as overhead product from this column. This light naphtha also contains the lighter hydrocarbons like off-gas and LPG. The column top pressure is controlled by 3PC3201 located on E-1 vessel, which actually controls E1 pressure. The c/v 3PV3201 is set to maintain a pressure fixed in the range of 2.2—2.9 kg/cm2(g) by liberating off-gas either to fuel gas system or to flare system. Safety valve 3PSV05 set at 3.15 kg/cm2(g) pressure is provided on vessel. This PSV releases pressure to flare. Though stripping steam is not used currently, the provision of the following is there. Below the flash zone where 8 trays are provided, crude is steam-stripped to vaporize kerosene and other light components. Stripping steam is introduced below tray no.1 through a flow controller 3FC3205. A pressure controller 3PC3205 is provided at upstream of 3FC3205 to regulate the stripping pressure. The overhead vapours are condensed and cooled in the condensers T-7A and T-7B working in parallel and the product is received in the reflux drum E-1. A reflux temperature indicator 3TI3204 is provided on the outlet of T-7A/B. 2 nos of 100% capacity safety valve 3PSV3201A/B discharging to flare are provided on overhead vapour line to condensers. These PSVs are set at 3.7 kg/cm2(g). A provision of steam for flushing and fuel gas for gas back up is provided on E-1. One of the pumps H-6/8A takes suction from E-1 and discharges a part of liquid as reflux to K-1 through 3TC3201. The rest commonly known as E-1 gasoline is pumped by pumps P-306A/B and goes as stabilizer feed to K-4 through 3FC3203, cascaded with 3LC3202, E-1 H/C level controller. Also provisions are there for (i) routing off-grade E-1 gasoline to intermediate tank-214 of AU-3, (ii) Direct routing of E-1 gasoline to AU-I/II for processing. The sour water separated in E-1 boot is drained through inter-phase level controller 3LC3203 to DMW tank E-12 or to OWS. Ammoniated water and Corrosion inhibitor are injected in the


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 57




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

overhead vapour line to maintain E-1 water pH and to avoid corrosion in condensers and reflux drum E-1. Heavy Naphtha-I is a side-cut product withdrawn from 22nd tray under level controller 3LC3205 and steam-stripped in a stripper K-6A (K-6 top section, I.D. = 800 mm; Ht. = 6500 mm, TL to TL) having 6 nos. sieve trays. From this stripper Heavy Naphtha-I is pumped by one of pumps P304A/B/C and injected to SRGO via flow control valve 3FV3209 before exchanger E-102A/B (SRGO/Crude) for R/D to HSD. The stripped off vapours along with steam return to K-1 above 23rd tray. Kerosene-I is also a side draw-off product withdrawn from 14th tray under level controller 3LC3206 and steam-stripped in a stripper K-6B (K-6 bottom section, I.D. = 800 mm; Ht. = 7750 mm, TL to TL) having 6 nos. sieve trays. From this stripper pumps P-305A/B pump Kerosene-I and the product goes through 3FC3208 to exchanger E-301A/B for exchanging heat with crude. Before entering E-301A/B it combines with Kerosene-II ex K-3C. The product is cooled in a cooler T-14A before sending it to storage as Kero R/D. The stripped off vapours along with steam return to K-1 above 17th tray. In order to maximize the heat recovery and to balance the column loads, circulating reflux Kero-I CR (CR-I) is provided. Kero-I CR (CR-I ) is withdrawn by pumps P-301A/B from Kerosene-I draw-off line before 3LV3206 and sent to column K-1 above 17th tray after exchanging heat with DM Water in exchanger E-313A/B.

*Currently, no side cut from K-1 is drawn and above system kept in mothballing from Aug’2013 after consulting TS

Bottom level of column K-1 is controlled by 3LC3201, which is cascaded with 3FC3110, crude flow to the column. 3FC3110 also controls crude flow to the Unit. The bottom residue (pre-topped crude) at a temperature of

2450C is pumped to Preheat Train-III by K-1 bottom pumps

H41A/B/C(two of which run simultaneously).

PREHEAT TRAIN-III


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 58




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Crude residue (i.e. pre-topped crude) is further preheated in exchanger E-317A/B (pre-topped crude/CR-III) and E-309A/B/C (pre-topped crude/RCO) exchangers. The pre-topped crude is heated to a temperature of 2650C before sending it in three parallel parts to furnaces F1, F2 and F3.

4.3 FURNACES

The furnaces are provided along with APH, FD fan and ID fan. All the three furnaces F-1, F-2 and F-3 operate in parallel. Furnaces F-1 & F-2 have the option to operate either in balanced draft or forced draft or natural draft. While furnace F-3 has the option of operating either in balanced draft or forced draft.

4.3.1 FURNACE F-1

One parallel part (=6”) of crude feed from Preheat Train-III enters the convection section of furnace F-1 through 3FC3301 at 264OC. Low flow alarm 3FL3307B, low flow trip for cutting fuel oil/fuel gas to furnace and pressure gauge are provided. Down stream of flow control valve, emergency steam connection is provided for purging the coils with MP steam to avoid coking in furnace tube in case of power failure. Pre topped crude after getting heated up in convection section enters radiation zone at 305—310OC. Temperature indication 3TI3316 and pressure gauge are provided on the cross over between convection zone and radiation zone.

Furnace F-1 coil outlet temperature is controlled by 3TC3312 which regulates the firing rate by changing the set point of either fuel gas control valve 3FC3303 or fuel oil control valve 3PC3301. On furnace outlet, a temperature indicator, high temperature alarm and pressure gauges are provided. The only of partially vaporised crude from Furnace F-1 comes out in a =10” dia transfer line which later s with =20” part of F-2 transfer line near K-2 feed entry. One jump over line is provided from F1 outlet to F2 outlet through 3HV3401 for balancing F1/F2 heat load. At present, it is kept non-operational


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 59




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

To facilitate furnace operation, following instruments are provided on the furnace: 1.

Draft gauge DG-806 and DG-807 after and before stack.

2.

Draft gauge DG-808A/B at firebox

3.

Draft gauge DG-810 at hip arch

4.

Furnace arch pressure high alarm 3PAH3801 (+1mm WC)

5.

Furnace arch pressure very high 3PH3802 (+5mm WC)

6.

Furnace inlet temp 3TI3313

7.

Flue gas temp after stack damper 3TI3303

8.

Flue gas temp before stack damper 3TI3302, 3TI3307

9.

F-1 stack temp high alarm 3TAH3303

10.

Furnace arch temp 3TI3304, 3TI3305

11.

Fire box temp indicator 3TI3306

12.

Furnace coil outlet temp 3TI3310, 3TI3317

13.

Coil outlet temp high 3TAH3315

14.

Coil outlet temp controller 3TC3312

15.

Temp at cross over 3TI3316

16.

Oxygen Analyzer 3AC3301

17.

SO2 analyzer 3SO3403

18.

3DPC3302 for maintaining differential pressure between fuel oil and atomizing

steam. 19.

Low fuel oil pressure alarm 3PAL3303A [2 kg/cm2 (g)]

20.

Low fuel gas pressure alarm 3PAL3304A [0.2 kg/cm2 (g)]

21.

Feed to furnace low flow alarm 3FAL3307B [80 m3/Hr]

22.

Steam-air decoking facility

23.

4 Soot blowers are provided in the furnace convection zone to remove Soot deposit from the tubes.

24.

Interlock and combustion control system. * Presently Combustion control system is not working.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 60




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

4.3.2 FURNACE F-2

The second parallel part (=8” dia) of crude feed from Preheat Train-III, which enters F-2, is split into two streams (=6” each) before entering its convection zone and the flow is controlled by 3FC3402 and 3FC3403B. On each of these streams a pressure gauge is provided. On feed line to F-2 a pressure gauge, temperature indicator 3TI3401, flow alarm low 3FL3401A are provided. At the downstream of flow control valve, emergency steam connection is provided in each for purging the coils with MP steam.

Pre-topped crude after getting heated up in convection section enters radiation zone at 310 to 315OC. Temperature indicator 3TI3420/3TI3421 and pressure gauges are provided on cross over between convection zone outlet and radiation zone inlet on each . Crude is heated up to the desired temperature (max 370OC) to get 3 to 4% over flash in column K-2. Coil outlet temperature, which is measured by 3TI3412 and 3TI3413 of individual , is controlled by common coil outlet temperature 3TC3418 by regulating the firing rate by changing the set point of either fuel gas control valve 3FC3411 or fuel oil control valve 3PC3417. On furnace outlet, temp alarm high and pressure gauge are provided. The two es (=6”) of partially vaporised crude from furnace F-2 come out to combine in a =16” transfer line. This transfer line expands to =20” feed line in its downstream before K-2 feed entry. On this 20” part, F-1 transfer line s. The coned =20” feed line further combines with =22” part of F-3 transfer line immediately before the K-2 feed entry nozzle (=22”). To facilitate furnace operation, following provisions are made: 1.

Draft gauge DG-852 and DG-853 after and before stack damper

2.

Draft gauge DG-854A/B at firebox

3.

Draft gauge DG-855 at hip arch

4.

Furnace arch pressure high alarm 3PAH3820 (+1 mm WC)

5.

Furnace arch pressure very high 3PAH3821 (+5 mm WC)

6.

Furnace inlet temperature 3TI3401

7.

Flue gas temp after stack damper 3TI3402


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 61




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

8.

Flue gas temp before stack damper 3TI3403

9.

Flue gas temp high alarm 3TAH3404

10.

Hip arch temp 3TI3405 and 3TI3406

11.

Fire box temp indicator 3TI3407

12.

Skin temp 3TI3408A/B and 3TI3409A/B

13.

Furnace coil outlet temp 3TI3412 and 3TI3413

14.

Combined coil outlet temp 3TI3416 temp alarm high 3TAH3417.

15.

Transfer line temp control 3TC3418

16.

Temp at cross over on each 3TI3420 and 3TI3421

17.

Oxygen analyzer 3AC3401

18.

SO2 analyzer 3SO3403

19.

3DPC3419 for maintaining differential pressure between fuel oil and atomizing steam.

20.

Low pressure alarm 3PC3411B (2 kg/cm2g) on fuel oil and

21.

Low pressure alarm 3PL3412B (0.2 kg/cm2g) on fuel gas

22.

Feed to furnace low flow alarm 3FSL3401B (160 M3/Hr)

23.


24.

6 Soot blowers are provided in convection zone to remove deposited soot from tubes.

25.

Interlock and combustion control system (combustion control system not working)

4.3.3 AIR PREHEATER (APH) SYSTEM

The air pre-heater system improves the efficiency of the furnace by exchanging heat between the hot flue gases leaving furnace and combustion air ex FD Fan. The APH system consists of a common recuperative type air pre-heater common for both the furnaces, ID fan and FD fan. Flue gases from both the furnaces are combined in the flue gas duct and heat combustion air in APH. FD fan supplies the requirement of combustion air for the furnaces F-1 and F-2, whereas ID fan sucks


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 62




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

flue gases from furnaces upstream of stack dampers through APH and put it back to the stack of furnace F-2, down stream of stack damper through ID fan.

A. COMBUSTION AIR CIRCUIT Combustion air is sucked from atmosphere by the FD fan. The total combustion airflow is controlled by 3FC3801, which actuates FD fan suction vane 3FV3801. A pressure gauge, temperature gauge, vane position indication 3AL3808 vane open position indication 3AH3808 are provided on FD fan suction. On FD fan discharge a pressure gauge, a pressure indicator 3PI3810 pressure alarm low 3PL3811, FD fan current low alarm 3IL3801 and manually operated damper HC3802 are provided. 3PL3811A and 3IL3801 actuate tripping circuit through interlock system and bring furnace on natural draft.

Combustion air from FD fan enters APH. By is provided to divert cold air with the help of manually operated damper HC-3804 in case APH outlet temp is below 176OC to avoid corrosion. Hot air from APH is bifurcated. One part goes to F-2 under 3FC3802, which maintains combustion airflow to F-2 by operating the damper of 3FC3802. A pressure gauge and temp gauge are provided on the combustion air to F-2. Balance quantity of combustion air goes to F-1 through 3FC3803. A manual loader HC-3813 is provided which can be operated from the field. For better distribution of air it is required to keep HC-3813 only 20 to 30% open. A pressure gauge and a temp gauge are provided on combustion air to F-1. Vane close indication 3AL3813 and vane open indication 3AL3808 are provided in control room.

Hot combustion air from APH enters into plenum on F-1 and F-2. In case of FD fan failure, Dropout doors (DODs) are provided through which required combustion air is sucked in from atmosphere. There are 2 nos of DODs in F-1 and 4 nos of DODs in F-2. These DODs are opened or closed from control room. For each DOD, indication lamps are provided in control room to show its open and close position.

B. FLUE GASES CIRCUIT


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 63




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

To divert flue gases to APH stack damper HC-3811 is provided on F-1 stack and damper HC3812 is provided on F-2 stack. These stack dampers are closed from the control room and their close and open position indications are shown in control room by 3AL3812, 3AH3812, 3AL3806 and 3AHH3806 respectively. On hot flue gases duct to APH damper HC-1801 on F-1 side and damper HC-1810 on F-2 side are provided which can be operated from control room. Their close and open position indications are shown in control room by 3AL3810, 3AH3810, 3AL3811 and 3AH3811 respectively. In addition to this, manually operated guillotine dampers are provided for positive isolation of APH.

Hot flue gases from F-1 and F-2 are sucked by ID fan through APH. On APH a pressure gauge, a TG, pressure indicator 3PI3817, temperature indicator 3TI3803, temp alarm high 3AH3807 are provided. On outlet of APH a PG, pressure indicator 3PI3818, 3TI3804, temp alarm low 3TAL3805, temp alarm high 3TAH3806, pressure alarm high 3PH3819A (this activates interlock system and brings furnace on natural draft) are provided. On flue gases outlet from APH, hand operated damper HC-1807 is provided to isolate the APH. Snuffing steam connection is provided on inlet and outlet of APH and service water connection is provided at APH inlet for washing air pre-heater when it gets fouled up.

In control room furnace F-1 pressure is indicated by 3PC3801 whereas of furnace F-2 by 3PC3820; pressure alarm high 3PAH3801 and 3PAH3820 set at +2 mmWC are provided on F-1 and F-2 respectively. In case furnace pressure exceeds +5 mmWC pressure alarm high 3PH3802 and 3PH3821 are provided on F-1 and F-2 respectively which activate S/D circuit and bring the furnace on natural draft. Furnace pressure is controlled through a high-pressure selector switch, which operates ID fan vane controller 3PVC3814 through 3PIC3814. ID fan vane position is shown by indicator 3AH3809 in control room.

On ID fan discharge, a pressure gauge and manually operated damper HC-1809 are provided. In case of low current of ID fan 3IC3802 actuates shutdown circuit and brings furnace on forced draft operation by tripping ID fan and by opening automatic stack dampers of both the furnaces.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 64




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

4.3.4 FURNACE F-3

The third parallel part (=8” dia) of crude feed from Preheat Train-III, which enters F-3, is split into two streams (=6” each) before entering its convection zone and the flow is controlled by 3FC3003 and 3FC3005. On one stream (-I) to F-3, a pressure gauge PG3003, a temperature gauge TG3001, flow alarm low 3FT3002 are provided. And on the other stream (-II), a pressure gauge PG3004, a temperature TG3002, feed flow alarm low 3FT3004 are provided. At the downstream of flow control valves, emergency steam connection is provided in each for purging the coils with MP steam.

Pre-topped crude after getting heated up in convection section of F-3 enters radiation zone at 281OC to 292OC. Temperature indicators 3TI3019/3TI3020 and pressure gauges PG3021/PG3022 are provided on cross-over between convection zone outlet and radiation zone inlet on each . Crude is heated up to the desired temperature (max 370OC) to get 3 to 4% over flash in column K-2. Coil outlet temperature that is measured by 3TI3023 and 3TI3024 of individual is controlled by common coil outlet temperature 3TC3013 by regulating the firing rate by changing the set point of either fuel gas pressure control valve 3PC3003 or fuel oil pressure control valve 3PC3005. On furnace outlet, temp alarm high and pressure gauge are provided. The two es (=6”) of partially vaporised crude from furnace F-3 come out to combine in a =12” transfer line. This transfer line expands twice to =14” and =22” feed line in its downstream before K-2 feed entry. On this 22” feed entry line, F-1/F-2 coned transfer line (=20”) s immediately before the K-2 feed entry nozzle (=22”). To facilitate furnace operation, following provisions are made: 1.

Draft gauge PG-3007 and PG-3008 after and before stack damper

2.

Draft gauge PG-3006 & PG-3009, and pr. indicator 3PI3017 at firebox (radiant)

Draft gauge PG-3005 at hip arch Draft gauge PG-3010 & pr. indicator 3PI3018 at convection arch zone


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 65

. Indian Oil Gujarat Refinery 5.



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Furnace arch pressure high alarm 3PT3016A, 3PT3016B, 3PT3016C (+10 mm WC)

6.

Furnace arch pressure very high 3PAHH3016

7.

Furnace inlet temperature gauges TG-3001 & TG-3002

8.

Flue gases temp after stack damper 3TI3018

9.

Hot flue gases temp gauge TG-3006 & indicator 3TI3015, pr gauge PG-3012 and pr. Indicator 3PI3007 at APH inlet

10.

Cold flue gases temp gauge TG-3009 and indicator 3TI3028, pr gauge PG-3015 and pr indicator 3PI3010 at APH outlet

11.

Cold flue gases temp alarms TAH3028, TAL3028 & TAHH3027 at APH outlet

12.

Hip arch temp gauge TG-3003 & indicators 3TI3025, 3TI3031

13.

Skin temp indicators 3TI3001, 3TI3002, 3TI3007 & 3TI3008 at convection zone and 3TI3003, 3TI3004, 3TI3005, 3TI3006, 3TI3009, 3TI3010, 3TI3011 & 3TI3012 at radiation zone

14.

Furnace coil outlet temp 3TX3023, 3TX3024 (-I and -II)

15.

Furnace COTs high alarms 3TT3023A, 3TT3023B (-I and -II)

16.

Combined coil outlet temp 3TT3013, 33TX3017

17.

Transfer line temp control 3TC3013

18.

Temp at cross over on each 3TI3019 and 3TI3020

19.

PG at cross over on each PG3021 and PG3022

20.

Oxygen analyzer 3AC3002 at hip arch zone

21.

SO2 analyzer 3AI3001 after stack damper

22.

3DPC3006 for maintaining differential pressure between fuel oil and atomising steam.

23.

Low pressure alarm 3PT3013 (1.6 kg/cm2g) on fuel oil and

24.

Low pressure alarm 3PT3004 (0.4 kg/cm2g) on fuel gas

25.

Feed -1 flow low flow alarm 3FT3002 (10 T/hr)

26.

Feed -2 flow low flow alarm 3FT3004 (10 T/hr)

27.

Self-actuating c/v 3PCV3001 on FG line to pilot burners


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 66




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

28.

Mass flow meter on FO line, 3FX3007

29.


30.

6 Soot blowers are provided in convection zone to remove deposited soot from tubes.

31.

Interlock and combustion control system

AIR PREHEATER (APH) SYSTEM

The APH system consists of a recuperative type air pre-heater, one ID fan and two FD fans. Flue gases from the furnace’s post-convection zone ing through the flue gas duct heat combustion air in APH. The two FD fans supply the requirement of combustion air for the furnace F-3, whereas ID fan sucks flue gases from the furnace upstream of stack damper through APH and puts it back to the stack of furnace, down stream of stack damper through ID fan.

A. COMBUSTION AIR CIRCUIT Cold combustion air is sucked from atmosphere by the FD fans. The total combustion airflow is controlled by 3FC3012, which actuates FD fan suction vanes 3FY3012A/B. Vane position indicators 3ZI3002, and 3ZI3003 are provided on FD fans’ suction. Pressure indicators 3PI3008A and 3PI3008B are provided on each FD fan’s discharge.

Combustion air from FD fan enters APH. By is provided to divert cold air with the help of the damper 3TC3028 in case APH outlet temp is below 175OC to avoid corrosion. Hot air from APH goes to F-3 and this is actually controlled by 3FC3012 (or manually by either 3FY3012A or 3FY3012B). A pressure gauge PG3014, temperature gauge TG3008 and two temp indicators 3TI3014 & 3TI3026 are provided on the hot combustion air to F-3. Hot combustion air from APH enters into a closed annular duct around F-3 bottom. Its crosssection is rectangular. There are six radial distributing ducts from this annular duct to the six burners. Each of these six ducts has a damper assembly with expansion bellow in-between. Primary and secondary air inlet dampers or s are provided there in the damper assembly for


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 67




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

regulating air flow to burners manually. There are no Drop-out doors (DODs) at F-3 fire box floor like F-1/F-2.

B. FLUE GASES CIRCUIT To divert hot flue gases to APH, stack damper 3HS3001 is provided on F-3 stack. This stack damper is closed from the control room and its close and open position indications are shown in control room by 3ZI3001. Quantity of hot flue gases to APH can be controlled by 3PC3001, which

actuates the suction vanes of ID fan. Manually operated guillotine dampers are provided on hot flue gases duct ex F-3 and cold flue gas return duct to F-3 for positive isolation of APH.

Hot flue gases from F-3 is sucked by ID fan through APH. On APH inlet a pressure gauge PG3012, a TG, pressure indicator 3PI3007, temperature indicator 3TI3015, pressure alarm high 3PAHH3011 are provided. On outlet of APH, a pressure gauge PG-3015, pressure indicator 3PI3010, temp indicator 3TI3028, temp alarm low 3TAL3028, temp alarm high 3TAH3028. Wash water connection is provided at APH for washing air pre-heater when it gets fouled up.

In control room, furnace F-3 hip arch pressure is indicated by 3PC3001; pressure alarms low/high 3PT3016A, 3PT3016B and 3PT3016C

set in the range –20mmWC to +20mmWC are

provided on F-3. In case furnace arch pressure exceeds +10 mmWC or pressure alarm high 3PAHH3011at APH inlet is sensed, these high pressure alarms activate the interlock circuit and the stack damper will open immediately and ID fan trips. If the stack damper fails to open within 30sec, FO & FG to furnace will be cut off automatically and followed by ID & FD fan trip. Furnace arch pressure is controlled by ID fan suction vane controller 3PV3001 through 3PC3001. ID fan vane position is shown by indicator 3ZI3004 in control room. Hand selector 3HS3001 can also be operated for controlling the movement of stack damper, which alternatively controls the arch pressure. On ID fan discharge, a pressure gauge PG-3016 and pressure indicator 3PI3012 are provided. In case of low current of ID fan, 3IT3003 actuates shutdown circuit and brings furnace on forced draft operation by tripping ID fan and by opening automatic stack damper of the furnace.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 68




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The pre-topped crude is heated to a temp of 3660C in all the three furnaces before sending it to column K-2.

4.4 MAIN FRACTIONATING COLUMN :

4.4.1 OVERHEAD SYSTEM Pre-topped crude after getting heated to 355--3660C in F-1/F-2/F-3 enters the flash zone of the main fractionating column K-2 (I.D. = 3400 mm; Ht.= 30350 mm, TL to TL) through a =22” nozzle above the 6th tray. This column has 41 trays, out of which the bottom 1 to 6 trays are sieve trays and 7 to 41 are valve trays. 5 nos of 100% safety valves 3PSV-3501A/B/C/D & 3PSV3502 set at 1.5 kg/cm2(g) are provided at the top of K-2. These PSVs release excess pressure to atmosphere. One vent line is also provided on the column top.

The column K-2 is operated at 0.6 to 1.0 kg/cm2(g) pressure. Column K-2 pressure is controlled with the help of split range controller 3PC3503 acting on the gas line of its reflux accumulator E-2. This pressure controller its gas into E-2 through gas make-up (from E4 vessel) line or releases gas from E-2 to flare depending on whether the column K-2 pressure is lower or higher than desired. A safety valve 3PSV-3503 set at 1.2 kg/cm2(g) pressure is provided at E-2. This PSV releases excess pressure into atmosphere.

Naphtha boiling up to about 110 to 125OC is the overhead product from column K-2 and is commonly known as E-2 gasoline. This naphtha is devoid of the light hydrocarbons like gas and LPG. The overhead vapour from the column K-2 enters overhead condensers T-8A, T-8B, T-8C and T-8D working in parallel and the condensed liquid is received in the reflux accumulator E-2. A reflux temperature indicator 3TI3512 is provided on this line. A steam connection is provided on vessel E-2 for steam flushing. Ammoniated water and Ahuralan are injected in two O/H vapour lines of K-2 to maintain E-2 boot-water pH and to avoid corrosion in condensers and reflux drum.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 69




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

One of the pumps H8/H9 takes suction from the bottom of E-2 and partly discharges through controller 3TC3507 as reflux to column K-2 to maintain the column top temperature between 115 to 120OC. The balance is discharged through controller 3FC3510 which is cascaded with E-2 level controller 3LC3504 maintaining the H/C level in E-2 , and is sent to naphtha rundown as Naphtha2.

There is a provision for:

a) Routing off-grade E-2 gasoline into intermediate tank-214 of AU-3, b) Normal routing to General / GOP naphtha c) Direct routing of E-2 naphtha to AU1 for reprocessing

Water accumulation in E-2 is drained through inter-phase level controller 3LC3505 to E-12 or OWS.

4.4.2 SIDE-CUT HEAVY NAPHTHA-II CIRCUIT

Side-cut heavy naphtha-II is withdrawn as 1st side cut (139—170OC) from tray No.36. This withdrawal temperature is maintained at around 151OC with the help of controller 3TC3506 on naphtha withdrawal line from K-2 to stripper K-3A (K-3 top section, I.D. = 1200 mm; Ht. = 6720 mm, TL to TL) thereby varying the internal reflux amongst trays in this region.

Six sieve trays are provided in the side-cut Naphtha-II stripper. The side-cut naphtha from K-2 enters above top tray of K-3A. Stripping steam is introduced at the bottom of the stripper through 3FC3509 and the stripped off vapours along with steam return to column K-2 above tray 37. Stripping steam to K-3A is adjusted to regulate Naphtha flash point, which eventually controls the flash point of HSD, a mixture of SRGO, side-cut naphtha-II and I at run-down. On average 100 kg/hr steam is required per MT of naphtha-II withdrawn per hour. On heavy naphtha line ex K-3A, a temperature indicator 3TI3511 is provided.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 70




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The side-cut heavy naphtha-II from K-3A is pumped with P-304A/B/C and injected to SRGO before E-102A/B. In E-102A/B, it along with SRGO and K-6A naphtha exchanges heat with shell side crude. Then it es through cooler E-315 to rundown system. Stripper level is controlled by 3LC3502, which actuates a control valve on heavy naphtha line at the discharge of P-304A/B/C. The flow is measured by 3FC3210. 4.4.3 KEROSENE-II CIRCUIT

Two draw-off pipes of 14” dia ex diametrically opposite column nozzles are provided below 28th tray of K-2 for kerosene withdrawal. These two 14” draw-off lines ex K-2 combine into one single 20” dia line. Kerosene and Kero CR (CR-II) are withdrawn as 2nd side-cut (208-215OC) from 28th tray of column K-2 and pumped with the help of pumps H-10/10A to heat exchangers. Its withdrawal temperature is indicated by 3TI301 provided on the 20” combined part.

Kerosene-II is withdrawn under temperature controller 3TC301 provided on a 10” line ex 20” combined part and sent to stripper K-3C (I.D.= 1300 mm, bottom part below seal pan; = 1100 mm, top part containing trays and seal pan; H1 = 3673 mm, TL to seal pan; H2 = 4807 mm, seal pan to TL after top manhole) in which six sieve trays are provided. Withdrawn kero is fed above top tray of stripper. 3LC3516 maintains the bottom level of K-3C. Stripping steam is introduced in the stripper through 3FC3517 to strip off light components for improving kerosene flash point. The stripper overhead vapours are returned to K-2 above 31st tray.

On kerosene line ex K-3C bottom a temperature indicator 3TI073 is provided. Kerosene ex K-3C bottom is pumped with H-10/10A and sent to tube side of E-303 for exchanging heat with shell side crude. A flow controller 3FC3111 is provided on the tube outlet of E-303, which is cascaded with K3C level 3LC3516. At run-down kerosene-II is combined with K-6B kerosene (Kero-I) before ing through the tube side of crude exchanger E-301A/B. Kerosene ex E-301A/B cools down in cooler T-14A and is sent to storage (OM&S). Provision is made at run-down after T-14A for routing kerosene to diesel pool by block-valve operation, as and when required also to slop tank of AU3.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 71




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

One of pumps P-302A/B draws kerosene-II CR (CR-II) via a 12” line from the =20” combined draw-off line before 3LV3516. Kero CR-II from pump discharge is divided into two parts. One part goes directly to the tube side of crude exchanger E-104A/B and the other part enters as a lower stream to a 3-way control valve 3TV3130, which is provided, on the tube outlet of E-104A/B. The controller 3TC3130 controls the return temperature of CR-II. Increasing its ‘OP’ decreases CR-II return temperature. On downstream of 3TC3130 a flow controller 3FC3502 is provided which controls the circulatory reflux flow back to K-2. The CR-II is returned to K-2 above 31st tray and the return temperature is also indicated by 3TI3502.

During 2013 M&I control routing AU3 kerosene to LABFS tank commissioned. Kerosene can be sent to diesel pool(EURO-3) along with AU3 disel after ing through diesel salt drier. Kerosene can also be sent o DHDT feed tanks, DHDT unit along with AU3 diesel

4.4.4 SRGO (HSD) CIRCUIT

SRGO along with SRGO CR (CR-II) is withdrawn as 3rd side cut from 16th tray of column K-2 through two diametrically opposite draw-off lines ( = 12”) like Kerosene-II draw-off. Both the lines combine into a  = 18” common pipe. The withdrawal temperature of SRGO is maintained at around 285OC to 300OC with the help of 3TC3505 on SRGO withdrawal line ( = 8”) parted from the 18” dia common draw-off pipe, thereby varying internal reflux amongst trays in the draw-off region inside K-2. Drawn-off SRGO is then fed via this 8” line to a stripper K-3B (bottom section of K-3, I.D. = 1200 mm; Ht. = 6800 mm, TL to TL) above top tray. Stripper K-3B has been provided with six sieve trays. Stripping steam is introduced at the stripper bottom through 3FC3508 and stripped off vapours along with steam return to column K-2 above tray no. 20. When SRGO (HSD) meets the flash point requirement without being stripped, stripping steam to column K-3B is then kept isolated. Stripping steam is introduced only when hot oil is made for UDEX to meet flash point


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 72




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

requirement of 66OC. While making hot oil for UDEX, heavy naphtha injection to be stopped by fully dropping HN to KERO. There is no provision available for routing HN to other naphtha streams / slop tank. Temperature of SRGO ex K-3B is indicated by 3TI3510. A level controller 3LC3503 maintains the level of K-3B when cascaded with 3FC3135, SRGO run-down flow controller.

SRGO from K-3B is pumped with H-4/5A through tube side of E-306A/B and then E-305 where it cools down by exchanging heat with crude and enters exchanger E-311 for preheating K-4 feed. In E-311, SRGO cools down by exchanging heat with K-4 feed. A 3-way combining type control valve 3TV3131 is provided on E-311 tube outlet to control K-4 feed temperature. A 6” dia line taken from upstream of E-311 enters the 3-way control valve as lower stream. Decreasing the lower stream flow increases K-4 feed temperature. At downstream of 3TC3131 flow controller 3FC3135 acts in cascade mode on the stripper level control valve 3LV3503 provided next to 3FI3135.

SRGO ex E-311 and through 3TV3131, 3LV3503 enters the tube side of crude exchanger E102A/B. But before entering, it combines with Heavy Naphtha-I & II ex P-304A/B/C discharge to maintain flash point. SRGO may be termed as HSD also and finally it goes to HSD pool. HSD ex E102A/B cools down in cooler E-315 and routed to OM&S. At run-down, a provision is made to route kerosene ex T-14A to HSD as per requirement. Coalescer in HSD r/d line is commissioned in order to route entire HSD through coalescer. There is also provision to route off grade material into slop tank of AU3.

During RUP commissioning in 2010, AU3 diesel to RUP DHDT feed tanks and to DHDT unti facility commissioned. In Jan’2013 Diesel salt drier commissioned to curtain water content in diesel going to rundown.

With a view to maximize heat recovery and to balance the column loads, another circulating reflux, namely, diesel CR (CR-III), is provided to the column K-2. Suction ( = 10”) to CR-III pumps P-307A/B is taken from the SRGO withdrawal line (combined part,  = 18”) before


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 73




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

3TC3505. On the discharge of P-307A/B, a 3-way diverting type control valve 3TV3605 is provided for controlling the temperature of partially vaporised naphtha coming out from the tube side of thermo siphon reboiler E-106. In other words, 3TC3605 controls the bottom temperature of K-4. CR-III ex 3TV3605 enters the shell side of E-106. Lower stream of 3TV3605 s with CR-III outlet from E-106. CR-III ex reboiler enters the tube side of E-317A/B where it exchanges heat with shell side K-1 bottom residue. It then is divided into two parts. One part enters the tube side of crude exchanger E-307. Another part goes as lower stream to a 3-way control valve 3TV3135 provided on the tube outlet of E-307. 3TC3135 controls the return temperature of CR-III back to column K-2. A provision is made to take a part of CR-III ex E-307 tube outlet through an 8” dia. line to E-313A/B for heating DM water, required for injection to crude before desalters. A flow controller 3FC3519 located on the downstream of 3TV3135 controls the CR-III return flow-rate.

The CR-III returns

to K-2 above 20th tray through two 8” dia. lines.

4.4.5 RCO CIRCUIT

Partially vaporised crude from F-1/F-2/F-3 enters in column K-2 above 6th tray (flash zone). Unvaporised RCO (reduced crude oil) falls in bottom section of K-2, along with over flash hydrocarbons, which acts as stripper. Stripping steam (3 ata) is introduced at the bottom section below 1st tray in K-2 through a controller 3FC3501. 3 ata stripping steam is regulated by 3PC3701 located before 3FC3501 near K-2 bottom on ground floor. Column bottom temperature is indicated by 3TI3503.

RCO from K-2 bottom is pumped by pumps H-11/11A and H-42 to exchange heat with crude in heat exchangers. A flow indicator 3FI3507 is provided on pump discharge. A diverting type 3-way control valve 3TV040 is provided on this discharge line before E-309C. Lower stream of 3TV040 acts as by to all three exchangers E-309C & E-309A/B. Upper stream ex 3TV040 enters the tube side of E-309A/B/C where RCO exchanges heat with K-1 bottom residue. The lower stream combines with E-309A tube outlet. 3TC040 controls K-1 feed preheat temperature. Increasing the


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 74




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

lower stream flow will allow more of hot RCO to by E-309A/B/C and travel to downstream crude exchangers, viz., E-308A/B/C, HM1A/B,HM1C/D,HME/F etc.

RCO stream ex E-309A/B/C is divided into two parts. Two number globe valves installed in 2013 M&I instead of gate valves for proper flow control. One part es through shell side of exchangers E-308A/B/C and E-302A/B/C in counter-current flow with preheated crude of Preheat Train-I. A flow indicator 3FI3131 is provided between E-308A and E-302C to measure RCO flow in this section. And the other part of RCO stream es through shell side of HM1A/B, HM1C/D,HM1E/F of Preheat Train-II in counter-current flow with crude. Flow indicator 3FI3107 provided before HM1A/B to measure RCO flow through the two branches. RCO from these two branches combines together to through E-320A/B, HM3A/B and exchanges heat with crude. Flow indicator 3FI3130 is provided before E-320B.

RCO from HM3A/B is divided into two parts and exchanges heat with crude in E-103A and E103B. On each flow indicator 3FI3103 and 3FI3104 are provided to adjust RCO flow for optimizing heat recovery.

Two number new HV’s installed at the down stream of

E103A/B(HV1001A) and E302A/B(HV1001B). Combined RCO Ex these HV’s gets cooled in RCO coolers T-16/16A/16B/16C/16D/16E. Out of these six coolers operating in parallel, 5 coolers remain in line normally. This RCO can be routed to FPU/OM&S via 3FC3507 (actuating 3LV3501) which maintains column K-2 level under cascade control with 3LC3501A. Flow controller 3FC3120 can also be cascaded with 3LC3501A, as per requirement. An additional flow control valve 3LHV3501 is provided (Revamp, 2000) near RCO coolers for handling high RCO yield at maximum throughput. A high level alarm is provided at K-2 bottom. RCO can be routed to following places: 1.

A 4" tapping is taken before 3FV3507 (or 3LV3501) to route RCO to VBU. (Not in use)

2.

6" line to OM&S under 3FV3507

3.

8" line to OM&S via AU-2. When this flexibility is used cold RCO to FPU ex AU-1, AU-2 and AU-4 will require to be stopped and valve on cold RCO to FPU line at AU-3 to be closed. (Not in use)


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 75




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

4.

8" line through 3FC3117 to VBU tanks (Not in use)

5.

8" line to FPU-1 (FCC)

6.

10" RCO line to FPU surge drum. A 10" hot RCO line through 3FC3115A is provided to route hot RCO to FPU-1. And through 3FC3115B to FPU-2 (GHC).

7.

4" line from RCO R/D d/s of 3FV3507 (3LV3501) is hooked up to RCO receiving line to VR surge drum and IFO tanks E6/E7.

8.

4" line to GRE for IFO. In this line IFO from job 50 meets. By utilizing these ines RCO from AU-3 can be taken in IFO tank E-6/7, and in VR surge drum.

9.

Cold RCO to VR (HV) through 3FC3116. (Not in use)

10.

One tapping is provided on u/s of 3FC3507 to route RCO to 6" cold RCO to OM&S through 3FC3113. (Not in use)

11

RCO to IFO tanks

4.4.6 NAPHTHA STABILIZER

E-1 gasoline, i.e., unstabilized naphtha contains LPG component. LPG is removed in naphtha stabiliser column K-4. Column K-4 is provided with 34 valve trays and 2 nos. of 100% capacity safety valve 3PSV3601A & B set at 9.4 kg/cm2(g). Out of these PSVs, one shall remain in line. A service steam connection is provided at column bottom and PG at top and bottom. One vent line is also provided at column top.

One of the pumps P-306A/B takes suction from E-1 and discharges to shell side of E-310A/B where E-1 gasoline exchanges heat with tube side K-4 bottom naphtha. Unstabilized naphtha then es through shell side of HSD exchanger E-311. It then enters stabilizer K-4 through 3FC3203, which remains under cascade control with 3LC3202, E-1 H/C level controller. Feed enters K-4 on the 11/15/17th tray at 129OC. One 2" dia. drag streamline ex CRU enters at E1 gasoline inlet to E310A/B through 3FC3602 and one unstabilized naphtha line ex GRE is also connected with the same inlet to E-310A/B. A temperature indicator 3T13604 is provided on feed to K4. Feed


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 76




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

temperature is controlled by 3TC3131 located on E-311 tube outlet by increasing or decreasing K-4 feed flow through E-311.

K-4 overhead product is condensed in condensers T-9A/B and is received in an accumulator (reflux drum) E-4. A temperature indicator 3TI3602 is provided on this line. The column top pressure is maintained at 8 - 8.3 kg/cm2(g) by a pressure controller 3PC3601 actuating a control valve on the gas away line from E-4 (i.e. gas to fuel gas system). A pressure safety valve 3PSV3601 set at 9.4 kg/cm2(g) releasing excess pressure to flare is provided on E-4. Also a pressure gauge and a service steam connection are provided at E-4. At frequent interval water from E-4 should be drained. 3TI3603A indicates the reflux drum temperature.

Pump H-15 or H-15A takes suction from E-4 bottom and a part of the discharge goes through 3TC3603 back to the column top tray as reflux to maintain the column top temperature around 60—62.4C. Reflux flow to column is indicated by 3FX3601. The rest quantity goes as LPG to GRE/AU1 for caustic wash through 3LC3602 which controls the level of E-4, the LPG rundown flow being recorded with 3FX3604.

The column bottom temperature is maintained around 167—176OC with reboiler heat supplied by SRGO (HSD) CR (CR-III), which heats part of K-4 bottom in thermo-siphon reboiler E-106. 3TC3605 maintains partially vaporised naphtha temperature ex E-106 to column by setting a diverting type 3-way control valve 3TV3605 on CR-III line by allowing required quantity of HSD CR to flow through E-106. A temperature indicator 3TI3612 is provided at K-4 bottom. K-4 bottom product stream exchanges heat with feed to K-4 in exchanger E-310A/B. A cooler T-18A cools down the product ex E-310A/B. A provision is kept to pump K-4 bottom ex E-310A/B by pump H-14 to E-106 to establish cold circulation and to heat K4 bottom during start up. K-4 bottom is routed to General Naphtha R/D to OM&S via GRE (3” line) and AU1 (4” line) or routed to GOP Naphtha R/D to OM&S under 3LC3601. A shut-off valve is provided at down-stream of 3LC3601, which gets actuated in case of very low level in K-4. This provision is made to avoid escape of hot gas to OM&S tanks. To route K-4 bottom to OM&S in case of high level at the time of


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 77




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

start up when K-4 pressure is not adequate, provision is given through pump H-14 to empty out K-4 column. Off-spec product (i.e., slop or colored material, in case E-1 naphtha enters K-4 when K-1 is very upset ) can be routed to TK-214. Provision to route FPU-II Hy HSD to GR-II tanks 212-214 made in 2006. Modification is also done in order to route the slop/off grade product in Tk 213. Hence Tk 214 M&I job can be done.

4.5 DESIGN OPERATING CONDITIONS The following operating conditions are to be maintained during normal running of the Unit at 9000 TPD crude input. This may differ from the actual conditions in the plant due to change in feed rate, crude quality, crude mix and other unforeseen eventualities. To optimize the yield pattern and quality of product, these conditions are to be changed Case-I : NG55%+ IMP 45% Case-II : NG55%+ BH 45% Case-III: NG100%

4.5.1 PRE-TOPPING COLUMN K-1 PARAMETER

UNIT

Top Top pressure Top temperature Top Reflux flow Top Reflux Temperature Unstab.Naphtha Flow Side-cut Heavy Naphtha-I Draw off temperature Temperature ex stripper

CASE-1 NG55%+ IMP 45%

CASE-II NG55%+ BH 45%

CASE-III NG100%

kg/cm2(g) 0C MT/Hr 0 C

2.9 129 39.4 45

2.5 132.8 30 45

2.2 110.3 22.6 45

MT/Hr

36.8

31.59

8.5

C

165

163.1

137

C

136

139

128

o

0


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 78

. Indian Oil Gujarat Refinery Stripping steam R/D flow



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Kg/Hr MT/Hr

300 4.5

450 8

450 3.5

C

193

189

168.6

Kero-I Draw off temperature Temperature ex Stripper Stripping steam R/D flow

C

178

175.8

156.5

Kg/Hr MT/Hr

250 13.2

300 13.9

300 9.9

CR-I Flow Temperature Return temperature

MT/Hr 0C 0C

23 193 140

22.58 189 135

36.15 168.6 135

kg/cm2(g) 0C MT/Hr. Kg/Hr

3.0 245 325 3200

2.65 223.5 321.58 3200

2.35 240 353 3200

MT/Hr 0C

375 259

375 233

375 248

UNIT

CASE-1

CASE-II

CASE-III

kg/cm2(g) 0C MT/Hr 0 C

0.5 110.5 25.23 45

0.6 111.6 30 45

0.6 125 29.1 45

MT/Hr

2.5

3

3

o

0

Bottom Pressure Temperature Flow Stripping steam Feed Flow Temperature

4.5.2 MAIN FRACTIONATING COLUMN K-2 PARAMETER Top Top pressure Top temperature Top Reflux flow Top Reflux Temperature Naphtha flow


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 79

. Indian Oil Gujarat Refinery PARAMETER

VOL-I: Addendum UNIT

Side-cut Heavy Naphtha-II OC Draw off temperature OC Temperature ex Stripper Stripping steam Kg/Hr R/D flow MT/Hr Kero-II Draw off temperature Temperature ex Stripper Stripping steam R/D flow



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CASE-1

CASE-II

CASE-III

138.5

136

151

121.0

119

131

100 2.5

100 4.5

100 3.0

O

C

210.7

208.3

215.5

O

C

203.5

301.8

290.6

Kg/Hr MT/Hr

200 42.0

200 44.25

200 38.5

SRGO Draw off temp Température ex. Stripper Stripping steam R/D flow

C 0C

300 299

302.6 301.8

298.64 290.6

Kg/Hr MT/Hr

200 47.0

200 44.25

200 38.5

CR-II Flow Temperature Return temperature

MT/Hr 0C 0C

167.0 210.7 157

213 208.3 157

110.6 215.5 157

CR-III Flow Temperature Return temperature

MT/Hr 0C 0C

151.0 300 250

178 302.7 250

150.15 298.6 250

kg/cm2(g) 0C MT/Hr

1.0 360 235.0

.85 356 205

.85 362.9 265

Bottom Pressure Temperature Flow

0


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 80




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

PARAMETER Stripping steam

UNIT Kg/Hr

CASE-1 3799

CASE-II 3800

CASE-III 3400

Feed Flow Temperature

MT/Hr 0C

325 366

321.5 363

353 363

C 0C

264 366

264 366

264 366

Furnace Inlet temperature Coil Outlet temp

0

4.5.3 NAPHTHA STABILIZER K-4 PARAMETER

UNIT

CASE-1

CASE-II

CASE-III

Top Pressure Top Temperature Top Reflux flow Top Reflux Temp LPG R/D flow Feed flow Feed temperature Bottom Temperature Stab. Naphtha Flow Bottom pressure

Kg/cm2(g) 0C MT/Hr 0C MT/Hr MT/Hr 0C 0C MT/Hr Kg/cm2(g)

8.3 60 11.68 45 3.3 27.3 129 167 24.0 8.6

8.3 62.4 6.5 45 1.85 31.58 129 176 29.7 8.6

8.3 60


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

45 0.2 8.5 129

8.6

Vol-I (Addendum)

Page 81


4.6



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

NORMAL OPERATING PARAMETRS (At the present condition, after introduction of

APC, all the parameters have changed abruptly.)

4.6.1 Columns

Safe working range Alarm Limits

Operating Parameters PV 8800 (T'put 7000- 9000 MT/day) Mt/d K1 K-1 Top Pressure 1.95 K-1 Top Temp. 126 K-1 topReflux 15.5 Feed Flow ----Feed Temp 228 K-1 Level 50 K-1 Bottom Temp 223 K-1 Bottom Pr. 2.05 E1 E1 HC level 45 E1 Boot water level 25 E1 Naphtha R/D 18

PVLL PVLO 1.80 100 10 150

PVHO

Remarks

PVHH Unit Present

30 175 1.80

1.90 110 16 200 190 35 200 2.4

2.40 132 25 630 268 60 225 2.65

25 10 1.0

40 15 1.5

55 35 25

65 % 70 % 40 m3/hr

0.7 100 10 330

0.75 116 45 340

0.85 125 60 350

0.89 kg/cm2 145 0C 65 T/hr 360 0C m3/hr m3/hr 52 % 0C 1.3 kg/cm2 kg/hr

-

2.68 kg/cm2 134 0C 30 m3/hr 675 m3/hr 0C 75 % 285 0C 2.85 kg/cm2

K2 K-2 Top Pr. K-2 Top Temp K-2 Top Reflux k-2 Feed/Flash Zone temp K-2 Feed Flow K-2 Overflash K-2 Level K-2 Bottom Temp K-2 Bottom Pr. K-2 Steam

0.8 127 24 353 480 ----32 348 .92 2900

-

20

0.3 -

10 23 320 0.5 1000

40 41 370 1.2 3200 -


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 82

. Indian Oil Gujarat Refinery RCO R/D

Operating Manual for JR AU-III VOL-I: Addendum 340

-


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

100

220 -

32 22 8

58 75 20 -

m3/hr

E2 E2 HC level E2 Boot water level E2 Naphtha R/D K-3A HN WD Temp K3A Level HN RD K-3C Kero WD Temp Kero /CR-II Reflux Kero /CR-II Temp K-3C Level Kero R/D K-3B HSD WD Temp HSD /CR-III Reflux HSD /CR-III Temp K-3B Level HSD R/D K-4 K-4 Top Pr. K-4 Top Temp K-4 Top Reflux K-4 Feed Flow K-4 Level K-4 Bottom Temp K4 R/D E-4 E4 HC level E4 Boot water level E4 LPG R/D

45 35 13 150 45 5 204 135 160 55 26 288 148 208 55 77

7.8 59 9 19 55 188 19 45 --.6

25 20 1 -

-

-

-

15 5

25 9

65 15

190 25

192 35

212 65

-

40 25

275

280

-

-

-

-

3 50 5 1.0 35

5 60 9 1.5 45 100 5

15

25

-

-

0

305

C 80 % 20 m3/hr 0

310

75 75

20 45

35

% % m3/hr

215 0C 70 T/hr % 80 90 0C 60 m3/hr

-

30

65 85

C m /hr 0C % 95 m3/hr 0

3

8.35 8.75 kg/cm2 75 80 0C 25 35 m3/hr 25 40 m3/hr 65 75 % 0C 160 70 m3/hr 55 -

0.5

75

2.5

% % 3.0 m3/hr

VR DRUM


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 83

. Indian Oil Gujarat Refinery Level VR drum Pr. VR/IFO Temp UTILITIES Water Pr. Water Flow Steam Pr. Steam Flow 3-ATA Steam Instrument Air FG Pr. To unit FG Flow FG Return to Gas Away FG to Gas Away FO BPC


Operating Manual for JR AU-III VOL-I: Addendum 60 1.4 168

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

50

55 1.0 50

4 Kg/cm2 1140 T/Hr 10.5 Kg/cm2 10100 Kg/cm2 2.4 5.5 1.6 3400 0 05.6 2.5

2.0 200 5 1200 2.0 3.5 1.0 600 0 30 4.5

-

70 75 2.5 350 8.0 2500 15 4800 4.0 8.0 2.5 3200 6 6.5

% kg/cm2 0 C kg/cm2 T/hr kg/cm2 kg/hr kg/cm2 kg/cm2 kg/cm2 m3/hr kg/cm2 m3/hr 7.5 kg/cm2

4.6.2 Furnaces

Safe working range Alarm Limits

Operating Parameters PV 8800 (T'put 7000- 9000 MT/day) Mt/d F1 Feed Flow to F1 Feed inlet Temp F1 COT FO Pressure FG Flow DPC Steam Flue gas Temp aft STD F1 Hip Arch Temp F1 Skin Temp F1 fire Box Temp F1 O2 Air Flow to F1

PVLL

110 261 360 4.8 500 2.9 352 775 430 3.0 9800

PVLO

45 330 1.5

PVHO

55 250 340 1.8 200 1 200 625 150 500 0.5 2000

150 300 370 5.8 900 3.4 900 900 450 950 5.0 18000


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Remarks

PVHH

Unit

380 6.2

950 465

m3/hr 0C 0C kg/cm2 m3/hr kg/cm2 0C 0C 0C 0C % m3/hr

Vol-I (Addendum)

Page 84

. Indian Oil Gujarat Refinery F1 Draft F2 Feed Flow to F2 Feed inlet Temp F2 COT FO Pressure FG Flow DPC Steam Flue gas Temp aft STD F2 Hip Arch Temp F2 Skin Temp F2 fire Box Temp F2 O2 F2 SO2 Air Flow to F2 F2 Draft F3 Feed Flow to F3 Feed inlet Temp F3 COT FO Pressure FG Pressure DPC Steam Flue gas Temp aft STD F3 Hip Arch Temp F3 Skin Temp F3 fire Box Temp F3 O2 F3 SO2 Air Flow to F3 F3 Draft



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

-10.8

-10

2

5 mmwc

205 261 360 5 900 2.6 230 800 445

55 20 340 2.9 400 1.0 200 500 350 500 0.5 0 6000 -10

150 300 370 5.8 1600 3.2 800 890 450 950 5 4 30000 2

m3/hr 0 C 0 C kg/cm2 m3/hr kg/cm2 0C 0C 0C 0C % ppp m3/hr mmwc

50 20 340 2.9 0.2 1 150

80 300 360 4.5 4.5 2.2 375 890

330 2.5

3.0 ---10800 -7.0

173 261 360 3.0 0.8 1.4 175 830 426 895 2.5 20500 -13.5

14 330 2.5

0.5 20

5 80

-5

-0.5

380 6.2

950 465

5

365 4.9 4.9

950 480

2

m3/hr 0C 0C kg/cm2 kg/cm2 kg/cm2 0C 0C 0C 0C % ppm m3/hr mmwc

4.6.3 Desalters

Safe working range


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 85




Operating Parameters

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Remark s

Alarm Limits PV 8800 Mt/d PVLL

(T'put 7000- 9000 MT/day) Desalters Crude Inlet Temp Crude Flow Old DS Crude Flow New DS Desalter O/L presseure DM Water Inlet Temp Brine Outlet Temp DM Water flow old DS DM Water flow new DS ∆Pmix Old DS ∆Pmix New DS LDIC Old LDIC New

PVLO

PVHO

45 10

PVHH

136 280 130 12.6 63 62 4.5

9 2

2.5

13.25 5.0

3.0 1.2 1.2 38 38

1.5 10 15

2 20 20

5 45 45

-

-

Unit

15.25 8

C m /hr m3/hr kg/cm2 0C 0C m3/hr 0

3

8 m3/hr - kg/cm2 - kg/cm2 50 % 50 %

4.7 CRITICAL PARAMETERS

4.7.1 Columns Safe working range Alarm Limits


PV 8800 (T'put 7000- 9000 MT/day) Mt/d PVLL PVLO K1 K-1 Top Pressure 1.95 1.80 K-1 Top Temp. 126 100 Feed Temp 228 K-1 Level 50 30 K-1 Bottom Pr. 2.05 1.80

PVH 1.90 110 190 35 2.4

Remarks

PVHH

Unit

2.40 2.68 kg/cm2 0C 132 134 0C 268 60 75 % 2.65 2.85 kg/cm2


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 86




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

K2 K-2 Top Pr. K-2 Top Temp k-2 Feed/Flash Zone temp K-2 Level K-2 Bottom Pr. K-2 Steam Kero WD Temp Kero /CR-II Reflux Kero R/D HSD WD Temp HSD /CR-III Reflux HSD R/D K-4 K-4 Top Pr. K-4 Top Temp K-4 Bottom Temp K4 R/D VR DRUM Level VR/IFO Temp UTILITIES Water Pr. Steam Pr. Intrument Air FG Pr. To unit FO BPC

0.8 127 353 32 .92 2900 204 135 26 288 148 77

0.7 100 330 20 0.3

35

45

7.8 59 188 19

3 50

5 60 100 5

60 168

50

55 50

70 75 350 -

2.0 5 3.5 1 4.5

8 15 8 2.5 6.5

4 10.5 5.5 1.6 5.6

0.75 116 340 23 0.5 1000 192 35 25 280

190 25 275 -

2.5

-

0.85 125 350 41 1.2 3200 212 65 60 305 75

0.88 kg/cm2 0 135 C 0 360 C 52 % 1.3 kg/cm2 kg/hr 0 215 C 70 T/hr m3/hr 0C 310 m3/hr 95 m3/hr

8.35 8.75 kg/cm2 0C 75 80 0C 160 70 m3/hr % C

0

kg/cm2 kg/cm2 kg/cm2 kg/cm2 7.5 kg/cm2

4.7.2 Furnaces Safe working range Alarm Limits



Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Remarks

Vol-I (Addendum)

Page 87


VOL-I: Addendum

PV 8800 (T'put 7000- 9000 MT/day) Mt/d PVLL PVLO F1 Feed Flow to F1 110 45 Feed inlet Temp 261 F1 COT 360 330 Flue gas Temp aft STD 352 F1 Hip Arch Temp 775 F1 Skin Temp 430 F1 O2 F2 Feed Flow to F2 205 Feed inlet Temp 261 F2 COT 360 330 Flue gas Temp aft STD 230 F2 Hip Arch Temp 800 F2 Skin Temp 445 F2 O2 3 F3 Feed Flow to F3 Feed inlet Temp F3 COT Flue gas Temp aft STD F3 Hip Arch Temp F3 Skin Temp F3 O2



173 261 360 175 830 426 2.5

14 330

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

PVHO

PVHH

Unit

55 250 340 200 625 150 0.5

150 300 370 900 900 450 5

m3/hr 0 C 380 0C 0 C 0 950 C 0 465 C %

55 20 340 200 500 350 0.5

150 300 370 800 890 450 5

m3/hr 0C 380 0C 0C 950 0C 465 0C %

50 20 340 150

80 300 360 375 890

0.5

5

m3/hr 0C 365 0C 0C 950 0C 480 0C %

4.7.3 Desalters Safe working range Operating Parameters

Alarm Limits


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Remark s Vol-I (Addendum)

Page 88




VOL-I: Addendum PV 8800 mt/d

(T'put 7000- 9000 MT/day) Desalters Crude Inlet Temp Desalter O/L presseure DM Water Inlet Temp DM Water flow old DS DM Water flow new DS ∆Pmix Old DS ∆Pmix New DS LDIC Old LDIC New

PVLL

PVLO

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

PVHO

PVHH

Unit

136 12.6 63 4.5

9 2

10 2.5

13.25 5.0

- 0C 15.25 kg/cm2 - 0C 8 m3/hr

3.0 1.2 1.2 38 38

1.5 10 15

2 20 20

5 55 55

8 m3/hr - kg/cm2 - kg/cm2 60 % 60 %

4.7.4 Critical Instruments / Critical Operating Parameters & Its Implication Of Operating Outside Allowable Limits Sl.N o

Equipment

Critical Parameter

Instrument Provided

1

Furnace flow

80-140 m3/hr

FRC

2

Furnace COT

348 – 3630C

TC cascaded with PC on oil or PC on gas

IMPLICATION

 If flow decreases, its skin & COT will increase.  If flow increases, its skin & COT will decrease.  Ensure flow above low alarm limit  Ensure equal flow through all es  Ensure steady oil temp.  Ensure steady oil pressure.  Ensure steady gas pressure  Ensure steady atomizing steam pressure.  Ensure healthy burner condition  If COT increases more than the limit, skin / arch temperature will increase. Tube life time will decrease, leak or coking in tube may occur.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 89



3

Furnace O2

2.0-3.0%

O2 analyzer

4

Furnace arch pressure

-5 to +2 mmwc

PI

5

Furnace 800 to 9000C arch temperatur e

TI

6

Furnace < 2500C stack temperatur e

TI

7

K2 Column top Pressure

PC split range between FG & Flare

0.8-1.0 Kg/Cm2


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

 If COT is lower than the limit, proper fractionation may not occur, product quality will hamper & RCO yield will increase.  2 to 3% excess air requirement should be maintained  More excess air means energy loss. Fuel consumption will be more.  Less than required air will lead to smoky burner & burner tip coke up.  Chance of back fire is there in case of high arch pressure  Its STD will open  Inter lock will cut off furnace and FD in case STD does not open at high arch pressure with in 10 sec.  Open more ID suction vane  Reduce Excess air  Explosion door will open in case of excessive arch pressure.  Adjust burner flame height.  Adjust air requirement  If required reduce T’put  High arch temp. Tube life will reduce. Refractory may damage. Ensure furnace is not hard fired  Arrange for APH cleaning  At high stack temp. APH efficiency will reduce & fuel consumption will increase.  Ensure controller tuning  Ensure good desalter operation  Ensure steady top temp.  Ensure boot water level  Higher pressure will hamper product quality. Product may got colored  Lower pressure also will hamper product quality


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 90




8

Column top Temperatu re

120-1300C

TC cascaded with top reflux

9

Over Flash

15-20 m3/hr

FI

10

Column Bottom Level

40-60%

LI / LCV cascaded with bottom R/D flow

11

Desalter Interphase Level

30 to 40%

LDIC

12

Desalter Amps

< 150 amps

Ammeter

13

Desalter

11.0 to 14.5

PG / PC

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

    

Ensure controller tuning Ensure normal reflux temp. Ensure steady top pressure Ensure boot water level High temp: Top product quantity will increase & quality will not be proper.  Low temp: Product quality will hamper.  Maintain Over flash flow of 5-6 vol% by adjusting Gas Oil draw as per HSD recovery / pour point  High: HSD production will reduce & RCO production will increase.  Low: HSD production will increase & RCO production will decrease. Chance of HSD coloration will be there if it is too low.  Maintain 40-50% level  High level may colour gas oil  Low level may vapor lock bottom pump. In some column SDV is provided, which cutoff bottom draw at low level.  Ensure that 30-40% level is maintained  At high level desalter load will increase, resulting poor desalter operation. Water carries over to column.  At low level chance of crude draining along with brine is there Higher amps means higher desalter load. May be due to high inter-phase level, high water emulsion in crude oil or Due to sludge carry over with crude. >Increase demulsifier rate & reduce mixing valve pressure drop.  Ensure controller tuning


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 91



Pressure

on pre desalter crude pump discharge line.

14

De-salter 120-140 temperatur e

15

Reflux drum boot level

40 to 50%

LCV

16

Boot Water

Chloride content

High

Fe content

High


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

 Ensure that pressure is well below PSV set point  Ensure furnace flows are steady.  High pressure: PSV may pop, resulting product coloration.  Low pressure: Water carry over to column & non achievement of required t’put.  High temp. De-salter will not work., At more than 150 deg post desalter pump may get vapor lock  Low temp: Desalter efficiency will reduce. Oil carry over in brine .  Ensure 30-40% level.  At low-level naptha may drain along with sour water.  At high-level water will carry over with reflux, resulting column condition upset.  Ensure desalter good operation  Increase caustic dozing & adjust ammonia to maintain boot water PH of 6-6.5 & Cl_ of < 10 ppm  For control Fe content < 2 ppm increase corrosion inhibitor dozing

4.8 CHEMICAL INJECTION SYSTEM Chemical injection system is provided in the Unit to achieve the following: 1. To facilitate demulsification in desalter, demulsifier is added. 2. To protect K-1, K-2 and K-4 overhead systems against corrosion, ammonia solution, Corrosion Inhibitor and caustic solution are added.

4.8.1 DEMULSIFIER


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 92




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

A demulsifying agent is injected into the crude oil at the crude pumps common suction header in the Unit. It is injected at the rate of 3-15 ppm on crude t'put and of 5-20 ppm on crude while processing slop depending upon demulsifier quality. Demulsifier helps in faster demulsification inside the desalter, thereby helping in faster removal of water injected for dissolving salt. Demulsifier is injected with the help of pumps H-29/29A, which take suction from demulsifier tank E-13. Injection rate of demulsifier is adjusted by varying the pump stroke.

4.8.2 CAUSTIC INJECTION Calcium and Magnesium Chloride present in crude hydrolyse on heating and release HCL that attacks the overhead system. Some of these calcium and magnesium chloride are removed in the desalters. To neutralise the chlorides escaping from desalters, caustic solution is added into crude. In presence of caustic they get converted into harmless NaCl. The caustic dosing is done at a rate of 30 to 40ppm on N/G crude and is injected in desalter crude outlets common line via vortex mixer. Caustic is received from OM&S in the form of caustic lye of approximately 48% strength in Tank-C. Caustic is diluted by adding water to make 06--10% solution. Caustic from Tank-C is transferred into one of the dilute caustic tanks A and B and a solution of 6.0% strength is prepared by diluting with service water. Dosing of dilute caustic in crude is done with one of the two pumps H-25 and H-26.

4.8.3 AMMONIA SOLUTION INJECTION Ammonia is injected into overhead vapour lines of K-1 and K-2 to: 1. Neutralise residual hydrochloric acid by converting it into NH4Cl. 2. Maintain pH of E-1/E-2 water in the range of 6 to 6.5, because effectiveness of corrosion inhibitor is more in this range of pH.

Ammonia is received in the Unit in 40-kg cylinders. Ammoniacal water solution is prepared by bubbling gaseous ammonia from cylinder through fresh water in ammonia tank. There are two


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 93




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ammonia tanks. There are three dosing pumps available (both pumps to be used to maintain pH) for injection, viz. H-30, H-30A and H-31. Ammonia is injected through rotameters into O/H vapour lines of K-1 and K-2 so that E-1 and E-2 water pH remains in the range of 6.3 to 6.7.

4.8.4 CORROSION INHIBITOR INJECTION Corrosion inhibitor (Ahrulan) is an organic chemical, which acts by forming a continuously renewable monomolecular layer on the metal surface, thereby preventing direct of the metal surface with the corrosive elements present in the system. The dosing is done into the top sections of K-1, K-2 and K-4 separately, at the rate of 5 ppm of production of overhead material in the respective columns. The dosage rate to be adjusted on the basis of make (i.e. quality) and generally manufactures guidelines are to be followed.

Corrosion inhibitor is received in drum and unloaded into solution tank E-9 with off-loading pump H-21A. In this vessel naphtha from E-2 is taken to prepare 1:4 ratio (by volume) solution of Corrosion inhibitor /Naphtha and circulated for an hour with H-21B to achieve a homogenous solution. Pumps H-21A/C/D are used for injecting Corrosion inhibitor into the overhead lines of columns K-4, K-2, and K-1 respectively. Rotameters are provided at the pumps discharge lines to measure injection rate. The rate can be adjusted by adjusting pump strokes. In case one of the dosing pumps is out, flexibility is there to inject Corrosion inhibitor by any of other pumps i.e. one pump shall dose into two columns.

4.9 UNIT PERFOMANCE MONITORING The Key operating parameters for efficient monitoring and operation of this unit are: 4.9.1 Quality of crude w.r.t. to BS&W & free water : While preparing the crude tanks sufficient time (>24hrs) is to be given for settling/draining the free water & residual salts. High BS&W and shots of free water loads the desalter and might be carried over to the column corroding the internals & creating upsets in the unit.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 94




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Also there is the problem associated the old crude tanks where the sludge has been accumulated at the bottom & when the dip of crude tank is low it is being carried to the unit causing disturbances in the unit. As the density of this sludge is quite different from crude, all the flow & level controllers do not function properly. And if there is pockets of water the situation gets worsened. Some typical BS&W & Salt values for North Gujarat Crudes:

Date BS&W,%V/V Salt,ptb 18.05.05 0.5 3.64 11.05.05 1.6 7.1 27.04.05 0.05 3.7 31.03.05 3 9 16.03.05 2 16.14 09.02.05 4 18 03.02.05 3 11 01.12.04 0.05 6

4.9.2 Desalter Operating Variables & Performance Desalter is the heart of a crude distillation unit. If the performance of desalter is not satisfactory there can be the problem of water carryover along with crude & if the crude is high in chloride content there can be corrosion problem in unit.

An experienced operating approach to be adopted for obtaining the optimum condition for a particular desalter for a particular crude.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 95



VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The efficiency of the desalter can be judged based on the oil content in the brine & Salt content of Desalter outlet Crude. Some typical results:

Date Sample Den@15C BS&W Salt 11.05.05 Inlet 0.8875 1.6 O/L Old 0.8852 2 O/L new 0.8852 2.4

7.1 1.8 0.9

16.03.05 Inlet O/L Old O/L new

0.8896 0.889 0.8889

2 0.4 0.5

16.14 5.38 10.76

01.09.04 Inlet O/L Old O/L new

0.892 0.893 0.892

0.6 0.1 0.1

3.61 1.81 2.71

4.9.3 Pre-Heat Preheat is the very good parameter to see the heat recovery from the run down & circulating reflux srtreams. It also helps in getting the idea of water carryover along with crude. If the preheat is getting low there is chances of fouling inside exchangers & cleaning is recommended. A low preheat increases the furnace load & so fuel consumption. 4.9.4 Furnace Outlet Temperature A particular temperature will give desired over flash & distillate recovery. If the temp is low it will result in high RCO Yield & also low RCO temperature will lead to low preheat & whole distillate yield pattern will be disturbed.

4.9.5 E1/E2 PH monitoring E1 & E2 chlorides is to be monitored to get the idea of desalter performance Also if the Chlorides remain on higher side metallurgy to be upgraded to handle the corrosion problem.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 96




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

In Au3 there has been the problem of high corrosion both in E1 & E2 boot waters. The chloride in E1 reported to be in the range of (0-30 ppm) whereas in the E2 boot water it is as high as 120 ppm. A high DM water injection rate will surely help in separating residual salts, but if the crude is high in npathenic salts ( it is active in high temp range) the problem can be handled by suitable metallurgy as this will not be neutralized by addition of ammonia.

Fe content of E1 & E2 is also a good indicator of corrosion & need to use corrosion inhibitor.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 97




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER - 5 UTILITIES SYSTEM


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 98




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The utilities system consists of Instrument Air, Plant Air, Circulating Water, DM water, MP Steam, Service Steam, Fuel Oil, Fuel Gas, Flushing Oil, Closed Blow Down, Flare, Slop, ivation facility and OWS. The distribution of each of the above mentioned utility in AU-3 is described in this section.

5.1 INSTRUMENT AIR

A 3" instrument header supplies dry air to instruments provided in the Unit. Instrument air is supplied by TPS and for this purpose there are two sets of silica-gel dryers. TPS Instrument air header is connected with GRSPF air system also. Instrument air from TPS is received in vessel E-11 [ 6.0--6.5 kg/cm2(g) ] and sent to instruments through a pressure controller 3PC3705 which maintains instrument air pressure at 3.0 kg/cm2(g). A 2” line taken directly from upstream of 3PV3705 goes to F-1/F-2 DODs. Two 2” lines branch from its downstream, one supplying instrument air to F-1/F-2/F-3 side instruments and the other supplying instrument air to other plant instruments. At inlet of E-11, provision is given to receive plant air when instrument air is not available. A low pressure alarm 3PSL3705 is provided on E-11 which is set at 3.0 kg/cm2(g).

5.2 PLANT AIR

A 4" plant air header supplies service / industrial air. On this line a PG, a pressure indicator 3PI3710 and battery limit valve is provided. Service air is used for agitating caustic solution during dilution, steam air decoking and caters to the requirement of service stations provided in heat exchanger, pump, column and furnace area. In case of non-availability of instrument air, an interconnecting 1" line from plant air header supplies air to instrument air vessel E-11.

5.3 CIRCULATING WATER SYSTEM

Circulating water to meet cooling water requirement of Unit is supplied by GRE/AU-5 circulating water system. Circulating water is supplied through a =24" line and it returns to


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 99




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

cooling tower under pressure through a line of same diameter (i.e., =24”). These lines are laid under ground in battery limit area. Inlet to Unit expands to 28” at d/s of B/L isolation block valve before going under ground. This further expands to a =32” header laid under ground. End part of the header near Pump House west corner reduces to 17” in diameter. Tappings have been taken from different points of this 32”---17” header for supplying C/W to condensers, coolers and pumps. Tapping for service water is also taken to cater to the requirement for decoking pot during steam air decoking of furnace coils, pump gland/bearing cooling, caustic solution preparation and service station requirement at pump house, desalter, furnace and heat exchanger area. Circulating water supply and return lines are provided with isolation block valves at battery limit. The inlet to the Unit is provided with a flow recorder 3FI3704, a flow integrator 3FQ3704, a pressure indicator 3PI3711 and low pressure alarm 3PL3711 set at 1.5 kg/cm2(g).

5.4 FIRE WATER

A separate fire water system has been provided in the Refinery by running headers by the side of each main road, with sectional isolation arrangements and with suitable extensions to the units. AU-3 also has such an extension, running at the west of the Unit and parallel to Road No. 1 & 4. The entire network is provided with hydrants to which hoses can be connected for fire water supply.

Four power driven and five diesel driven pumps are used in the fire water network to boost up the network pressure to about 9 kg/cm2; the fire water network is otherwise kept charged continuously with fresh water header pressure through inter-connections with fresh water header (fitted with non-return valves). To cater to the emergency requirement of firewater in Unit, following provisions have been provided: 1.

Two tapping from Road No. 4-fire water header, each for monitors located near desalter and ammonia pump.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 100




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Tappings have been taken from fire water header on Road No.1 and from header in the west side of AU-3 to make a ring and monitors have been provided by taking tapping from this near:

3.

a.

Old Control Room ( Now New El. Substation )

b.

Condenser T8D on condenser platform

c.

Hydrant at top for K5 column ( redundant )

d.

Fire water monitors at F1 and F2

e.

Hydrant near 45-PM-002A/B

f.

One monitor above VR pumps for K1 top fire fighting

g.

One 4" line for sprinkler in pump house

h.

One 3” isolated line up to E4

A tapping from fire water header parallel to Road No.1 for monitor near F-2 and hydrant near FD fan.

4.

To safe guard pumps, sprinklers have been provided on the ring. At the time of fire in pump house, on opening isolation valves water will sprinkle in pump house to cool down pumps.

5.

Two 3" tappings from west side 6" line have been taken for fire hydrant header (04") near P-305A/B and one 3" line from this is provided at E4 for fire monitor.

5.5 DM WATER DM water is received through a 2" line from TPS in vessel E-12 under level controller 3LC3109. A tap-off for PDF is taken to supply DM water before battery limit valve. On E-12 a LG is provided for level indication. Also a over-flow line and drain are provided on this tank. A provision is there to receive stripped sour water from AU-IV in case of scarcity in DM water supply. (Provision is also to receive E1/E2 boot water to DM water tank –not used). Pumps H-28/28A/P231C supply DM water to crude line to Desalter-I (old) and Desalter-II (new) through 3FC3906 and 3FC3907 after it is preheated in E-231A/B/C and E-313A/B.

5.6 STEAM


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 101




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Steam in AU-3 is used for the following purposes: i.

Atomizing steam for fuel oil burners in F-1/F-2/F-3.

ii.

Stripping steam to K-1, K-2 and other strippers.

iii.

Fire fighting and other utility steam

iv.

Heating steam, as in fuel oil tanks E-6/E-7.

v.

Steam for steam tracers

vi.

LP steam for heating VR in VR surge drum

vii.

HP steam for heating VR in 45-EE-003-A/B & C/D

HP STEAM 36 ATA steam is being supplied to AU-3/UDEX from main HP steam line going from TPS to FCC. - HP steam is used in VR burning heat exchanger viz. 45-EE-003A/B and 45-EE-003C/D for maintaining VR temperature, which is supplied to F1/F2/F-3 as fuel oil. Its condensate is supplied to AU-2 condensate pot. - HP steam from main header to AU-3 is inter-connected with MP steam with isolation valves. - HP steam is utilized when VR is used as fuel oil in the furnaces. - MP steam is utilized when IFO (RCO) is used as fuel oil for furnaces. - HP steam pressure is 36 kg/cm2, temperature 435OC - MP steam pressure is 13 kg/cm2, temperature 320OC

MP STEAM

Extraction Steam at a pressure of 12 kg/cm2 is supplied to the Units. Further additional process steam needed is supplied through the pressure reducing station in TPS where the pressure of 40 kg/cm2 steam is brought down to 12 kg/cm2. The process steam at 12 kg/cm2 made available from the above two sources together before being supplied to the Units.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 102




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The steam supply to the Units/offsite facilities is through two 200 mm headers parallel to each other. Every Unit is connected with each of these headers with an independent isolation valve, so that any Unit can be fed from either of these headers any time.

Provision for isolating a complete header from the TPS end is also there and in such a case the Units can be fed from one header only. The two supply lines from the two headers at each Unit to form a common inlet to the Unit, on which a battery limit valve is provided. In AU-3, on the Unit side of the battery limit valve, a pressure controller 3PC3702 is provided to control the steam supply pressure to the Unit. Additionally an orifice meter with flow recorder 3FI3701, an integrator 3FQ3701 and a low pressure alarm 3PSL3702 set at 6.0 kg/cm2 have been installed on this line. Steam from the main line goes to the steam manifolds of F-1, F-2 and F-3 from where it gets further distributed for burner oil atomisation, furnace coil purging, fire fighting, decoking, header box purging etc. for each of the furnaces. Further, the steam line goes around the Unit. Block valves are provided at different places for isolating different portions of the line.

Stripping steam to K-2, K-3A/B and K-3C is supplied at a pressure of 3 kg/cm2(g), which is obtained by reducing the main supply steam pressure to 3 kg/cm2(g) through another pressure controller 3PC3701. From this line tapping for utility steam is taken which caters to the requirement of hose stations at column platforms, reflux drums, pump house, heat exchanger and desalter area. In addition to this, connection for service steam to K2 top PSVs release is provided. One tapping is also provided to supply steam-to-steam coils of VR burning surge drum. K-1, K-4, K5 (redundant), E-1, E-2 and E-4 are also getting steam from this. A separate tapping is taken from the main supply header for stripping steam to K-1 which is obtained by reducing the main supply steam pressure to around 3.5—4.0 kg/cm2 (g) through a pressure controller 3PC3205. Stripping steam to strippers K-6A/B is also taken from this controller. In case of surplus steam generation in GRE/GRSPF Complex; steam can be received from that Complex also.

5.7 FUEL GAS SYSTEM


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 103




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The fuel gas produced in AU-3 goes to the main gas bullets no. 114 and 115 located near CRU from where fuel gas is supplied to all Units. At fuel gas bullet a FG line from FCCU is meeting from this line excess FG from FCCU can be consumed in GR Units. All the Units of GR-I & II and TPS are connected to this fuel gas supply system. Fuel gas system pressure is maintained at around 2.0 to 2.4 kg/cm2 (g), either by making up through LPG vaporizer located in AU-1 or by releasing excess pressure, through a control valve located at gas bullets into the flare. The indication for this control valve opening is available in CRU control room. Fuel gas to the Unit is supplied through a 150 mm line provided with a battery limit valve. A flow recorder 3FI3703, flow integrator 3FQ3703, low pressure alarm set at 1.0 kg/cm2(g) and a pressure indicator controller 3PC3704 are provided on fuel gas line to Unit. Three parallel lines supply FG to F-1/F-2/F-3 for gas burners. A hook-up is provided on this line to supply fuel gas to FGH.

5.8 FUEL OIL SYSTEM

5.9 VR BURNING FACILITY

In Au-3 facility is provided to burn VR ex FPU-1 and FPU-2. VR ex FPU-1&2 is supplied to AU-3 VR surge drum 45-VV-003 through dia 6" line through 3LC3901. A flow orifice 3FI3902 is provided before this LIC. One fuel oil line dia 3" from JOB50/AU-3 RCO RD is connected with VR receiving line before 3LC3901. At this point, one 2" line ex E6/E7 pump discharge is also given for emptying out E6/E7 to VR drum. Dia 2" FLO line is also connected for flushing these lines. Dia 1” CBD line is also provided at this manifold. VR surge drum is provided with steam coil for warming up the liquid in the drum. LP steam tapping after 3ATA steam C/V 3PC3701 (located near K-2 bottom on ground floor ) is provided to this steam coil. Condensate out-let from VR surge drum coil is drained out to OWS. Pressure in this drum is maintained by split-range controller 3PC3901. Make-up is from dia 2" fuel gas line ex main fuel gas header and released to the flare knockout drum 45-VV-004. Two safety valves PSV-4501 and PSV4502 are also provided on top of this drum which release its pressure to flare knock-out drum.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 104




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

3LI3901 indicates level of the surge drum. On south side of the drum one TG is provided for measuring temperature of VR in the drum. On the top 3PT3901, TG-3901 and one level indicator is provided.

One =6" outlet from drum is ing through filter 45GN-005A/B. One over-flow drain line and CBD drain line is provided on these filters. These filters can be cleaned keeping one filter in line. Dia 2" FLO line is provided on these filters for flushing purpose. Liquid ex VR drum ing through 45-GN-005A/B enters suction of pump 45-PM-002A/B. On discharge of these pumps, safety valves PSV-4505 and PSV-4504 are provided which release to pump suction suctions itself. One dia 3" pressure equalizer line from discharge to suction is provided. After PSV tapping NRV and discharge block valve is provided. 1/2" line after discharge B/V to upstream of NRV is provided for warming up the pump. Discharge from 45-PM-002A/B enters 45-EE-003A/B and 45EE-003C/D in parallel. Only one heat exchanger is remaining on line whereas the other one remains stand-by. HP steam through 3TC3901 is ing through these exchangers for heating FO going to furnace supply header. FO is heated up to 230OC through these exchangers. One return line from BPC 3PC3706 is coming back through return line to VR surge drum. Supply and return lines of E6/E7 are connected with VR burning supply and return lines with required isolation B/Vs. Facility is there to use IFO in VR surge drum. MP steam is utilised when IFO is used in this facility. Required tappings are provided for using either HP steam or MP steam. Fuel oil outlet from 45-EE-003A/B and 45-EE-003C/D is ing through 45-GN-005A/B. Only one filter remains on line. Filters and FO pumps are provided with dia 2" FLO line for flushing. The slop distillates ex FPU-I/II can be received in GRE storage tanks. From GRE the same can be received in AU3 VR drums and can be used as fuel inplace of VR.

5.9.1

ALTERNATE FUEL OIL SYSTEM

Fuel oil supply to the Unit is made from TK-57 and 58 located in JOB-50 through pumps H-13 or H-14. This is received in the Unit tanks E-6 or E-7 where IFO is settled and water, if any, is drained out. Provision is there to receive Unit RCO through IFO to AU-4 line in emergency. Provision is also there to receive AU3 RCO. Two fuel oil pumps H-20 and H-20A have been


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 105




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

provided, one running at a time, for supplying FO to AU-3 furnaces. In case running pump gets tripped auto change over system is provided to start stand-by pump. Provision is there to supply FO through same pump and tank or through separate pump and tank. Fuel oil supply line pressure is maintained at around 5.4—6.0 kg/cm2(g) with the help of back pressure controller and balance fuel oil returns to the tank through return line. Tappings are taken from fuel oil line to supply fuel oil to furnaces F1, F2 and F-3 under individual PIC and a part is returned to return line.

5.10

FLARE SYSTEM

A 10" flare header with isolation valve at battery limit is provided. Flare header carries gas released from safety valves on K-1, K-4 and from vessel E-1 and E-4. Excess pressure of E-1 can be released through pressure controller 3PC3201 to flare header. Flare header s the flare knockout drum at GRE. Gas to Unit can be depressurized in flare header if necessary. In june’09 planned shutdown ,K2 &E2 vessel hook up job to LP flare header commissioned.

5.11 FLUSHING OIL Diesel is stored in TK-212 to meet flushing oil requirement. Flushing oil through pump H-101 is supplied to Unit through 4" slop line to pump H-2A/B for flushing the Unit during shutdown. For heat exchanger flushing a separate 4" flushing oil line is provided.

5.12 SLOP Colored gasoline/kero and diesel from TK-214 is processed in Unit by using pump H-101/102. This pump discharges to the suction of crude pump H-2A/B. Provision is there to route colored E-1 gasoline, E-2 gasoline and SKO/HSD into respective off-site tanks.

5.13 CLOSED BLOW DOWN SYSTEM To drain and flush heat exchangers and coolers, a closed blow down system is provided. All coolers and heat exchangers are connected with CBD vessel E-8 through 4" header. Material received in vessel E-8 is pumped for processing along with crude. A level indicator 3LI3701 is provided on the vessel for monitoring level inside vessel. During 2013 M&I a new slop line to GRE


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 106




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

slop tank laid by connecting AU3 CBD pump discharge, AU3 slop pumps discharge(H101/H102) and RCO rundown line. This new facility commissioned in June’2013.

5.14 OWS SYSTEM Pump house, column, heat exchanger, furnace area drains are diverted to underground OWS manholes. Through these manholes Unit effluent is sent to CETP through 15" drain line, which meets main 600 mm OWS line to CETP.

5.15 IVATION FACILITY Last 5 tubes and transfer-lines of all three furnaces F-1, F-2 and F-3 are made of SS316L. Before exposing them to Oxygen, they are required to be ivated to avoid stress cracking due to chloride and polythionic acid. For the ivation 2% sodium carbonate and 0.5% sodium nitrate solution shall be supplied by FPU through a 4" line. For this FPU has a solution tank (5.0 M3 capacity), dilution tank (100 M3 capacity) and pumps to supply ivation solution. Provision is there to supply this solution through booster pump H-8 ( of AU-3 pump house ) directly by FPU pump.

CHAPTER - 6

EQUIPMENT OPERATING PROCEDURE

6.1 DESALTER Desalting is the accepted industry term for an electrostatic process for removing contaminants such as salts, solids and water from crude oils at a refinery. Most of the contaminants in crude oil are present in the oil as it is produced, although the oil can be contaminated with seawater when tanker or barge transports it. Salts produced with crude oil are generally present as brine a solution of salts in water. In addition, the crude oil contains solids such as finely divided sand particles, clays,


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 107




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

drilling mud, and rust and scale accumulated during production and transportation of the oil to the refinery.

Before the crude oil is refined, these impurities must be removed for several reasons. Solid contaminants can contribute to plugging of equipment and to scale formation. The more water crude oil contains the greater the amount of heat that must be applied to raise the temperature of the oil and water mixture to the temperature required for distillation, Chlorides, one of the types of salts found in crude oil, can be responsible for the formation of hydrochloric acid at the temperatures commonly encountered in a crude oil distillation tower. Hydrochloric acid is extremely corrosive. Removal of contaminants in crude oil can increase distillation capacity, cut down on refinery fuel costs, and reduce corrosion and plugging problems. For all these reasons, desalting is the first and one of the most important stages in a refining operation.

Crude supplied from OM&S have water in emulsion form which cannot be separated at OM&S by settling. This water contains calcium, magnesium and sodium salts in dissolved form. Calcium and magnesium chlorides on heating get hydrolyzed and release HCl, whereas sodium salts will get deposited on heat exchanger surface which will foul them. To remove these salts along with water, desalting process is used. For this two desalters are provided in the unit.

DESALTING OF CRUDE OIL IN REFINERIES

Electrical desalter is installed as an integral part of a crude distillation unit. When crude oil enters a refinery, it typically contains a small amount of water, approximately 0.1 to 0.5 volume percent. The water remaining in the crude oil contains water-soluble salts, and the crude oil contains insoluble particulate matter. To lower the level of impurities in the crude oil, water must first be added to the crude. The desalting of the crude oil is a two-part process; the first consists of forming an emulsion of crude oil and water and the second is a demulsification process in which the emulsion of crude and water formed in the first part is broken by means of an electrical field and demulsifier.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 108




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The salt occurs in the form of highly concentrated brine droplets dispersed throughout the curde. These droplets are extremely small and are difficult to with the fresh water added to crude. Desalting process consists of diluting this high salt content brine with incoming fresh water to produce a low salt content water. After demulsification and settling, the BS&W which remains in the crude is a diluted water instead of a concentrated brine. For ing incoming water effectively a fairly light emulsion must be formed. This is done by means of a mixing valve ahead of electric desalter or injecting water at the front of preheat exchanger train. Obviously, the greater the mixing or shearing action as well as higher the velocity, the greater is the pressure drop, the samller is the particle size and higher and more stable is the emulsion.

The process of demulsification is accomplished by coalescing the small particles of emulsion together so that they can form droplets of sufficient size to permit separation by gravity settling. This is accomplished in electric desalting by ing the emulsion through an electric field. The particles of water becomes polarized, orient themselves in a straight line approximately in the lines of force in the electrical field and by random collision form large droplets which settle.

6.1.1 DESCRIPTION OF DESALTER

The desalter is a pressure vessel fitted with electrodes inside it to create an electric field. The crude water emulsion enters the desalter in the bottom section of the vessel through an inlet distributor to ensure uniform distribution over entire cross section and also to attain low velocity condition. A large header, known as outlet crude collector is mounted inside the vessel at top portion and extends over the entire length. This header is connected to the external withdrawal header, for drawing off the desalted crude. The water draw off piping is a header at the bottom of the vessel and extends over the entire length. It is connected to the effluent drain header outside the desalter vessel.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 109




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

At times, there can be sludge build up at the bottom of the vessel. A header with nozzles has been provided at the bottom for creating turbulence by pumping water. Water mixed with sludge can be drained out through a drain line. Steam also can be used in place of water for the above purpose. This process is called desludging. It can be continuous as in AU-3 or can be done intermittently also. Desludging is dealt under separate heading.The electrode system is the heart of desalter. These electrodes are suspended from special suspension insulators, one electrode being immediately above the other so that an electric field is created in the gap between the electrodes. The lower row of electordes is connected to 18KV supply while top row of electrode is securely earthed. Both old and new desalters in AU-3 operate on single phase supply.

6.1.2 DESALTER OPERATION

As the crude oil enters the unit, it is injected with a predetermined dosage of a chemical called demulsifier that helps in subsequent breaking of emulsion in the electric field inside desalter. Crude after ing through a number of exchangers, attains a temperature of around 130OC and at this point water is injected into the crude at the predetermined rate, the mixture is ed through the mixing valve (emulsifying valve) and is fed into the desalter. The water for the above injection should contain minimum salt, and hence DM water /Stripping water (exit AU4) & boot w from E-1 and E-2 is used for this purpose. This water is received in storage tank E-12 and any make up required is done with DM water for which a permanent connection with the tank is provided. DMW make-up is done under 3LC3109 taken from TPS. Water from this tank is pumped with pump H-28/28A/P-231C and heated in E-231A/B/C and E-313 before injecting into the crude line up-stream of the mixing valve. Water separated in the desalter will settle down and will be drained out from bottom through the interface level control valve. This water after exchanging heat with DM water is routed to a flash drum E-19, open to the atmosphere, where water vapours are vented out and the water is drained into the OWS system. A unit switch is provided through which supply to desalter can be put on or off. A pilot lamp is provided which glows steadily till the current is normal and its intensity gets reduced once current exceeds 150 amps. Low-level magnetic switch is provided on


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 110




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

desalters, which trips desalter in the event of low crude level in desalters. In addition to this one voltmeter and one ammeter is provided at site for each desalter. One ammeter alongwith high current alarm is provided in control room for both desalters. To release excess pressure two PSVs 901/902 and PSVs 3101A/B set at 19.0 Kg/cm2(g) releasing to flash zone of column K-1 are provided.

6.1.3 OPERATING VARIABLES Desalter unit operation entails a great many variable factors, some of which have greater influence than others in effective unit operation and desalter efficiency. How these factors can be taken into while optimising desalter operation is discussed below :

6.1.3.1 RAW CRUDE QUALITY Crude oils with high viscosities, high specific gravities and asphaltic in nature are generally more difficult to desalt. Light crude oils are easily desalted because the separation of oil and water is facilitated by the low hold up effect of the light crude oils on the dispersed water droplets. Separation is thus easier. In heavier oils, water droplets formation is slower and hence separation is difficult.

6.1.3.2

SLOP ADDITION / OIL

Oil slops collected in the refinery consist of recovered oils from the effluent system or other oils to be reprocessed. These will sometimes adversely affect demulsification because of the stabilizing effects of contaminants picked up in the effluent system.

6.1.3.3

FEED RATE

Since the desalting process is a largely physical and dynamic function, velocity and residence time will affect its performance. Throughput changes will affect flow characteristics.

6.1.3.4

WATER INJECTION

Desalting may be linked to washing of the oil and hence requires sufficient wash water. The usual recommendation is 3 to 8% vol (water) /vol (crude). If water is less desalting efficiency is


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 111




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

reduced due to inability to all the droplets of high BS&W crude. If too much water is present, desalter may shut out or current will rise to the point where operation becomes expensive. It is normally added just upstream of the mixing valve. Some refineries divide the wash water injection, locating one entry point (@ 1%) ahead of the preheat train, to help keep this clean. In case salt content is high, provision is there to inject water at inlet or outlet of E-101 to increase time. The quality of the water used is of course important particularly when caustic is added. Caustic addition to hard water will cause precipitation of salt, which may plug up lines and be of considerable trouble. Normally DM water is used. Most of refineries use stripped sour water. Normally water injection rate is varied from 2 to 6% of crude to get required degree of desalting. Once the optimum rate is adjusted, it is not changed until crude quality and mix is changed. During slop processing water rate is reduced due to high ingress of water along with slop oil.

6.1.3.5

TEMPERATURE

In order to produce a good emulsion the viscosity of the crude oil must be kept below 40 cSt. This means that sufficient temperature must be maintained to get a low viscosity of crude. Increased temperature assists water settling when oil viscosity and density are as low as possible. However, oil conductivity generally increases with temperature which may give some cause for concern when an alarming rise in amperage is observed. So normally most desalters are operated in the range of 120 140 0C.

6.1.3.6

PRESSURE

Pressure is not an operating variable except that the pressure should be high enough to prevent vaporization within the desalter. Operating pressure of 2 to 3 kg/cm2 above the vaporization pressure at a given temperature is normal.

6.1.3.7

MIXING ENERGY

Thorough mixing of the wash water and oil is necessary to extract the impurities. The closer the ixing, the better is the removal. However, excessive mixing may form an emulsion too stable for the desalter to break resulting in carryover of water containing salt with the oil. The mixing


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 112




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

energy is controlled by the "Mixing Valve". Higher the pressure drop across the mixing valve, more thorough is the mixing.

As the pressure drop is first increased, good desalting is quickly obtained, for a long period of increased pressure drop no appreciable change in the salt content of the effluent is noticed, then a point is finally reached where the effluent salt content will suddenly drop to practically zero. There will be another point where slight increase in pressure drop will suddenly raise the salt content of the effluent crude oils to almost the original value. BS&W of the crude increases gradually as the pressure drop is increased until a limiting value is reached when the BS&W curve will turn abruptly upward. Average optimum pressure drop through mixing valve is approximately 0.5 to 1.0Kg/cm2(g). In case of slop processing it may be required to reduce pressure drop as slop contains sludge and solids, which may produce tight emulsion.

6.1.3.8

INTERFACE LEVEL

Interface level controller is provided which maintains water level in desalter. This interface should be maintained at 85 to 105cm below the lower electrode. The exact point of control for maximum desalting efficiency will depend upon the type of crude being desalted and appearance of effluent water. To counter check position of interface, a number of try lines are provided. Normally interface level remains between 2nd and 3rd try line from bottom and maximum it can be taken up to 4th try line. If interface level is high, current drawn will shoot up and water and salts carryover along with crude will increase which in turn will disturb column operation. Improper functioning of the interface level controller will result in high oil content in effluent water or high current drawn.

6.1.3.9 CHEMICAL AGENT A chemical agent is usually added to crude to help desalting. Its main functions are as follows : *

Help water coalescence


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 113




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

*

Wet out solids

*

Avoid hydrocarbon dispersion in the aqueous phase

*

Assist in emulsion breaking

These agents often referred to as "Demulsifier" are added to the crude oil at the rate of 3-10 ppm vol/vol ahead of the charge pump and water injection.

6.1.3.10 AMPERAGE & VOLTAGE

A good demulsification calls for the maintenance of a high voltage across the electrodes. As the conductivity of the fluid flowing between the electrodes increases, the current flow across the electrodes will also increase and the voltage will drop. Generally this drop in voltage will result in poor demulsification. When the conductivity of this becomes so great the voltage drops below approximately 200 volts on the primary circuit, the unit will fail to break the emulsion and the voltage may rapidly drop further to the point where the overload will kick out and shut the desalter down.

There are various factors that affect the conductivity of the flowing fluid. The type of crude is one variable. The temperature of the crude water mix will also have a marked effect on conductivity. As the temperature increases, the conductivity increases. Thus from this stand point it is desirable to operate at as low a temperature as possible.

The biggest factor affecting conductivity is the percentage of water. Increase in water percentage, increases conductivity until it reaches a point where the electrode will short out. Voltage required for good desalting in approximately 3000 volts per inch of distance between electrodes. This high voltage is obtained by means of transformers. Fluctuations in voltage are usually due to localized appearance of water or emulsion and are generally not serious.

6.1.3.11 pH


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 114




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

pH has a big effect on conductivity. The conductivity becomes high at either high or low value of pH. For this reason it is generally desirable to operate in the middle range. An operating range of pH from 6.5 to 8.5 is acceptable. In the high pH range it has been noted that the sodium naphthenates formed by reaction of caustic and naphthenic acids in crude act as emulsion stabilizers and the emulsion becomes very hard to break. During 2000 revamp caustic addition lines were removed and caustic addition is discontinued. Presently Caustic is added to crude after desalter outlet.

6.1.3.12 SOLIDS AT WATER OIL INTERFACE

Invariably sludge will form at the water oil interface and if it is not removed, the sludge layer will gradually build up until it finally reaches the electrodes and cause trouble. Some desalters have skimming lines of removing the sludge periodically. Sludge or solids have a tendency to build up at the bottom of the desalter. Some refiners have installed steam in the bottom of the desalter with the holes facing the bottom of the vessel. Periodically steam is introduced through the drain out with the desalter effluent water.

6.1.4 RETROFITTING OF DESALTER-I Old Desalter Modified from Monoelectric Desalter to Bielectric Desalter in Revamp, 2000. 6.1.4.1 PETRECO BIELCTRIC DESALTING A Petreco/Baker Process desalting system mixes wash water (water low in contaminants) into crude oil in a special mixing valve that disperses the water in extremely small droplets. This intimate mixing of water and oil causes fresh water droplets to brine droplets and various water-soluble impurities in the oil. The water and oil mixture is piped into the desalter vessel where the mixture is metered out at a low velocity into an electrical field. The electrical field causes the oil and water to separate. The droplets of wash water (now combined with droplets of brine) form large drops that are separated from the crude oil by high voltage electricity and the force of gravity. This process is called electrostatic coalescence. If the wash water were not added, the total population of


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 115




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

water droplets in the crude oil would not be sufficient for much coalescence (combining) of water droplets to occur. The addition of wash water to the crude oil increases the total water volume in the crude and permits removal of contaminants through electrostatic coalescence of the water droplets. A chemical (demulsifier) can be added to the crude oil charge ahead of the mixing valve, preferably at the raw crude charge pump suction. If this arrangement is not convenient, then the demulsifier should be added at a selected point ahead of the preheat exchangers. The demulsifier helps reduce the amount of oil entrained (trapped) in the water, thus reducing the amount of oil carried out of the desalter with the effluent water. The demulsifier may also be added to the crude charge to aid in separating the dispersed water droplets from the crude oil.

Details of how desalting works are below :

6.1.4.2 PROCESS DESCRIPTION Process Description – Bilectric Desalter – Single-Stage Operation

Ahead of the desalter vessel, wash water is added to the incoming crude oil stream. The crude oil and water mixture es through a special mixing valve before it enters the desalter vessel. The mixing valve creates an emulsion. Water is thus dispersed throughout the crude oil in extremely small droplets by this emulsifying action. Once the water and oil are mixed, the incoming crude oil stream enters the bottom of the desalter vessel, flows through a riser pipe, and then into the distributors. The distributors are responsible for metering the crude oil at a uniform flow rate throughout each high voltage electrical field., One electrical field is produced by the lower and middle electrodes inside the desalter vessel, and the other produced by the middle and upper electrodes.

Grids of metal bars and rods make up the electrodes. The high potential gradient for the electric field is furnished by power units installed externally on top of the desalter vessel. When crude oil enters the two electrical fields, the electrical charges in each water droplet are separated. That is,


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 116




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

the negative charges concentrate to one end of the droplet and the positive charges to the other end. Each droplet becomes an induced dipole – a particle carrying two equal but possible electrical charges, or electrical poles.

The positive end of each water droplet is attracted to the opposite, or negative pole in the electrical field that is acting on the water droplet. Each negative end of each water droplet is attracted to the positive pole in the electrical field.

Since the electrical charges in each droplet are separated, the negative poles of droplets are attracted to the positive poles of other droplets. Almost immediately after the crude oil enters an electrical field, the water droplets begin to combine, or coalesce, as opposite electrical charges attract one another.

The coalescing action created by the attraction of the water droplets to one another creates larger and larger droplets, until finally, water drops are large enough to fall out of the crude oil by the force of gravity. Large droplets fall through the crude oil and into the bottom of the desalter vessel. When the desalter is in operation, the bottom one-third to one-half of the vessel is filled with water.

An interface controller connected to a displacer at the oil/water interface controls the rate at which the water leaves the desalter vessel in order to maintain a water level that meets operating specifications. Water exits the desalter through an effluent water disposal line. Treated oil exits the desalter vessel through a collector pipe near the top of the vessel. Bilectric Desalter Process Description The unit is equipped with two energized electrodes. Each electrode is energized by a single power unit and the electrodes are set out of phase. The emulsion enters the vessel at the bottom center of the vessel and enters an internal distributors, which is used to split the crude into distributor head assemblies. The distributor head splits the flow between the upper and lower pairs of electrodes. The emulsion enters the electrical treating field horizontally.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 117




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The PETRECO Bilectric® desalter was designed following considerable research and many years of varied operational experience. The design was developed to achieve a more efficient utilization of the interior volume within the desalting vessel. This is accomplished by establishing laminar horizontal flow between the electrodes, with water coalescence occurring in the electrical treating field, then vertical water separation from the crude. As a result the falling water has less resistance to overcome than in a low velocity design. After separation, in a low velocity unit, water must displace the rising crude to achieve separation. This is much less of a factor in the Bilectric desalter. The principle of treating the emulsion between energized electrodes using horizontal fluid flow with vertical water separation has been used for many years in several PETRECO designs.

Water separated from the crude enters the water phase in a “rain like” fashion. This minimizes turbulence in the water phase and is helpful in improving effluent water quality by providing “Quiescent Zone” water phase residence time in the vessel.

It is to be noted that the crude separated from the water between the center and lower electrodes must through the upper electrode in a converging countercurrent flow with the separating water from the upper set of electrodes. This creates a second washing zone for half the feed in the unit in a strong electrical field. We believe this helps improve filterable solids removal from the crude. In a low velocity design a 50-60% filterable solids removal rate is generally considered acceptable.

With lighter crudes the theoretical doubling of crude capacity is achieving with this design. With heavier feeds this theoretical value decreases slightly. For purposes of design, we use a value of 1.75 as opposed to 2.00 to rate the capacity of the unit as compared to a Low Velocity design (New Desalter). This is achievable without needing to increase the length of the vessel requirements for heavy oils.

The following table lists the principal design features of the Bilectric desalting unit :


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 118




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Petreco Bilectric® Design Features



Maximum Usage of Vessel Dimensions



Maximum Utilization of Electrode Areas



Sophisticated Crude Distribution System



Efficient and Effective Oil/Water Mixing



Maximum Water Residence Time for a Given Vessel



Properly Sized Power Units with Special Design Features for the Crudes being Processed



Ease of Operation for Operating Personnel



Sediment Wash System



Quiescent Zone, Low Turbulence Water Phase



Stable Level Control System

6.1.4.3 DESCRIPTION OF COMPONENTS Components Inside the Desalter The following components are the features of Desalter-I A. Distributor B. Outlet collector C. Electrode assembly D. insulators E. Entrance bushings F. Interface level probe assemblies G. Sediment wash piping and nozzles

A. DISTRIBUTOR The PETRECO Biletric Desalter uses a device called a distributor to uniformly meter the incoming crude oil throughout the two electrical fields in the desalter vessel. The distributor creates a pressure drop that is sufficient to properly distribute the crude oil flow. Three distributors are used to meter crude oil into the two electrical fields of the desalter vessel.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 119




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

B. OUTLET COLLECTOR The collector is an internal pipe located at the top of the vessel, above the electrodes and near the crown of the vessel. This pipe collects clean, treated oil, which exists the vessel through this pipe.

C. ELECTRODE ASSEMBLY The Bilectric Desalter uses two electrical fields to desalt crude oil. Three electrodes create the two fields. Each electrode is constructed of bars and a framework of rods. The electrodes are energized by power units installed external to the vessel. The electrodes must be installed level and must remain level to insure uniform voltage between them. D. INSULATORS The electrodes are suspended from the vessel by insulators. These insulators are attached to brackets at the top of the vessel. The insulators are fabricated of solid, 100 percent virgin, electrical grade Teflon. E. ENTRANCE BUSHINGS High voltage electricity is transmitted from a transformer outside the desalter vessel through an electrical conductor (wire) enclosed in conduit and then through a specially designed high voltage bushing into the vessel. One bushing is required for each power unit. An oil-filled pipe conduit carries the high voltage conductor from the power unit to a flanged connection at the top of the desalter vessel. At the flanged connection, the high voltage conductor enters the insulating Teflon entrance bushing which insulates the conductor and isolates it from other desalter equipment until the conductor connects to a or. The or makes physical and electrical with the electrode assembly in the vessel. Entrance Bushing Design Policy BARG / PSIG

°C / °F

Maximum Operating Conditions

31 / 450

176 / 350

Maximum Inert Gas

10 / 150

to

Maximum Steam

10 / 150

187 / 370


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 120




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Notes : 1.

Pressure / Temperature must not exceed vessel design limitations.

2.

Inert gas to be used for startup / shutdown purging and vessel closure integrity verification

only.

F. INTERFACE LEVEL PROBE ASSEMBLIES The point at which water and oil meet inside the desalter vessel, called the interface, must be kept at a specified level for proper operation of the desalter. The required interface is maintained by measuring the water level with an interface capacitance probe connected to a controller. The controller causes either more or less water to be drawn off at the bottom of the vessel by controlling an automatic valve on the effluent water outlet line.

G. SEDIMENT WASH PIPING AND NOZZLES To prevent the accumulation of undissolved solids at the bottom of the vessel, this desalter plant is equipped with a sediment wash system. The sediment wash system incorporates solids removal piping that extends through the length of the settling zone near the bottom of the vessel. Injection nozzles in the piping point downward. Desalter effluent water from the water discharge line is moved it into the solids removal piping. Desalter effluent water from the nozzles stirs up solids at the bottom of the vessel so the solids can be carried out with the effluent water.

Components Outside the Vessel

1.

Meter

2.

Power unit / reactors

3.

Vent line

4.

Relief valve

5.

Mixing valve

6.

Entrance bushing conduit

7.

Interface control transmitter

8.

Interface control valve


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 121


1.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

9.

Safety float switch.

10.

Steam-out connection.

11.

Sampling.

12.

Chemical pump

METER The meter provides a point for engaging or disengaging the electrical supply that energizes

the desalter power units. The meter houses one voltmeter and one ammeter for each power unit, and an Off/On pushbutton for applying electrical power to the power units. The customer must provide a remote circuit breaker in line ahead of the meter.

2.

POWER UNIT / REACTORS The power units provide the high voltage for the primary treating field that causes water and oil

to separate. The power units are a reliable oil-immersed design made to Petreco’s exacting specifications. A current-limiting reactor is connected in series with each power unit. A reactor protects each power unit from damage by limiting the amount of current that can enter that power unit. The electrical system at each plant is 100% reactance controlled. As the required electrical load varies with the conductivity of the fluid mixture in the vessel, the reactors automatically adjust the applied voltage and power unit current.

3.

VENT LINE The vent line permits purging the vessel of all air and/or gas when the desalter is placed in

operation. The vent line is opened to a visible sewer so an operator can determine where the vessel is liquid full. If the desalter is to be shutdown, the vent line must be opened to relieve the vacuum inside the vessel as the vessel is pumped out.

4.

RELIEF VALVE A relief valve must be installed at the desalter by the customer to protect the vessel from

excessive pressure. The valve is normally set to open at a pressure less than the vessel design pressure. The discharge from this valve is piped to a blow-down drum, closed sewer or other disposal site.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 122


5.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

MIXING VALVE A mixing valve is installed ahead of desalter. The valve is operated either manually or

automatically, depending on the installation. The mixing valve disperses wash water into the crude oil. Typically, this mixing is accomplished with a minimum pressure drop at the mixing valve. The optimum pressure drop required for creating a water-in-oil emulsion in a given crude oil must be determined by some experimentation. In general, a (1.5 - 1.75 kg/cm2) pressure drop is the maximum required. Presently both the desalters in AU3 are being operated at 1- 1.1 kg/cm2.

6.

ENTRANCE BUSHING CONDUIT As discussed under entrance bushings, this conduit is an oil-filed, flexible pipe containing an

electrical conductor that connects a power unit to an entrance bushing at the vessel.

7.

INTERFACE CONTROL TRANSMITTER An interface controller receives measurement information from the interface capacitance probe

inside the vessel. The controller uses this measurement information to control the action of the vessel’s interface control valve. This valve in turn maintains the vessel’s water-oil interface at the desired level.

8.

INTERFACE CONTROL VALVE This valve is installed on the vessel’s effluent water line to control the flow rate of water leaving

the vessel. The amount of compressed air applied to the diaphragm in the valve actuator determines the percent by which the valve is open. Signals transmitted by the level controller determine how much air is supplied to the valve actuator.

9.

SAFETY FLOAT SWITCH


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 123




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

A float mechanism mounted on top of the vessel rises or falls with the level of oil in the desalter vessel. If the level of oil in the desalter falls below the full operating level, the float switch disengages power to the electrode zone.

10.

STEAM-OUT CONNECTION The steam-out connection is used for applying steak (or another purging medium) to the vessel

interior when the vessel is purged of air or vapors. The valve for the steam-out line is reached from the top of the vessel safety platform. The vessel and its components must not be overheated if they are steamed out.

6.1.5 COMMISSIONING OF DESALTER

During commissioning, it is desirable to bring the unit on stream with the desalter. The steps are as follows : 1.Drain out any possible water accumulation in the desalter before itting oil. 2.Close the desalter O/L valve and open the vent valve to expel air. 3.it crude slowly into the desalter by opening desalter crude I/L valve.

When the desalter vessel is full with crude oil and the air has been expelled, close the vent valve. Settle the water and drain it After draining water, open the O/L valve slowly. Once the flow through the desalter is established, slowly close the by valve. When the crude oil in the desalter reaches the required temperature, energize the desalter. If the meters show good voltage and low amps, start water and demulsifier injections keeping ~1.0 kg/cm2 pressure drop across mixing valve.

Key Point: During filling up of the vessel, do not energize the desalter to avoid any accident.

6.1.6

SHUTDOWN OF AND HANDING OVER OF DESALTER


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 124




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Refer Chapter-9 Item 9.1.H

6.1.7

DESALTER DESLUDGING

During operation, some sludges get carried over with the crude from storage tanks at Crude Control and get settled at the desalter bottom. Excessive build-up of this sludges interferes with interface level control of desalter resulting in improper separation of water from crude and carry over of emulsion/oil into OW&S causing recovery problem in Effluent Treatment Plant. The aim of desalter desludging is to remove the accumulated sludge over a period from vessel. For desludging two principal methods are used: 1. Continuous desludging 2. Intermittent desludging

6.1.7.1

CONTINUOUS DESLUDGING

In continuous desludging, a part of the desalter brine is recirculated through a desludging pump P-231 A/B. The re-circulated brine does not allow the sludge to settle at the bottom of the desalter by the churning effect of the re-circulated water. Thus it helps in achieving the goal of desludging. The desludging water injection rate is adjusted by seeing the interface level and the desalter current. Desludging is done for 12 hours in Desalter-I (Old Desalter) and in Desalter-II (New Desalter) for the next 12 hours.

6.1.7.2 INTERMITTENT DESLUDGING

In this process sludge is allowed to settle for some days and then the sludge is removed once or twice a week as per requirement. The method of desludging is described below :


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 125




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

1. Inform ETP personnel about duration and starting time of desludging operation. This will enable ETP personnel to take remedial measures at their end, particularly during the period of excessive oil effluent likely to be received during desludging. 2. Stop water injection to desalter and bring down the water interface level in desalter upto 1st try line point. Draining of water upto 1st try line can be either through regular interface control valve or if required through bottom desludging line. 3. Stop demulsifier injection 4. Commission water to desalter through desludging line and build up interface water level in desalter up to 3rd try line point. It is expected that sludge settled at the bottom will get desludged due to force of water jets introduced for desludging purpose. 5. Stop water injection and drain sludge plus water from bottom drain line upto 1st try line point. 6. Repeat steps 4 & 5 three times in the same sequence 7. Introduce water through desludging line and continue desludging at a controlled rate. 8. Normalize desalter operation with demulsifier and water injection

6.1.8

SR NO 1.

2.

TROUBLE SHOOTING

PROBABLE CAUSES OF REMEDY PROBLEM Too much salt re- Mixing valve pressure drop Increase mixing valve pressure drop mains in the trea- is too low ted oil Insufficient amount of Increase fresh water flow rate wash water being injected Operating temp too low Increased temp of untreated oil PROBLEM

There is too much Mixing valve pressure drop water in treated is too great oil Water injection rate too great Untreated crude has a very high BS&W content insufficient oil and water separation is occurring.

Reduce mixing valve pressure drop Reduce water injection rate Sample crude for BS&W; a change in fresh water injection or mixing valve pressure drop may help.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 126

. Indian Oil Gujarat Refinery SR NO

3.

4.

Operating Manual for JR AU-III VOL-I: Addendum PROBABLE CAUSES OF PROBLEM Voltage at the electrode assembly is too low Not enough demulsifier chemical is being added to untreated crude, or demulsifier should be changed. Oil /water interface too low

PROBLEM

Dirty/crude mixed effluent water is existing at the effluent water line


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

REMEDY Check electrical system for operating problem Increase demulsifier chemical injection rate/or change type of demulsifier chemical.

Adjust controller set point as necessary

Incorrect amount or wrong type demulsifier chemical is being added to untreated oil Oil temp is too low for good operation of plant. Mixing valve pressure drop too great or process water injection rate too great. Set point at level controller may be improperly adjusted or the valve on the effluent water outlet may be stuck open.

Adjust injection rate of demulsifier chemical and/or change type of demulsifier chemical Check temp and increase as necessary. Reduce mixing valve pressure drop and/or process water injection rate.

Voltmeter Vessel operating temp too readings vary high or back pres. widely and Insufficient continuously Incorrect amount or wrong type demulsifier chemical is being added to untreated crude. Mixing valve pressure drop too great An insulator inside the vessel has failed

Check vessel temp. adjust temp of oil if necessary. Check action of back pressure valve. Adjust injection rate of demulsifier chemical and/or change type of demulsifier chemical.

Energized electrode become grounded

Check controller set point and valve action. Adjust if necessary.

Reduce pressure drop at mixing valve Take desalter out of service. When entry is permitted, enter vessel & determine which insulator has failed and replace the same.

has Shutdown system. Inspect vessel interior and locate point at which electrode is grounded. Unground the electrodes.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 127

. Indian Oil Gujarat Refinery SR NO

5.

6.1.9

PROBLEM



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

PROBABLE CAUSES OF REMEDY PROBLEM Set point at level controller Check the controller set point and valve is improperly adjusted or and adjust as required. valve on effluent water outlet line is sticking.

Voltmeter Stable (difficult to break) readings are emulsion has entered the continuously very desalter. low.

Stop the injection of process water. Allow the vessel to operate for about 30 minutes without water injection. If this does not seem to clear the emulsified material out of the electrode zone, use the following procedure : Reduce the level of water in the vessel. Stop operation of vessel for about two hours and then resume operation. If voltage returns to normal, resume injection of wash water, but without a pressure drop across the mixing valve. Once water injection has resumed, increase the pressure drop at the mixing valve until the desired operating conditions are reached. Temperature in the vessel is Check temperature of oil too high or too low. Incorrect amount or wrong Adjust the injection rate of demulsifier type demulsifier chemical is chemical and/or change type of being added to the untreated demulsifier chemical. oil. A separate vessel entrance Check bushing and replace. Check the bushing has failed. bushing only if tests indicate that the transformer connected to that bushing is not the source of the problem.

INSTRUMENTATION

For the monitoring of the desalter performance certain instrumentations are involved.

1. P ACROSS MIXING VALVE


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 128




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The differential pres. indicator across mixing valve gives the pres. drops. Seeing the pres drop the mixing valve is adjusted to get the required Delta p.

2. BACK PRESSURE CONTROLLER The back pressure controller 3PC3101 maintains the desalter pressure and this helps in avoiding the water carryover along with the crude oil.

3. AMMETER The ammeter reading shows the current consumption in the desalter. Higher the ammeter reading, higher is the water carryover along with crude. At certain high valuel of current trips the desalter.

4. LDIC The most important instrumentation in the desalter is the LDIC, which maintain the interface level of the desalter by controlling the brine discharge from the desalter. LDIC dictates the actual performance of the desalter efficiently and the performance of the desalter is satisfactory, then the oil content in the brine should be very less. If oil content in the brine is high the performance and dosage of the demulsifier is to be checked and the desalter operating parameters are to adjust.

6.1.10 LABORATORY TEST

To monitor the performance of the desalter following laboratory test are required : -

Density of the crude

-

BS&W of the crude

-

Salt content of the crude inlet

-

Salt content of the crude outlet

-

Oil content in the brine


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 129




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Density of the Crude Crudes with high specific gravity and high viscosity are more difficult to desalt.

BS&W of the Crude It gives an idea of the water injection requirement, chemical dosage requirement and the desludging requirement.

Salt Content Salt content of the

crude inlet and outlet give the idea of the performance of the desalters.

This also indicates the requirement of the water injection for washing of the salts. Salt content is normally reported as pounds salts measured as Sodium Chloride, per thousand barrels of oil (PTB). The range of salt content generally varies from 100 PTB to 200 PTB.

Oil Content in the Brine

In the desalter, the chemical demulsifier is used to break up the emulsion and if the demulsifier works. There should not be any oil carryover in the brine. A oil carry over of < 100 ppm is expected for a normal working desalter.

6.2 FURNACES F-1/F-2 AND AIR-PREHEATERS

Furnace F-1 and F-2 are of single cell horizontal tube, cabin type with convection and radiation section. These furnaces are equipped with a common recuperative type Air Pre-heater (APH), ID Fan, FD Fan and Decoking Facilities. For efficient and safe operation, DCS instrumentation has been provided along with combustion control with lead lag mechanism. Safety interlock system is provided in view of balanced draft operation keeping stack dampers in closed position.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 130




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

PROCESS DESIGN CONDITION

SR. NO 1

2

ITEM

F-1

APH

F-2 FLUE GAS

Service

Throughput,

Vaporisation

Vaporisation

Heating com-

of K-2 Feed

of K-2 Feed

bustion air

AIR

108.5

239

50.14

47.3

8.63

16.02

-

2.53

285/370

285/370

385-190

35/256

10.4/4.2

9.6/3.1

-30/-100

260/25

mmWC

mmWC

( MT/Hr ) 3

Heat absorption, ( MMKCal/Hr )

4

Inlet / Outlet Temp., ( OC )

5

Inlet /Outlet Pressure, [ kg/cm2 (g) ]


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 131




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.2.1 FURNACE F-1

Furnace F-1 is vertical box type furnace with horizontal tubes. The furnace is upright steel structure with a casing lined with insulating fire bricks and with a cylindrical stack mounted on top of convection section.

The combustion chamber houses 44 nos. radiant section tubes arranged in one . Metallurgy of last 5 tubes is SS 316L and others 5 Cr. ½ Mo. In this section heat is transferred by radiation from the flame and the hot combustion products. The convection section provided on the top of the radiant section serves to increase thermal efficiency of furnace by removing further heat from flue gases leaving radiation section. First two rows of tubes in this section (3 tubes in each row) receiving both radiation and convection heat are called shock bank tubes. Tubes in shock bank are bare tubes. Metallurgy of these tubes is 5 Cr. ½ Mo. Balance convection section consists of two zones, one above the other. The upper zone consists of 6 nos. of studded tubes (2 rows) and lower zone consists of 12 nos. of studded tubes (4 rows). Metallurgy of all studded tubes is 5 Cr. ½ Mo. Between the two zones there are 4 nos. of soot blowers for effective cleaning of outer surface of tubes. On the top of convection section stack damper HC-1811 is provided which can be opened or closed from control room. Provision is also there to open or close it from field with winch mechanism.

6 nos. of dual firing type John Zinc burners are mounted at the bottom of furnace

with primary and secondary air dampers. Hot air is supplied to the burners through the burner plenum..

2 nos. of drop-out-doors (DODs) are provided at plenum chamber through which

combustion air to furnace is provided when furnace is operating in natural draft. These dampers can be opened and closed from control room with the help of power cylinders provided on it. Draft gauges, oxygen and CO analyzers are provided on furnace to measure draft and to control excess air being supplied to furnaces. SO2 analyzer measures the stack sulfur emission. Fuel gas sample point below stack damper (After convection zone) is provided. Explosion doors are provided to protect it from sudden rise in pressure. Snuffing steam connections are given at convection


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 132




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

section, radiation section return bend boxes and in furnace. These can be used during start-up and shutdown for purging furnace.

6.2.2 FURNACE F-2

Furnace F-2 is vertical box type furnace with horizontal tubes. The furnace is upright steel structure with a casing lined with insulating fire bricks and with a cylindrical stack mounted on top of convection section. The combustion chamber houses 60 nos. radiant section tubes arranged in one . Metallurgy of last 5 tubes is SS 316L and other 5 Cr. ½ Mo. In this section heat is transferred by radiation from the flame and the hot combustion products. The convection section provided on the top of the radiant section serves to increase thermal efficiency of furnace by removing further heat from flue gases leaving radiation section. First two rows of tubes in this section (4 tubes in each row) receiving both radiation and convection heat are called shock bank tubes. Tubes in shock bank are bare tubes. Metallurgy of these tubes is 5 Cr. ½ Mo. Balance convection section consists of two zones, one above the other. The upper zone consists of 8 nos. of studded tubes (2 rows) and lower zone consists of 12 nos. of studded tubes (3 rows). Metallurgy of all studded tubes is 5 Cr. ½ Mo. Between the two zones there are 6 nos. of soot blowers for effective cleaning of outer surface of tubes.

On the top of convection section stack damper HC-1812 is provided which can be opened or closed from control room. Provision is also there to open or close it from field with winch mechanism. 10 nos. of dual firing type John Zinc burners are mounted at the bottom of furnace with primary and secondary air dampers. Hot air is supplied to the burners through the burner plenum.. 4 nos. of drop-out-doors (DODs) are provided at plenum chamber through which combustion air to furnace is provided when furnace is operating in natural draft. DODs can be opened and closed from control room with the help of power cylinders provided on them.

Draft gauges, oxygen and CO analyzers are provided on furnace to measure draft and to control excess air being supplied to furnaces. Fuel gas sample point below stack damper (After convection


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 133




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

zone) is provided. Explosion doors are provided to protect it from sudden rise in pressure. Snuffing steam connections are given at convection section, radiation section return bend boxes and in furnace. These can be used during start up and shutdown for purging furnace.

6.2.3 AIR PREHEATER

One common air pre-heater has been provided, for preheating combustion air for F-1 and F-2. Fuel gases are withdrawn from furnace through duct. One guillotine damper and control dampers are provided on each duct. At APH inlet service water and steam connections are given for cleaning APH. Flue gases from both the furnaces combine in flue gas duct which form the heating media in the pre-heater. These flue gases from upstream of stack damper are routed via APH t stack by means of ducts and ID fan. On hot flue gas to ducts two manually operated dampers at APH outlet and ID fan discharge are provided whereas one control damper is provided on ID fan suction. (This is presently out of service).

Combustion air from FD fan through air duct is heated in APH. On air side, a by has been provided. Combustion air flows in three es through APH having three, four and three rows respectively. In each 22 tubes are provided. In first external fins are provided whereas in other two es fins are provided on both side. 66, 8 and 66 fins are provided on each tube in 1, 2 and 3 respectively.

Manually operated dampers are provided at FD fan discharge, APH inlet, outlet and by. Control dampers are provided at FD and ID fan suction and on hot air to F-1 and F-2 in combustion air ducts.

Combustion air duct (hot), flue gas duct and APH are lined with refractory.

6.2.4 FD & ID FAN


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 134



VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.2.4.1 GENERAL FD fan and ID fan handle cold atmospheric air and flue gases respectively. These fans should be started or stopped after closing inlet valves. FD fan bearing housings are filled with grease whereas in ID fan lube oil system (Servo System –21) and cooling water system are given.

Details of FD

and ID Fan are as following :

SR.

FD

ID

FAN

FAN

Atm. Air

Flue Gas

NM3 /Hr

65,980

88,180

ii. Normal, NM3 /Hr

56,700

73,300

iii. Minimum, NM3 /Hr

10,000

15,700

NO

6.2.4.2

ITEM

1

Service

2

Capacity

i. Rated ,

3

Differential pressure, mmWC

316

204

4

Motor power, KW

90

110

5

Rated amp, A

190

224

OPERATION

A. START UP OF FAN 

Ensure free rotation of the shaft



Check the direction of rotation



Check whether bearing is filled with grease/oil



Start cooling water to the bearing



Keep suction /discharge dampers closed



Start the motor



Check for abnormal sound or abnormal vibration etc.



Open discharge damper fully


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 135

. Indian Oil Gujarat Refinery 



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Open suction damper from Control Room as required by process load

B. NORMAL CHECK UP 

Check pressure, flow, current and bearing temperature at regular intervals.



Check for possible leakage level and quality of bearing lube oil.



Check for possible abnormal noise, vibrations or any other abnormal condition.

C. STOPPING OF FAN 

Switch off the motor



Close suction and discharge dampers

6.2.5

BURNERS

Furnaces F-1 and F-2 are provided with dual fuel fired burners. Each burner has got pilot gas burner, fuel oil gun in the centre and a fuel gas burner having tips in periphery (6 & 8 in F-1 and F2 burners respectively). In each gas burner tip 2 nos of firing ports are directing to centre and one ignition port in opposite direction to firing port. Each burner assembly has primary and secondary air damper to control air. Combustion air through primary air damper mixes with fuel

and

through secondary air damper meets the air requirement of burner. Further burner details are given below:

SR. NO

ITEM

F-1

F-2

6

10

1

Number of burners

2

Heat release - Maximum

2.2

2.403

Kcal /Hr

1.6

1.78

to -Oil

0.58

0.587

to --Gas

0.55

0.587

3.9

4.0

- Normal - Minimum

3

Max. oil pressure Kg/Cm2(g)


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 136



VOL-I: Addendum

SR. NO 4


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ITEM

F-1

F-2

30

30

% Excess air - Natural draft

15/10

15/10

Oil /Gas

- Forced draft

10/5

10/5

Kg/cm2(g)

1.75/0.1

1.75/0.1

Natural / Forced draft - Oil

4.5/8.0

4.5/8.0

- Gas

4.0/7.1

4.0/7.1

- Ignition port

1.6 x 1

1.6 x 1

- Firing port

3.3 x 2

2.95 x 2

6

8

Pressure required in Kg/ cm2(g)

0.32

0.32

Gas consumption Kg /Hr /Burner

1.2

1.2

Viscosity at burner tip at 170OC in cSt

5

6

Gas pressure (max/min)

7

8

Draft at burner :

Gas tip

- Nos. 9

6.2.6

Pilot Gas

SOOT BLOWERS

10 nos of soot blowers have been provided in F-1/F-2 heaters, 4 for F-1 and 6 for F-2. Two separate soot blower-operating s have been provided for F-1 and F-2 at their respective burner platform.

Soot blower consists of a retractable lance operated by an electrical motor. With the movement of lance the valve on the steam line connected to the lance opens automatically by lever arrangements providing steam for cleaning.

At the end of the forward travel the direction of rotation of the motor is reversed and the lance starts travelling back. The valve on steam line closes at the end of reverse travel and thus completing the cleaning cycle.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 137




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.2.6.1 GENERAL

To blow out soot deposited on studded tubes in furnaces four and six numbers of soot blowers are provided in F-1 and F-2 respectively. Soot blowers are retractable type, suitable for on load cleaning having 106.7 and 137.2 cm travelling in F-1 and F-2 respectively.

These soot blowers are electrically driven. A is provided for sequential operation of soot blowers by selecting and pressing buttons. On pressing start button motor rotates, lance and nozzle rotates and travels forward on reaching travel length, forward limit switch acts and motor rotates in reverse direction until the reverse limit switch acts bringing motor to rest. When nozzle ports are inside furnace, steam valve opens and soot blowing operation starts and on stoppage of soot blower steam valve gets shut off. Soot blower should not remain inside the furnace without steam blowing through it.

6.2.6.2 SOOT BLOWER

The soot blower consists of the following provision :

1. Ammeter - showing the load on the soot blowing motor 2. Lamps for indicating the status

a) live b) Lamps for individual soot blower programmed c) Lamps for individual soot blower operating d) Lamp indication for overload trip e) Lamp for time elapsed

3. Push Button


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 138




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

a) Individual soot blower programme push button b) Emergency retract push button. This push button will immediately retract any soot blower that is operating forward and cancels programme.

4. Selector Switch Two position selector switch, for programming and starting

5. ALARMS a) Motor overload If during operation a soot blower overload occurs “ overload tripped” light illuminates.

b) Time Elapsed If a soot blower has not completed its cycle within the time allowed “Time elapsed” light illuminates.

When any of the above alarms occur any soot blower operating will automatically retract if electrically possible, and the programme will be cancelled.

6.2.6.3

OPERATION

1. Ensure isolator is switched ‘ON’ and “ Live” light is illuminated. 2. Select “Programme” position on selector switch. 3. Select soot blower required to operate by depressing appropriate push button, thus illuminating each required soot blower “Programmed” light. 4. Select “Start” position on selector switch


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 139




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

5. First programmed soot blower in sequence will operate, this can be observed by the motor current reading, followed by the soot blower “operating” light illuminating. 6. The soot blower reaches the reverse limit switch (RLS). This is indicated by the “Programmed” light extinguishing. 7. The soot blower is fully retracted when the “operating “ light extinguishes and automatically operates the next programmed soot blower in sequence. 8. After all programmed soot blowers have operated the system self resets is ready for the next sequence.

6.2.7

FURNACE OPERATION

Furnace can be run in natural, forced and balance draft operation.

In natural draft operation, air is sucked inside by the draft effect of stack. As heat recovery is not taking place furnace efficiency remains on lower side (80%) . In forced draft operation FD fan supplies combustion air at ambient temperature. Due to higher draft available at plennum chamber burner performance improves. In balanced draft operation FD & ID fans remain on line and heat recovery from flue gases takes place. This improves furnace efficiency (90%).

6.2.7.1

BALANCED DRAFT OPERATION

After Unit is stabilised, change furnace operation from natural draft to balanced draft. For this following procedure is to be followed :

NATURAL DRAFT TO FORCED DRAFT OPERATION

1. Ensure dampers HC-1803, HC-1805 at APH inlet and outlet, HC-1802 and HC1809 on FD and ID fan discharge and Guillotine damper on flue gases duct F-1 and F-2 to APH are open and APH by HC-1804 is closed.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 140




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

2. From field close HC-1813 on hot air to F-1 with manual loader up to 20%. Keep 3FV3802, (combustion air to F-2 damper) full open from Control Room. 3. Put following switches on by mode : a) FD/ID run permit b) F-1, FG and FO pressure low c) F-2, FG and FO pressure low d) Furnace selector switch should be on “both furnaces” position. [Note : KEEP FD/ID FANS LOW CURRENT SWITCH ALWAYS ON AUTO

MODE ]

4. Close FD Fan vanes 3FC3801 from Control Room. Start FD fan. On starting FD fan, running signal will come. 5. Start opening FD fan vanes and bring up air flow to 35,000 NM3/Hr. 6. Check FD is normal i.e. discharge pressure and current is OK. Fuel oil/gas pressure is OK and switches are on by mode. 7. Start closing DODs one by one form Control Room. On closing of DODs light signal will come in Control Room. Ensure from the field as well as from scheme no AU314 colour code that DODs are closed and no smoke comes out from both the stacks. 8. Adjust air flow to F-2 by 3FC3802 and to F-1 by 3FC3803 and total air to get around 4% Oxygen. If required, damper HC-1813 on combustion air to F-1 should be adjusted to get required O2. Now both F-1 and F-2 are on forced draft for putting F-1 and F-2 on BALANCED DRAFT.

A. FORCED DRAFT TO BALANCED DRAFT OPERATION

1. Start ID fan and open 3PC3801 and 3PC3820. Adjust ID fan suction vanes keeping a watch on arch pressure controllers 3PC3801 and 3PC3820. Ensure that ID fan suction pressure high alarm 3PH3819A vanishes.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 141




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

2. Make sure that ( i ) Hip arch pressure 3PC3801 and 3PC3820 of F-1 and F-2 are OK, ( ii ) F-1 and F-2 fuel oil pressure 3PC3301, 3PC3417 and fuel gas pressure 3PI3306 and 3PI3420 are OK. Put “FD Run Permit” by switch in 'AUTO' mode. 3. Check furnace arch pressure 3PC3801 and 3PC3820 are normal. Close STD PB-13 and PB-65. During this period care should be taken that furnace is not getting pressurised. This requires immediate opening of ID fan suction vanes. 4. Adjust furnace for required O2 and draft. 5. Put “ID FAN RUN PERMIT” switch on auto mode. 6. Put F-1, FO and FG low pressure switch on auto mode. 7. Put F-2, FO and FG low pressure switch on auto mode.

Now BOTH F-1 and F-2 ARE ON BALANCED DRAFT

6.2.7.2

BALANCED DRAFT TO NATURAL DRAFT OPERATION

A. BALANCED DRAFT TO FORCED DRAFT Proceed as under : 1. Take “ID RUN PERMIT” on by mode 2. Open stack dampers of F-1 and F-2 3. STOP ID FAN 4. Close 3PC3801 and 3PC3820 Now BOTH F-1 and F-2 ARE ON FORCED DRAFT

B. FORCED DRAFT TO NATURAL DRAFT Proceed as under : Take “FD FAN RUN PERMIT” on by mode. 1. Open all DODs one by one.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 142




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

2. Stop FD fan after ensuring all DODs are in open condition. 3. Close HC-1813.

Now BOTH F-1 and F-2 ARE ON NATURAL DRAFT.

6.2.8

COMBUSTION CONTROL SCHEME

The main objective of this scheme is to balance the air and fuel required to maintain the coil outlet temperature at the desired level as dictated by TIC's and at the same time keeping the excess air at a safe minimum level so as to maximise the heater efficiency. The main emphasis is on the safety of the heater i. E. for a small interval of time a higher level of excess air is tolerated but not deficiency of air. This is achieved by an interlock known as LEAD LAG SYSTEM. The main function of the system is to increase air flow first and then increasing fuel flow whenever a fuel increase is desired either because of higher level of COT or because of higher level of throughput etc. In same way when fuel demand is loss fuel will be first decreased and then air flow will be decreased. Combustion control scheme is an inter-link of the following control loops to achieve the above-said objective :

1. F-1 & F-2 coil outlet temperature controllers 3TC3312 & 3TC3418 2. Total air flow controller 3FC3801 3. F-2 & F-1 air flow controller 3FC3802 & 3FC3803 4. F-1 & F-2 fuel oil pressure controllers, 3PC3301 & 3PC3417 5. F-1 & F-2 fuel gas flow controllers, 3FC3303 & 3FC3411 6. F-1 flue gases O2 analyser controller, 3AC3301 7. F-2 flue gases O2 analyser controller , 3AC3401


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 143




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Brief working of combustion control scheme is as follows :

(a) 3TC3312 and 3TC3418 will demand for fuel and air. (b) From air flow actual fuel that can be safely fired will be computed. (c) From the actual fuel oil and fuel gas flows air required for combustion will be computed.

Air demand as per step (a) and (c) will be compared and higher will be selected. This value will be trimmed properly by flue gases O2 analyser controller AIC depending on the Oxygen available in flue gases. The trimmer out put will adjust the measured variation (air flow) in such a way that excess air level of both the furnaces will be in the desired level. Fuel demand as per step (a) and (b) will be compared and lower one will be selected and ed on to either fuel oil PIC or fuel gas FIC whichever is on temperature control as selected by selector switches.

6.2.9

INTERLOCK SYSTEM

The interlock circuit amongst certain instruments in the APH circuit, combustion control circuit and the furnaces, ensure automatic operation of some equipments in contingency situations, ensuring safety of equipments and personnel and also tries to reduce the down-time of the Unit by switching over to Forced Draft or Natural Draft from the Balanced Draft operating mode.

The interlock system is connected to the following equipments / operating variables :

i.

FD fan

ii.

ID Fan

iii.

Drop out doors (DODs)

iv.

Stack dampers (STDs)

v.

Furnace pressures of the Hip Arch levels


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 144




vi.

Fuel oil pressures

vii.

Fuel gas pressures

viii.

Combined flows

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ix.

Shutdown valves of fuel oil / fuel gas supply lines to the furnaces

x.

On or Off dampers of the APH circuit

Once the healthiness of the interlock system is ensured, following automatic sequential actions are available.

6.2.9.1 FD FAN FAILURE

1. All the DODs of both the furnaces will oopen. 2. STDs of both the furnaces will open 3. Once opening of both the STDs are confirmed ID fan will trip.



CLOSE 3PC3801 AND 3PC3820 FROM C/R Now BOTH THE FURNACES WILL OPERATE ON NATURAL DRAFT

[NOTE : In case any of the DODs /STDs does not open within 20 seconds of FD fan failure, fuel (FO/FG) to both the furnaces will get cut off..]

6.2.9.2 ID FAN FAILURE

1. Both the stack dampers will open



CLOSE 3PC3801 AND 3PC3820 FROM C/R

[ NOTE : : In case any of the STDs does not open within 20 seconds of ID fan failure, fuel (FO/FG) to both the furnaces gets cut off..]


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 145




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.2.9.3 FURNACE ARCH PRESSURE HIGH

1. Alarm will be sounded at the when the arch pressure of any one of the furnaces reaches to ( + ) 2mm WC. 2. If it is reaches to ( + ) 5mm WC in any of the furnaces, the following actions take place simultaneously (provided selector switch is on for “Both Furnaces”) a) FD fan trips b) All the DODs will open c) Once opening of both the stack dampers are confirmed ID fan will trip.

[ NOTE : If the selector switch is positioned to F-2, the above actions will be actuated in case F-2 furnace hip arch pressure is high. In case the above actions (a), (b) and (c) do not take place within 20 seconds of sensing high arch pressure (+5mm WC), fuel to furnaces will be cut off. ]

6.2.9.4

LOW FLOW IN F-1

If the flow through F-1 coils comes below a present value, the following will take place :

1. Fuel to F-1 will be cut off .e. FO & FG to F-1. 2. DODs 1 and 2 will open 3. STD-1 will open 4. Furnace F-2 will also switch over to Natural Draft due to FD fan tripping.



Close 3PC3801 and 3PC3820 from C/R.

[ NOTE : Furnace F-2 can be brought back to the balanced draft with all other safety interlock on AUTO mode if F-1 DODs switch is kept on by- mode. ]


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 146




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.2.9.5 LOW FLOW IN F-2

If the combined flows of F-2 comes below a present value, the following actions will take place :

1. Fuel to both the furnaces (F-1 & F-2) will be cut off. 2. STD-1 & STD-2 will open. 3. ID fan will trip. 4. All the DODs of both the furnaces will open. 5. FD fan will trip.



Close 3PC 3801 and 3PC 3820 from C/R

6.2.9.6

TOTAL FUEL CUT-OFF TO FURNACE F-1

1. All the DODs of furnace F-1 will open 2. STD of furnace F-1 will open

[ NOTE : Furnace F-2 will also switch over to Natural Draft due to FD fan tripping if F-1 DODs limit switch (BPS-54) is kept on ‘A’ mode. ]

6.2.9.7

TOTAL FUEL CUT-OFF TO FURNACE F-2

i.

Fuel (FO/FG) to furnace F-1 will also cut off

ii.

STDs of both the furnace s will open

iii.

All the DODs will open

iv.

FD fan will trip

v.

Once opening of both the STD’s is ensured, ID fan will trip


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 147






Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Once ID fan trips close 3PC3801 and 3PC3820 from C/R

6.2.9.8

DOS AND DONTS OF INTERLOCK CIRCUIT

1. DODs cannot be closed unless FD fan is running. 2. STDs of both the furnaces cannot be closed unless ID fan is running. 3. When furnace is on balanced draft, automatic dampers on hot flue gases ducts cannot be closed. 4. Shutdown valves cannot be opened unless resetting is done. 5. Even if all the four shutdown valves on fuel lines are activated all the pilot burners of both furnaces will be on line. 6. ID cannot run on auto mode unless FD fan is on line

NOTE : 1. Fuel cut off of F-1 and F-2 together (i.e. activation of all the four S/D valves).

a) ID fan will trip b) STDs of both the furnace will open c) All the DODs will open d) FD fan will trip

2. In case FO/FG pressure low to F-2, only FO/FG line S/D valve of F-2 will be activated without disturbing any other interlock.

3. In case FO/FG pressure low to F-1, only FO/FG line S/D valve of F-1 will be activated without disturbing any other interlock.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 148




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.2.10 EQUIPMENT RUN PERMITS

For operating certain equipments/ instruments some pre-conditions are required to be fulfilled. These are known as run permits. Important run permits are as under :

6.2.10.1 FD FAN

A. FD FAN “RUN PERMIT”

Take FD fan run permit by switch (BPS-3) on ‘M’ mode to start the FD can be started by pressing the “Start” button at the field. At this stage switching off can be done from the control room as well as at the field. To switch off FD fan from control room press FD trip Push Button (PB4).

B. PRECONDITIONS FOR PUTTING FD FAN ON AUTOMATIC (A) INTERLOCK MODE :

The FD fan run permit by switch (BPS-3) which is on ‘M’ mode to start the FD fan can be put on Automatic interlock mode only after meeting the following conditions :

1. Hip arch pressures of both the furnaces should be okay. 2. F-1 DODs No.1 & 2 should be in ‘closed’ position or F-1 DOD’s status by switch should be on ‘M’ mode. 3. All the DOD’s of F-2 furnace should be in closed position. 4. F-2 fuel oil pressure should be OK, or F-2 FO by switch (BPS-51) should be on ‘M’ mode. 5. F-2 FG pressure should be OK, or F-2 FG by switch (BPS-52) should be on ‘M’ mode.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 149




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Now THE FD FAN RUN PERMIT BY SWITCH CAN BE PUT IN AUTOMATIC (A)

INTERLOCK MODE.

6.2.10.2 ID FAN

A. ID FAN “RUN PERMIT”

Take ID run permit by switch (BPS-8) on ‘M’ mode to start the ID can be started by pressing the “Start” button at the field. At this stage switching off can be done from the control room as well as at the field. To switch off from control room press ID trip Push Button (PB-5).

B. PRECONDITIONS FOR PUTTING ID FAN ON AUTOMATIC (A) INTERLOCK MODE

The ID fan run permit by switch (BPS-8) which is on ‘M’ mode to start the ID fan can be put on Automatic interlock mode only after meeting the following condition.

1. FD fan should be normal i.e. FD discharge pressure OK & FD fan motor current OK.

6.2.10.3

DODs

A. PRECONDITIONS FOR CLOSING DOD’s OF FURNACE F-2

1. FD fan should be normal (i.e. FD fan motor current normal and FD fan discharge pressure OK). OR FD fan low current by switch (BPS-1) and FD fan low discharge pressure by switch (BPS-61) should be on ‘M’ mode.

2. F-2 fuel pressure i.e. F-2 fuel oil pressure & F-2 fuel gas pressure should be normal OR


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 150



VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

All the following BPS switches should be on ‘M’ mode :

F-2 FO by Switch (BPS-51) and F-2 FG by Switch (BPS-5

At this stage F-2 can be closed individually by pressing the following buttons :

DOD-3 close (PB-61), DOD-4 close (PB-62), DOD-5 close (PB-63), DOD-6 close (PB-64).

B. PRECONDITIONS FOR CLOSING DOD’s OF FURNACE F-1

a) First 2 nos of conditions as stated under 5.10.3 (A). b) F-1 FO pressure OK OR By switch (BPS-4) on ‘M’ mode.

c) F-1 FG pressure OK OR By switch (BPS-5) on ‘M’ mode.

Now F-1 DODs can be closed individually by pressing following push buttons :

i.

DOD-1 close (PB-11)

ii.

DOD-2 close (PB-12)

NOTE :


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 151



VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

1. DOD’s can be opened at any time either individually or simultaneously using the respective open push buttons mounted on the control . There is no pre-condition for opening the DODs. 2. Option available for closing all the DODs simultaneously using PB-1

6.2.10.4 STACK DAMPERS

There are two separate stack dampers, STD-1 for F-1 and STD-2 for F-2. The preconditions for closing these two are given below :

A. PRECONDITIONS FOR CLOSING STD-1/2 (FOR F-1/F-2)

1. Automatic damper (3PC3801) on hot flue gases duct Ex f-1 to APH should be in open position. 2. Automatic damper (3PC3820) on hot flue gases duct Ex f-2 to APH should be in open position. 3. Either ID fan should be normal (i.e. ID fan motor current OK and ID fan suction pressure OK) OR Both the ID fan low current by switch (BPS-2) and ID fan suction pressure by (BPS-7) should be on ‘M’ mode 4. Furnace pressures should be normal 5. Either FD fan should be normal OR FD fan low current by switch (BPS-1) & FD fan low pressure by switch (BPS-6) both should be on ‘M’ mode. 4. Fuel (FO/FG) line pressure of both the furnaces should be normal. OR


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 152




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

All the following four by switches should be on ‘M’ mode :

a) (BPS-4) F-1 fuel oil pressure by switch b) (BPS-5) F-1 fuel gas pressure by switch c) (BPS-51) F-2 fuel oil pressure by switch d) (BPS-52) F-2 fuel gas pressure by switch

At this stage stack damper-1 and damper-2 can be closed by pressing the push button PB-13 and PB-65.

B. OPENING OF STACK DAMPERS

Both

the stack dampers STD-1 and STD-2 can be opened at any time without any pre-

conditions by using respective push button i.e. PB-3 for STD-1 and PB-55 for STD-2.

6.2.10.5 PRECONDITIONS FOR OPENING F-1 SHUTDOWN VALVES (FO/FG)

A. FOR NATURAL DRAFT OPERATION

1. F-1 flow should be normal OR F-1 low flow by switch (BPS-5) on ‘M’ mode. 2. F-2 flow should be normal OR F-2 flow by switch (BPS-53) on ‘M’ mode. 3. F-1, FO low pr. by switch (BPS-4) and F-1, FG low pr. by switch (BPS-9) on ‘M’ mode


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 153




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

4. F-2, FO low pr. by switch (BPS-51) and F-2, FG low pr. by switch (BPS-52) on ‘M’ mode 5. All DODs should be in open position. 6. Both the stack dampers STD-1 and STD-2 should be in open condition.

At this stage, F-1 shutdown valves can be opened by pressing fuel oil/fuel gas open push button, and then by pressing fuel oil/ gas reset push buttons respectively.

NOTE : For opening F-1 fuel oil shutdown valve press F-1 FO open (PB-18) and then press F-1 FO reset (PB-7) AND For opening F-1 fuel gas shutdown valve press F-1 FG open (PB-19) and then press F-1 FG reset (PB-17)

B. FORCED DRAFT OPERATION

In addition to the first four conditions (1), (2), (3), (4) of Natural draft operation the following other conditions are also to be met for running furnace in forced draft :

5. FD fan should be normal 6. All DODs should be closed 7. Both the stack dampers should be in open condition.

8. Both the furnace pressure are OK. At this F-1/2 is on forced draft.

C. BALANCED DRAFT OPERATION


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 154




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

In addition to the first four conditions (1), (2), (3), (4), of Forced Draft and Natural Draft operation, following other conditions are also to be ensued :

5. Both the furnace pressure should be normal 6. FD fan should be normal 7. ID fan should be normal

Close STD 1 & 2. Now furnaces F-1 & F-2 are on balanced draft.

6.2.10.6 PRECONDITIONS FOR OPENING F-2 SHUTDOWN VALVES (FO/FG)

A. NATURAL DRAFT OPERATION

1. F-2 flow should be normal OR F-2 flow by switch (BPS-53) on ‘M’ mode. 2. F-2, FO low pressure by switch (BPS-51) and F-2, FG low pr. by switch (BPS-52) should be on ‘M’ mode 3. All DODs should be open 4. Both the stack dampers should be open

At this stage both the shutdown valves can be opened by using the respective push buttons. For F-2 fuel oil shutdown valve opening, press F-2 FO open push button (PB-69) and then press F-2 FO reset push button (PB-71). For F-2 FG S/D valve opening press push button or F-2 fuel gas (PB-72) and then press reset push button (PB-70). B. FORCED DRAFT OPERATION

In addition to first two conditions (1) & (2) for Natural Draft operation the following other conditions are also to be ensured :


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 155




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

3. FD fan should be normal 4. All DODs should be closed 5. Both the stack dampers should be in open position 6. Both the furnace pressures should be OK

C. BALANCED DRAFT OPERATION

In addition to first two conditions (1) & (2) for Natural draft operation the following other conditions are also to be fulfilled :

3. Both the furnace pressures should be normal 4. FD fan should be normal 5. ID fan should be normal 6. F-2 DODs should be in closed position (in case F-2 alone is on line)

6.2.10.7 CLOSING OF SHUTDOWN VALVES

Fuel oil and fuel gas shutdown valves for F-1 or F-2 can be closed at any time without any preconditions by pressing the respective push buttons as given below :

a) F-1 FO close (PB-8) b) F-1 FG close (PB-9) c) F-2 FO close (PB-59) d) F-2 FG close (PB-60)

6.2.10. 8 EMERGENCY TRIP


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 156




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

To avoid confusion during abnormal situation an emergency Trip (PB-50) provision has been made. After pressing that the following actions will take place: 1. All DODs will open 2. Both the STDs will open 3. ID fan will trip 4. FD fan will trip 5. Fuel (FO/FG) to both the furnaces will cut off

6.2.10.9 CRACK OPENING TEST OF DODs

To ensure operability of DODs in exigencies periodic check operation is to be done. This is termed as crack opening test. For doing crack opening test the following procedure is to be adopted :

i.

Take FD fan run permit by switch (BPS-3) on ’M’ mode.

ii.

Crack open the DODs one by one by bleeding out the compressed air of the pneumatic cylinder, by pressing the handle of the three way spring loaded directional bleeder valve. Once the DOD starts opening leave the handle immediately to get the DOD closed back.

iii.

6.2.11

After testing put BPS-3 on automatic interlock mode.

FURNACE DRY OUT OPERATION

After refractory repair in furnace and flue gas duct, refractory is to be dried before process operation commences to remove absorbed moisture from the refractory. It is very important that


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 157




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

the rate of heating is gradual so that there is no spalling or cracking of refractory due to sudden vaporisation of moisture from the refractory.

Generally 3/5 days dry out cycle is required and it depends on extent of moisture in the refractory. If refractory is excessively wet, then pilots only should be lit for a day or two to remove excess moisture. During the dry out cycle moisture in refractory close to the flame evaporates within a short time. However, moisture inside refractory elsewhere is gradually heated and evaporated. Therefore, heater casing temperature will rise gradually to about 100 Deg. C. This indicates that moisture next to the shell is being evaporated gradually. After this shell temperature will drop to normal.

During the dry out operation, it is necessary to steam through all process tubes to prevent over heating of the tubes. The steam is to be vented out through the decoking pot. A close watch on skin temperature is to be kept and steam rate to be adjusted to keep skin temperature within safe limit during dry out burners are to be rotated for uniform heating.

Procedure for refractory drying is as follows:

1. Open stack damper wide. Open all burner s and peep holes. Allow refractory to dry under natural draft for 24 hours. 2. If refractory is excessively wet, light only pilot gas burners and allow refractory to dry out for a day or two. 3. Start firing the heater as per standard procedure. 4. Raise fire box temperature @ 25 0C/hr upto 120 0C. Hold the temp. for 24 hours. 5. Raise fore box temperature @ 25 0C/hr upto 200 0C and hold for 24 hours. 6. Introduce steam through the tubes at 200 0C after making sure that no condensate is present. 7. After 4 hours of achieving 200 0C temp. start ID fan, if refractory work is carried out in flue gas duct or APH.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 158




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

8. Raise temperature @ 25 OC upto 400 OC and hold for 24 hours 9. At 220 0C stop ID fan and close flue gas duct dampers. 10. Check skin temperature and ensure ample supply of steam before proceeding to final stage of drying. 11. Raise temperature @ 25 OC/hr upto 500 OC and hold for 24 hrs. In case 500 OC temperature is not achievable due to limitation of steam flow, to control skin temperature hold at maximum achievement temp for 36 hours. 12. Reduce temperature @ 40 to 50 OC/hr upto 200 OC. 13. Cut off coil purging steam and firing. Close all air s and stack damper fully. Allow for natural cooling. 14. After cooling check the condition of refractory inside and if required carry out repair work. 6.2.12 IVATION OF FURNACE

Last five tubes of furnace F-1 and F-2 and transfer lines of both furnaces are of SS316L material. ivation is required to prevent stress corrosion cracking of these due to chloride and polythionic acid attack. This is done by (i ) Preventing air ingress into the system by blanketing the system with inert gas, (ii) Neutralise the SS316L surface with a solution of Na2CO3/ NaNO3 so that a film of solution is left on the surface. This film will neutralise any polythionic acids which are formed. The details of the procedure are given below :

1. Prior to shutdown inform FPU-1 to prepare 85M3 solution of 2% sodium carbonate and 0.5% sodium nitrate (1734 kg sodium carbonate + 435 kg sodium nitrate). 2. Flush the furnace coils and transfer lines with gas oil and then with steam thoroughly keeping pilot burners and a small gas burner on as per normal procedure. Steaming is to be continued till clear steam comes from the vent provided at column K-2 feed entry keeping condenser inlet B/Vs closed. 3. Once dry steam starts coming out ( I ) cut off furnace firing (ii) stop steaming (iii) introduce inert gas to displace steam from the coils and transfer lines.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 159




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Note : A positive system pressure must be maintained at this stage.

4. Once inert gas starts coming out from the high point vent ensuring displacement of steam blind at K-2 feed entry ( Φ=22" ) ex F-1 and F-2 ( and F-3 combined ) keeping inert gas supply on. Stop inert gas purging once blinding job is over. 5. Start filling ivation solution in furnace coils through booster pump H-8A keeping vents on F-1 & F-2 transfer lines ( combined with F-3 transfer line ) to K-2 open. 6. Once chemical solution starts coming out from the high point vent, stop pump at FPU-1 and AU-3 and allow the soaking time of 4 hours. 7. Drain the solution to OWS after informing CETP.

6.2.13 STEAM AND AIR DECOKING

The principal mechanisms of decoking with steam and air are spalling and burning. During the spalling period steam is itted to furnace tubes at high temperature with furnace firing on. The comparatively cooler steam, coils and thermally shocks the coke causing it to crack and break away from the tube surfaces. The broken particles are picked up by the high velocity steam and scour the remaining surfaces. As much as 80-90% of the coke can be removed by spalling alone.

The coke burning consists of injecting both steam and air simultaneously into the coil while the furnace is fired at a higher rate. The residual coke after spalling is burnt by the air. Burning effectively removes all coke deposits but requires close scrutiny to prevent overheating of furnace tubes. The general description of the procedure in sequence of operation is as follows :

i. After shutting down, steaming out and ivation of heater coils and transfer lines, reverse the swing elbows at heater inlet and outlet to decoking position.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 160




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ii. Commission steam flow indicator 3FI3304, 3FI3406 and air flow indicator 3FI3305 and 3FI3416 of furnaces F-1 and F-2 respectively. Install pressure gauges at inlet manifold of F-1 and F-2. iii. Simultaneous spalling of more than 2 coils is not recommended since the quench system capacity may be exceeded, whereas for coke burning one coil is decoked at a time with cooling steam ing through the other waiting coils. iv. Light furnaces as per standard procedure. At fire box temperature of 200 OC introduce steam to coil @ 100 Kg/hr. v. Commission the water quench to the decoking drum inlet manifold, drum spray nozzle and drum surface water to reduce the temperature of effluent from the coils. vi. Select the heater to be decoked by spalling (maximum 2 nos). the remaining referred to as waiting . Steam in waiting is to be increased if skin temperatures 590 OC. vii. Increase steam flow to 2300 Kg/Hr and raise temperature in the upto 300 OC. Spalling may now begin.. Check the effluent from decoking pot for colour and coke scales. A Pyrex sample to bottle with a large neck shoulder to be used for taking the sample of hot effluent. viii. When the spalling stops raise the heater outlet temperature in steps of 10 OC to initiate further spalling . then wait for spalling to stop before next increase. ix. When 400 OC COT is reached, cycling of steam flow should be started. The steam flow is quickly increased to 4500 Kg/hr, hold for 30 seconds and then reduce to 2300 Kg/r. Wait a few minutes until no more scales appear then repeat the cycle five or six times until no more coke is displaced. x. Temperature cycling can now be started. Check that all burner pilots are alight and reduce the steam flow to about 1800 Kg/hr. while maintaining the outlet temperature at 400 OC. Check that the skin temperature do not exceed 500 OC ( for 400 OC outlet). Shut the fuel gas to the main burners and immediately increase the steam flow to 4500 Kg/hr and hold for 30 seconds. xi. Burners are then relit and the temperature gradually brought back to 400 OC Check the effluent for coke particles. xii. The temperature cycle is repeated two or three tines until no more coke appears on two successive cycles.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 161




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

xiii. Spalling is repeated with each of the other waiting es, one coils at a time. xiv. Maintain steam flow of 1800 Kg/Hr in each coil and coil outlet temperature to 460 OC. xv. Connect the air inlet line by using removable spool piece on each heater . xvi. In decoking coil it air @ 230 NM3/hr for 10 seconds. Wait 10 minutes for rise in the outlet temperature which should not exceed 500 OC. xvii. Repeat above operation for 20 seconds and repeat until temperature rises less than 500 OC. Observe the skin temperature. Skin temp. limit is 590 OC, however, for a period 620 OC is permitted. xviii. Increase air time to 30 seconds after no further temperature rises are noticed the tubes are ready for continuous air injection. xix. Introduce air @ 12 NM3/hr and monitor CO & CO2 in effluent gas. xx. With decrease in coke burning coil outlet temp. will fall. Increase air @ 10 NM3/hr at 10 minutes interval upto 230 NM3/hr, observe the outlet temp. which should be kept at 500 OC. xxi. If there is any sign of rapid temperature rise, the air flow must be cut and the steam flow should be increased maximum 2300 Kg/Hr. xxii. When two successive analysis show CO2 less than 0.5%, the steam flow is to be raised to 2300 Kg/hr to remove traces of ash, loose piece or coke. xxiii. Bring the steam flow to 1800 Kg/hr and repeat burning operation in waiting es. xxiv. On completion of burning in all es shut-off steam and firing and increase air rate to 350 NM3 and start reducing coil outlet temperature to 150 OC. xxv. Flush the coil with water and then with DM water.

6.2.14

PRE-COMMISSIONING ACTIVITIES

1. Flush the heater coils with air. 2. Flush the fuel oil and gas lines with air and do leak test 3. Flush the atomizing steam lines with steam and do leak test 4. Flush the burner tips with air 5. Flush the draft gauges' tappings and lines with air


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 162




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6. Check the burner alignment 7. Check the damper operation and calibrate it for 0%, 25%, 75% & 100% opening. 8. The refractory brick work and castable lining should be thoroughly inspected. 9. Soot blower checking 10. Before soot blower operation, ensure that the lance is free to travel into heater by hand operation. 11. Check the motor rotation 12. Check the soot blower operation with motor and check the limit switches performance

13. All instruments and interlocks should be carefully checked because upon these the furnace operation relies. 14. Check the furnace floor for cleanliness 15. Box up the man-way 16. Flush fuel gas lines with N2 and do the leak test 17. Commission FG header under N2 pressure

6.2.15

NORMAL FURNACE START UP

6.2.15.1 PREPARATION FOR START UP

i. Check that all fuel lines are blinded ii. Check that all the fire fighting steam hoses with lancers and fire extinguishers in position and in good condition. iii. Commission tracing steam to FO lines and establish FO circulation and maintain back pressure 3-4 kg/cm2(g) by adjusting BPC. Also reset SOVs and establish circulation for individual furnace. iv. Keep the stack damper open and lock it in that position v. Check all instruments and interlocks vi. Prepare the hand torches as a standby for ignitors


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 163




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

vii. Check the ignitor operation for better sparks. Venturies must be cleaned. viii. Check that all burners block valves in close position ix. Purge fire box sniffing steam for 30 min. or steam is seen coming out of the stack and check for the draft. x. Check that fuel gas, pilot gas, and fuel oil systems have no open ends and that all vents and drains are plugged or capped.

6.2.15.2 START UP OF THE FURNACE

1. Establish the circulation through coils for satisfactory flow, pressure and temperatur. 2. Deblind the gas to heater line 3. Flush the header to flare for removal of condensate if any. 4. Lighting Pilot Burners

i. Open pilot gas main block valve ii. Check the ignitor iii. Open gas to the pilot and press the ignitor switch. Observe that the pilot burner has ignited. If not, close gas to pilot and try it again after 5 minutes. iv. If necessary, adjust the air control of the pilot burner. v. Light all the pilot burner

Note : If ignitors are not working, light the pilot burners with external torch.

5. Lighting Fuel Gas Burners

i. Under no circumstances should gas burners be lit off from adjacent burner or hot bricks. ii. Recheck that all individual burner valves and main supply block valves are shut and that all drains and vents are isolated and plugged or capped.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 164




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

iii. Reset the shutdown valve and pressurize the main fuel gas control valve to give recommended fuel gas light up pressure at the burner [ 1.0 to 1.5 kg/cm2(g) ]. iv. Gradually open the burner gas valve until the burner ignites from the pilot. Continue opening the valve until a stable flame is obtained. If the first or only burner fails to ignite within five seconds, shut the valve and wait five minutes before making next attempt. Adjust air for proper flame shape. v. Light additional burners if required in same manner. vi. When the demands for gas comes within the control range of the fuel gas controller, gradually open the burner isolating valves fully, simultaneously adjusting gas flow to maintain constant heat input. Put the fuel gas pressure controller on auto control and subsequently on cascade mode. vii. Adjust air if necessary, to maintain a bluish coloured flame with a slightly yellow tip.

6. Lighting Fuel Oil Burners

i. Under no circumstances should attempts be made to light oil burners from an adjacent burner or from hot bricks. ii. Commission the atomizing steam supply to all burners, then adjust the atomizing steam control valve to provide the desired light up pressure [ 1.0 to 1.5 kg/cm2(g) differential ]. iii. Recheck that the individual burner oil valves are closed and that all pilot burners are alight and stable. iv. Open the individual burner purge steam valve and purge the gun barrel. Close the purge valve. v. Gradually open the burner oil valve until the oil spray ignites from the pilot flame or the main gas burner. If required, external torch can be used. vi. Continue opening oil to the gun until a stable flame is obtained. Adjust air resister for proper flame shape.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 165




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

vii. Light additional oil burners as necessary. This may require further manual adjustment of the fuel oil control valve. viii. At the first opportunity open individual burner valves fully and put the fuel oil controller on Auto Mode. Make final adjustments to the atomizing steam supply pressure and put on differential pressure control with respect to the fuel oil. ix. Inspect the flames frequently. If any are unsatisfactory or go out, shut off the fuel, replace the oil gun with a clean one and re-ignite.

6.2.16 NORMAL FURNACE SHUT DOWN

Take the heater TIC out of service and put the fuel on manual pressure control. As the feed rate to the unit associated with the heater is reduced to the specified level, reduce the number of main burners in service so that the desired temperature is maintained and fuel supply pressure does not fall below flame stability limit The shutdown of burners should be staggered so that the remaining burners are spaced to give even firing and heat distribution through out the fire box.

KEY POINT The heater must not be left unattended during this period and checks to be made frequently to ensure that pilot burners remain alight and burner firing conditions are satisfactory.

1. Put Off Oil Burners

1



Close the fuel oil valve to the burner



Keep on atomizing steam for some time



Flush FO line with purge steam



Remove the guns for cleaning if require

Put Off Gas Burners 

Close the primary air s of the burners to prevent flash back


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 166


2



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



Shut off the fuel gas valve to the burner



Purge with atomizing steam to prevent gas accumulation in burner throat.

The flow rates through the heater coils must be maintained above the minimum specified in the data sheet until all fires including pilot burners are put off.

3

When all the main burners are shut off main fuel gas supply to burner is to be stopped.

4

Check again that all pilot burners are still burning, then slowly open one main gas burner block valve to depressurize the system.

5

Close the burner block valve when the flame goes out. Do not leave the burner unattended during this operation.

6

Then close pilot gas block valves except one at farthest end.

7

Close pilot gas supply block valve.

8

Allow the header to depressurize and when flame goes out at that pilot burner, close the block valve.

9

Start snuffing steam and purge the firebox at least for 30 minutes.

10

Blind the fuel gas to furnace line.

6.2.17 EMERGENCY PROCEDURES

1. Total flame Failure

i. Shut off immediately all fuel supplied to the heater by either tripping al automatic SOV or closing a main block valve in each fuel supply line. ii. Close pilot burners B/Vs iii. Open up the steam purge to the fire box and header boxes. iv. Complete the valve isolation of the fuels to the heater by closing the main block valves and all the individual burner valves in each fuel supply system. v. Continue steam purge for at least 30 min. then shut off all steam and allow it to clean from the heater.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 167




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

vi. Arrange for gas test through air resistors and through inspection doors at high and low locations. vii. If the gas test shows the presence of an explosive mixture, repeat the steam purging. viii. If the fire box is free of gas, burners can be re-commissioned.

2. Flame Failure Where Pilot Burners Remain Alight

i. Trip the automatic fuel shut off valves and /or close the main fuel supply block valves,. ii. Close all the individual valves to main burners. iii. Ensuring above only, SOVs can be reset iv. Check that all pilot burners are burning satisfactorily v. Re-light main burners from pilot burners

3. Failure Of Individual Burners\

i. Close the fuel supply valve to the affected burner as per the standard procedure for closing the burner. ii. Check and rectify the cause of the failure iii. Check the pilot, if found burning satisfactorily relight the main burner. iv. If pilot had also failed, relight pilot by ignitor or torch and then light the main burner.

4. Liquid Carry Over into the Firebox

Flammable liquid can inadvertently enter the fire box from the fuel gas system or due to a faulty fuel oil burner which may cause uncontrolled fire in the fire boxes which may spread outside.

i. Immediately shut off the fuel to the furnace from safe distance ii. Rectify the cause of carry over, purge the FG header to flare


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 168




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

iii. Do not continue oil firing if combustion is occurring within the window box or burner chambers due to faulty oil burners.

5. Heater Tube Failure

i. Open snuffing steam to header and fire boxes. ii. Shut off all fuels to the heater iii. Shut off all air resistors to avoid the formation of explosive mixture.

6.2.18 OPERATING INSTRUCTION

i. The burner should be clean and in good condition ii. The burner flame should be nearly white with a bluish smoke at the tip of the flame. iii. The burners should be operated to provide flames which are as uniform in length and size as can be obtained. iv. It is normally desirably to fire all burners even when running at reduced capacity to assure a uniform heat distribution. v. The flame should not impinge on the furnace tubes. vi. There should not be too much of excess air which cause cooling, thereby increasing fuel cost. Desirable range is 20-25%. vii. The fire box should not develop positive pressure viii. The furnace temperature should be increased or decreased gradually to prevent thermal shock. ix. The peephole doors should be tightly closed to prevent air in filtration, resulting in a decrease in thermal efficiency.

ROUTINE CHECKS i. Individual flows and pressure drops.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 169




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ii. Furnace es outlet temperature and skin temperature iii. Furnace fire box temperature iv. Burner flame appearance and size v. Furnace tube appearance and movement vi. Condition of refractory and tube hangers.

6.2.19 TROUBLE SHOOTING

The causes of defective furnace operation can be classified as follows:

1. SMOKE AND SOOT

i. Insufficient air for combustion ii. Improper mixing of oil and air, too low steam pressure iii. Nozzle worn and clogged iv. Oil pressure too low v. Flame impinging on tubes vi. Insufficient draft vii. Insufficient atomizing steam viii. Chimney dirty and obstructed

2. HIGH OIL CONSUMPTION

i. Too much excess air ii. Improper oil or air mixture iii. High stack temperature iv. Nozzle too large

3. SPARKING FLAME


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 170




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

i. Wet steam ii. Suspended solid in the oil iii. Foreign matter inside burner or in the tip

4. FAILURE OF IGNITION

i. Too much steam for atomization ii. Fuel pressure low iii. Fuel valve plugged iv. Wet steam

5. BACK FIRING

i. Delayed ignition ii. Oil spray defective, too low steam pressure iii. Oil pressure too low iv. Oil leaking into chamber v. Low draft vi. Water in oil

6. NOISE

i. Insufficient draft ii. Chimney dirty and obstructed iii. Nozzle too large


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 171




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

iv. Oil pressure too low or excessively high v. Insufficient mixing of air and oil vi. Nozzle clogged vii. Wrong spray angle and flame impingement

CHAPTER - 6

6.3.1 GENERAL DESCRIPTION

The Crude Heater 410-F03 is a vertical cylindrical type heater with a horizontal overhead convection section and a top mounted stack.

The feed enters the convection section in a two arrangement. The convection section has six tubes per row. The upper part consists of nine rows of CS studded tubes of P5 material. The bottom part has three rows of bare tubes of P5 material, which serves as shock tubes.

The fluid enters the radiant section via external located cross-overs. Both es enter the radiant at one side. In the radiant section fifty tubes of P5 material and ten tubes of SS316L material are arranged along the perimeter. Each traverses along one half of the perimeter. The last five


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 172




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

tubes of each are of SS316L material. Opposite of the inlets the fluid leaves the radiant section. The two es are combined and routed via a transfer line to column K-2.

Six skin-thermocouples are installed at each process . Four pieces are located at the radiant tubes at equal spaced distances and two pieces are located at the shock tubes in the convection section.

Six forced draft low-NOx burners are installed in the radiant floor for upwards firing. The burners can be operated on both fuel gas and fuel oil or a combination of these.

A plate type Air Pre-Heater APEXTM is installed to regain the heat from the flue gas for preheating the combustion air. The air pre-heater consists of four blocks in vertical direction arranged. The flue gas enters the APEXTM at the top and flows downwards through three block of CS material and one bottom block of enamel coated material. The combustion air enters the APEXTM sideways at the bottom block and flows in cross-flow to the flue gas through the bottom block. The air is then routed via a return bend to the next block for again a cross-flow heat exchange. The combustion air leaves the top block sideways.

The APEXTM contains water wash facilities to clean the bottom block at a shutdown period. Two skin-thermocouples are installed to monitor the metal temperature of the CS block above the enamel coated block at the bottom.

The convection section has two rows of three soot-blowers for steam blowing the convection tubes.

The stack at the top of the convection section has a multi-blade actuator controller damper, which separates the flue gas ex convection and flue gas return from the air pre-heater. On the loss of the induced draft fan, the heater can operate on forced draft. The damper will be operated to


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 173




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

achieve the required arch pressure. The cold combustion air will be supplied to the burners via the by- along the air pre-heater.

The instrument connections supplied on the heater include a comprehensive set for flue gas draft and temperature measuring. Further instrument connections for monitoring firing condition include flue gas sampling and O2 measurements. In general, connections are located as follows:

a. At the heater floor: flue gas pressure connection. b. At the inlet of the convection section: flue gas temperature and pressure, sampling and O2 measurement connections. c. Below the stack damper: flue gas temperature and pressure, sampling connections. d. Above the stack damper: flue gas pressure connection.

6.3.2 OPERATING CONDITIONS The process conditions of the heater for the two process operating cases and the firing of various fuels are described in the heater datasheets given below : Unit Services Type Duty

: : : :

Crude Distillation Unit Crude Heater Vertical cylindrical plus horizontal convection section and top mounted stack. 13.95 MW (absorbed)

PROCESS DESIGN CONDITIONS Operating Case-I : 55%NG + 45%Imported Crude

DESIGN

NORMAL

PARAMETERS Radiant Zone

Convection Zone


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Radiant Zone

Convection Zone

Vol-I (Addendum)

Page 174




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Heater Section : Heat absorption Fluid

MW

9.27 HC

4.68 HC

7.94 HC

3.70 HC

Flow rate

kg/s

37.78

37.78

31.48

31.48

Pressure drop

Allowable

kPa

 to to - 1200 to ---

Calculated

kPa

 to to --428 to to 

Flux density allowable

Avg, Avg,

 to to -342 to to --

KW/ m2 ,,

33727

33727

31000

27350

,,

58800

62800

58800

50600

C kPa (a) wt%

284 580

250 658

282 515

250 572

0

0

0

0

C kPa (a) wt%

366 230

294 580

355 230

292 515

22.3

0

22.3

0

calculated Max, calculated Inlet Conditions : Temperature Pressure

0

Vaporization Outlet Conditions : Temperature Pressure

0

Vaporization Vapor Molecular Weight

kg/ kmol

189

189

PROCESS DESIGN CONDITIONS

Operating Case-II : 55%NG + 45%Bombay High Crude

DESIGN

NORMAL

PARAMETERS

Heater Section : Heat absorption Fluid

MW

Radiant Zone

Convection Zone

Radiant Zone

Convectio n Zone

9.24 HC

4.71 HC

7.91 HC

3.72 HC


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 175


VOL-I: Addendum

Flow rate

kg/s

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

36.25

30.21

36.25

30.21

Allowable

kPa

 to to - 1200 to ---

Calculated

kPa

 to to --518 to to 

Avg, allowable

KW/m2

33727

33727

Avg, calculated

,,

31850

27250

Max, calculated

,,

68100

62900

58300

50750

C kPa (a) wt%

283 671

235 748

281 531

235 547

0

0

0

0

C kPa (a) wt%

353 230

283 571

353 230

281 591

31.3

0

31.3

0

Pressure drop Flux density



Inlet Conditions : Temperature Pressure

0

Vaporization Outlet Conditions : Temperature Pressure

0

Vaporization Vapor Molecular Weight

kg/ kmol

177

 to to -417 to to --

177

[Notes : (a) Process data calculated for 100% oil firing at 170 0C, design excess air and ambient air at 13.6 0C. (b) Normal case applicable for flow distribution at 325000 kg/hr (Case-I) and 334000 kg/hr (Case-II).] The heater outlets are combined into a transfer-line to column K-2. The transfer-line from heater 410-F03 is combined with the exiting transfer-line of heaters F-01 and F-02 upstream the inlet nozzle(=22”) at this column. operation of the exiting

The operation of heater 410-F03 is thus linked to the

heaters F-01 and F-02. The performance of the transfer-line should be

monitored during varying load conditions of the three heaters. The heater has six burners installed. As many burners as possible should be brought into operation under all operating conditions. In case only part of the burners are fired (turndown conditions) then the burners in operation should be selected symmetrically. It is very important


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 176




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

that the burners are operated in such a way that they provide equal heat pick-up into the process coils. Mal-distribution of heat, causing high metal temperatures and/or distortion of the coils, is to be avoided. When combination firing is applied, it is recommended to operate each burner at the same oil/gas ratio to assure equal heat distribution. If the quantity of one fuel is not sufficient to fire all burners at the same ratio, it is recommended to route this fuel to part of the burners in a symmetrical way. This type of firing should be closely monitored and evaluated on equal heat distribution via the burner performance curves and/or flame dimensions. The burners are low-NOx type by means of staged air supply. The total air is divided into two channels inside the burner wind box. Each channel contains an air damper. The individual setting of these dampers should be done so that complete combustion takes place with low-NOx production. Minor modifications to these settings can be permitted in the following cases : a. Minimizing the NOx production. Adjustments may lead to poor flame performance.

All

burners should have the same flame pattern. b. Minimizing deviations in air supply during normal operation between the burners by trimming

burners’ dampers. The ratio between the two damper settings should be

maintained at all times. c. If one or more burners are shut off for a longer period due to maintenance or turndown conditions, it is advised to keep all burners at low firing instead of a few burners at higher firing rate. It is strongly advised to avoid frequent modifications to the burner dampers. The control of the air supply is arranged at the FD-fans. If the damper settings are established at start-up then no further modifications are required at a continuous operation. Review may only be necessary if the heater operation is changed significantly. The heater can be operated in forced draft mode. In that case the ID-fan is out of operation. The FD-fans will supply the cold combustion air via the air pre-heater by to the burners. It is recommended to close the guillotines at the stack to cut the flue gases to/from the air pre-heater to avoid condensation effects. Also the shut-off plates/guillotines at the combustion air inlet/outlet should be closed to avoid high cool down rates.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 177



VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Operation of the guillotines should be performed carefully. In order to avoid high pressure differentials over the APEXTM internals, following rules should be adhered to: a. The guillotine in the combustion air duct downstream the APEXTM should always be opened first. b. The guillotine in the combustion air duct upstream the APEXTM should always be closed first. c. Both guillotines in either air or flue gases duct should be operated at all times. d. The combustion air by- should be fully opened.

The heater is designed for firing Sulfur containing fuels. Two types of fuel oil are envisaged in the design, which may contain up to 1 %wt of sulfur. Also firing of two types of fuel gas are foreseen. One type contains up to 2.0 % vol of H2S, which is equivalent to 0.13 % vol SOx in the flue gases. The SOx in the flue gases determines the dew point temperature at which H2SO4 is possibly formed.

It is strongly advised to regularly check the SOx content of the flue gas.

Particularly when a fuel type switch is to be executed. In case the SOx level exceeds the design value then adaptation of the APEXTM operation is required to assure sufficient temperature margin towards this dew point temperature

For start-up it is strongly recommended to use sulfur free fuel to allow warm-up of the equipment to a level above the dew point without a risk for acid formation. When operating conditions are established, then a switch to one of the design fuels can be implemented. For the dry-out procedure it is mandatory to use sulfur-free fuels due to the large quantities of water in the system at low operating temperatures.

The installed plate type air pre-heater APEXTM has a number of mechanical constraints, which should not be violated. The installed instrumentation requires regular maintenance to assure reliable information.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 178




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The air pre-heater operation should be strictly according the process conditions as defined at the datasheets given below :


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 179




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

THERMAL DATA SHEET

Service

: Air Preheat System

Operating Case : Design case—Oil fired

OPERATING DATA Cold Fluid

Hot Fluid

Fluid

Air

Flue Gases

Total Quantity

6.21

6.7

By

0.10

Units kg/s kg/s

Cold Fluid

Hot Fluid

Units

6.11

6.7

kg/s

N2

78.2

70.9

vol%

O2

20.7

2.5

vol%

CO2

0.03

12.0

vol%

H2O

1.05

14.6

vol%

0.05

vol%

Vapour Quantity Composition :

SO2/SO3 Acid Dew Point

144

Allowable/Calculated temperature

min

metal

159

C

0

172

C

0

(-2)

Temperature In/Out

Normal

15.6

293

403

176

C

0

(APH O/L)

Pressure Drop allowable/calculated

Max

Fouling Coefficient

1.05 0.0001

Heat Transferred No of es

1.2

kPa

0.0002

m2.0C/W

1746

kW

4

Corrected MTD

131

Overall Heat Tr Coefficient

29.4

W/m2.0C

Calculated Surface

452

m2

Installed Surface

473

m2


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

C

0

Vol-I (Addendum)

Page 180




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

THERMAL DATA SHEET

Service

: Air Preheat System

Operating Case : Normal Case—Oil fired

OPERATING DATA Cold Fluid

Hot Fluid

Units

Fluid

Air

Flue Gases

Total Quantity

5.18

5.59

By

1.57

Vapour Quantity

3.61

5.59

kg/s

N2

78.2

70.9

vol%

O2

20.7

2.5

vol%

Cold Fluid

Hot Fluid

Units

CO2

0.03

12.0

vol%

H2O

1.05

14.6

vol%

0.05

vol%

kg/s kg/s

Composition :

SO2/SO3 Acid Dew Point

144

Allowable/Calculated min metal temperature

159

C

0

178

C

0

(-2) Temperature

Normal

In/Out

15.6

273

326

176

C

0

(APH O/L)

Pressure Drop allowable/calculated

Max

Fouling Coefficient

0.45 0.0001

Heat Transferred

0.85

kPa

0.0002

m2.0C/W

959

kW

No of es

4

Corrected MTD

93

C

0

Overall Heat Tr Coefficient

22.9

W/m2.0C

Calculated Surface

452

m2

Installed Surface

473

m2

The warm-up of the APEXTM should be performed in a slow manner to avoid temperature or pressure excursions beyond the constraints. Damage to the material is resulting.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 181




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The design of the APEXTM includes a 500C margin on the flue gases inlet temperature to cope for fouling of the convection tubes in the heater. It is expected that at start-up rather lower flue gas temperatures are present at the APEXTM flue gas inlet. However the flue gases outlet temperature should be maintained at 1750C. For this reason more combustion air should be routed to the by- duct to keep the metal temperature above the constraint value.

Two forced draft fans are installed for the supply of the combustion air. The fan design includes at 120% over design factor at a 120% heater design. It should be determined in practice, if at the specified normal heater conditions both fans and its inlet vane control will operate satisfactory.

6.3.3 FURNACE INSPECTION AND MECHANICAL CHECK

1. Before the heaters are started up the following general checks shall be performed. 2. Check and review free movement and clearance provisions for all parts subject to thermal expansion, heater tubing, piping, ducts, expansion ts, etc. 3. Check for interference between piping and ducting with structural or platforms. 4. Check that the refractory surfaces are in good condition and are correctly installed with expansion gaps. It should especially be checked that the expansion gaps between the firebricks in the floor are unobstructed. 5. Ensure that all debris has been removed from the heater floor, ducting, expansion ts, tube guides. Inspect the inside of flue gas collector and stack for any construction materials left there, on the finned coils or on the damper. 6. Check the burners to ensure that the gas spuds and oil guns are all correctly positioned and orientated and that no debris is left in the burner tips. 7. Check that the burner air dampers can be opened and shut properly and will move freely. Leave them in fully open position.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 182




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

8. Check that all bolts and nuts for the three(3) fans have been properly tightened and locked, and the coupling guards are in place. Confirm that impellers rotate freely. Check that the bearings with any bearing lubrication are all correctly installed. 9. Check for correct rotation direction for the fans. 10. Check that the forced draft fan inlet vanes are correctly fitted, with the opening direction leading into the impeller's rotation. Move the vanes to the minimum opening setting in order to see the position clearly.

11. Check all flue gas and air dampers for correct mechanical operation. Check that the shutoff plates/guillotines can move freely. 12. Ensure that all access doors and header housing doors are closed and bolted tightly, and all observation doors are closed. 13. Check the gas tightness of the unit under modest (10-15 mmH2O) positive pressure, with ID-Fan 14. and one FD-fan in operation. After overriding the high firebox pressure limit, start the fans with closed inlet-vanes.

Tighten, repair or renew bolts, seals, gaskets and bellows as

necessary. 15. Check soot blowers with their motor drives and turning mechanism. Check sequencing mechanism.

6.3.4 PREPARING FOR INITIAL COMMISSIONING

1. After pressure testing the process coils shall be flushed out and drained, followed by blowing out with air or inert gas to remove any water left and to ensure freedom from obstruction. 2. Ensure that all fuel gas, fuel oil, atomizing steam and pilot gas lines are cleaned. 3. All control valves on all fuel gas, fuel oil, atomizing steam and pilot gas lines shall be checked and operation verified. Check all automatic and manual firing controls. Ensure


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 183




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

that all by valves in these lines are closed, together with all fuel valves local to the burners. 4. Check and drain draft gauges. 5. Check the operation of all instruments, thermo-wells, pressure gauges, etc. associated with the process side. 6. Check the operation of temperature indicators associated with the flue gas and combustion air side. 7. Check the operation of the various analyzing instruments, particularly the oxygen and combustibles analyzers. These shall be fully calibrated prior to burner light-up. Their use during start-up is prerequisite.

It is also recommended to analyze the CO amount in the flue gas during the start-up period. Typically the sample point location below the convection section is used to take flue gas samples.

1. Check the correct operation of the induced draft fan draft control regulator. 2. Check all alarm and emergency/shut-down functions. 3. Check purging steam and steam tracing lines and valves and associated steam traps. 4. Check that all access and header housing doors are properly closed. 5. Check that the flue gases duct and air duct shut-off plates/guillotines are in the open position. For start-up it is recommended that only one FD-fan is taken into operation. The shut-off plate/guillotines at the other combustion air fan should be closed. 6. Check that portable combustible gas detection and/or other site safety equipment will be available for the start-up. 7. Check the operation of the portable gas igniter in a designated "safe area". 8. Check that fuel gas, fuel oil, atomizing steam and pilot gas will be available. 9. Check the availability of purging steam. 10. Check the availability of sufficient cooling medium for dry-out (or process feedstock at the required rate and temperature). All concerned equipment upstream/downstream of the heater should also be commissioned prior to start this procedure. The availability of the


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 184




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

cooling medium should be checked against the required process duty at the dry-out procedure. It is strongly advised to the process designer to review the proposed cooling method. Introduction of the fluid may commence at the appropriate time during dry-out procedure or at the start pending local conditions.

6.3.5 DRYING-OUT PROCEDURE

Before being put into service, the refractory lining of the heater, stack and flue gas ducting shall be thoroughly dried out to remove the free and the crystal bond water in the concretes, by slow evaporation. This operation should be scheduled in such a way that there is a minimum of delay between its completion and the initial start-up of the heater.

The dry-out procedure normally takes approximately four to five days, during which the firing rate should be slowly raised to produce a gradual temperature increase in the refractory.

This

curve should be followed in general, but should possibly be adapted to local conditions and the availability of the resources. The procedure described below should be used as a guide, which is based on experiences in the field.

It is mandatory to use sulfur-free fuels for the dry-out procedure. The procedure includes long periods of low temperature operation. Large quantities of water have to be removed from the system. Presence of SO2 in the flue gas should be minimized to avoid formation of H2SO4 at the cold regions in the heater and flue gas ducting. During dry-out the following temperatures shall be measured and recorded: a. The flue gas temperature at the air preheater outlet. b. The flue gas temperature at arch level. c. The flue gas temperature above the convection section. d. The flue gas temperature at the stack. e. The tube skin temperatures at the radiant tubes at APEXTM.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 185




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The burners should be operated with large excess of combustion air, compatible with good flame stability. This will ensure low flame temperatures so that no excessive heat rate is applied to either tubes or refractory.

The large flue gas quantity is necessary to carry away the water vapor

generated from the moisture that was necessary for the cements hydraulic setting. Later, at higher temperatures, sintering may take place. For even heat distribution the burners used shall be selected in symmetrical pattern. The flue gas and tubewall temperature readings listed above will give some indication of uneven temperature/heat release levels. Once commenced, the heating-up procedure should not be stopped or interrupted. In case of firing failure, etc., the lining must be kept warm by stopping the forced and induced draft fans or closing the burner air dampers and by ensuring that the stack damper is closed. When cooling down cannot be avoided, a re-start must be carried out in accordance with a heat-up rate as defined at dry-out start.

All preparation steps preceding the dry-out shall be performed in accordance with the start-up procedure (see section 5.3.6/A—Preparations and Venting)

The introduction of protective fluid in the tubes is required prior to proceed to higher temperature levels. It is very important to watch the tube skin thermocouples closely during the dry-out period. The material constraints of the installed tubes should not be superseded. Distortion and/or bending of the tubes may be resulting.

If cooling medium is present in the tubes, temperature at the arch can be raised at a rate not beyond 300C per hour. Monitor the air pre-heater performance and the functioning of damper in the by- air duct. Flue gas outlet temperatures should remain in the 175---1850C temperature range.

Raise the arch temperature till 650---7000C. All burners should be in operation. Keep the arch temperature at 7000C during 10 hours.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 186




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Check regularly the flame performance to assure an equal heat distribution to the tubes. if all burners receive equal amounts of air for proper combustion.

The excees air levels can be reduced to the design levels. The following table provides the data based on the design fuels.

Design excess air Fuel gas Fuel oil

10% 15%

O2 in flue gases %vol dry condition

%vol wet condition

2.1 - 2.3 2.9 - 3.2

1.7 - 2.0 2.5 - 2.8

The O2 analyzer should be monitored to achieve above values. Reduction of excess air levels should be performed at small steps and sufficient large settling times. The performance of the flames should be monitored closely to keep all flames in the same shape. If a CO analyzer is available, it is advised to check the CO content of the flue gas to assure each burner has full combustion conditions.

The dry-out heating procedure is completed after the firing at the 7000C level.

Should start-up not immediately follow the above sequences, reduce the burner heat release to allow the furnace to cool down to ambient temperature at a rate not exceeding 500C per hour. During the next start-up of the heater the temperature can be raised with 300C per hour to the operating temperature. Once the temperature has been at operating level for 72 hours, the heater is fully dried out. For subsequent restarts a temperature increase of 500C per hour can be used.

The cooling fluid flow through the coil can be cut when the flue gas temperature at the arch is cooled below 3000C. On reaching ambient temperature after dry out, it is recommended to inspect the refractory. Ensure that the heater is appropriately ventilated before entering.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Confirm the absence of

Vol-I (Addendum)

Page 187

. Indian Oil Gujarat Refinery combustible gases.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Carry out all procedures required by the Plant Operating Practices and

applicable safety regulations.

A network of small cracks may appear in the castable. Only cracks exceeding 6 mm or brokenoff parts need to be repaired, in accordance with ABB Lummus Heat Transfer B. V. approved repair procedure.

Usually it is necessary to circulate protective, cooling fluid through each coil during the later stages of the procedure to prevent overheating. This fluid may be inert gas (e.g. nitrogen), a hydrocarbon or steam, if not prohibited for plant safety reasons.

The initial dry-out by means of air can be performed by testing the installed fans for a couple of hours.

The dry-out procedure is preferably started at forced draft operation. The ID-fan and APH are not in operation in that case. The combustion air is routed via the air pre-heater by- duct to the burners. The stack damper is fully open until the draft in the heater is established at the negative pressure of 3 - 5 mmH2O at arch level. In the initial phase of the dry large quantities of water vapor are removed from the radiant and convection section. Because the flue gas ducting to/from the air pre-heater is still below the water dew point, condensation may take place in these ducting in case of balanced draft operation. At forced draft operation the water vapor is directly disposed via the stack to atmosphere.

Light the pilot flames in accordance with section 5.3.6/B—Start-Up Of Pilot Burners.

When all pilot flames are on, ignite one of the main burners initially on an approximate 30% heat release level (in accordance with section 5.3.6/C—Igniting The Main Burners On Fuel Gas). If the flame is established, slowly decrease the firing rate to minimum liberation at high excess air rate.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 188




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Raise the furnace flue gas temperature at arch level gradually, at a rate not exceeding 200C per hour till 110-1200C. Keep the arch temperature at 110-1200C during 16 hours.

It is recommended that the burners should be fired in rotation (symmetrically) during the dryout cycle. In this way every burner can be commissioned and each part of the heater will be exposed equally.

After this first holding time and after all signs of vaporization have disappeared, arch temperature can be raised at a rate not exceeding 200C per hour to achieve a convection outlet temperature of 1200C. Preferably more burners are taken into operation at low firing rate instead of firing one burner at higher firing rate. Keep this arch temperature level for 6 hours. At this point the forced draft operation can be switched over to balanced draft operation according the instructions in section 4.3.6/D--Switch From Forced Draft Operation To Balanced Draft.

Raise the arch temperature at a rate not exceeding 200C per hour to achieve an air pre-heater outlet temperature of 1200C. Keep this arch temperature level during 6 hours.

Raise the flue gas temperature in the arch to about 300-3500C at a rate not exceeding 200C per hour. Operate as many burners as possible to achieve equal heat distribution. Monitor the air preheater flue gas outlet temperature. If this temperature arrives in the range of 175-1850C then the damper in the air by- duct should be commissioned to control this temperature. Monitor the installed skin thermocouples closely Keep the arch temperature at 3000C during 12 hours.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 189




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Examine tubes, tube s, hearth and refractories for any interference with free thermal expansion movements and remove any restrictions found.

After completion of the dry-out procedure, it is preferable to maintain the firebox temperature over dew point (at approximately 650C) if the start-up is anticipated in the near future. Firing of one or more burner pilots can be applied for this reason.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 190




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.3.6 START-UP

The following precautions are intended as an overall guide to proper operation, augmenting the Plant's procedures.

A. Preparations And Venting 1. Firing rates should be kept under manual control during start-up, as the control system may be subject to severe cycling during this period. 2. Check that pilot gas, fuel gas, fuel oil and atomizing steam are available at the required pressures. 3. Check the fuel oil temperature in the vicinity of the burners (fuel oil circulation is operating). Check if steam tracing is properly functioning. Check the fuel oil viscosity by taking a sample and perform a laboratory analysis. Viscosity should be below 20 at operating temperature. 4. Check that no vent and waste gases can flow into the furnaces. 5. Open the pilot gas main valve and check the pilot gas pressure. If the fuel gas system is filled with nitrogen, purge the lines to a safe location until fuel gas is present up to the valve. 6. Open the fuel gas main valve and check the fuel gas pressure. If the fuel gas system is filled with nitrogen, purge the lines to a safe location until fuel gas is present up to the valve. 7. Check the pilot gas/fuel gas piping for leaks before proceeding. If leaks are detected, all fuel gas valves should be shut off and the leaks fixed before lighting the burners. 8. Open the damper in the air pre-heater air by. 9. Close the flue gas by damper in the stack. 10. Check that the air dampers of the burners for settings. 11. Open the guillotines in the flue gas duct at the stack and in the combustion air duct at the air pre-heater (see 5.3.2--Operating Conditions to Operation of the guillotines should be performed). if the concrete bars are placed in the guillotine slot to prevent air leakage. 12. Start the induced draft fan with closed inlet vanes.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 191




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

13. Start one of the forced draft fans with closed inlet vanes. Override the high combustion chamber pressure limit. Close the shut-off valve/guillotine of the other fan to avoid air recycling. 14. Adjust the air flow to approximately 50% of the design air flow by opening the inlet vanes and purge the furnace and air pre-heater with air. 15. Switch the arch pressure control acting on the inlet vanes of the ID-fan from manual to automatic. Close the flue gas damper gradually. the adjustments to the inlet vanes on basis of the required arch pressure. Monitor the power consumption of the fan to avoid a trip due to maximum power constraint (cold air). 16. Keep the fans running for 20 minutes or longer. 17. During the fan commissioning all draft gauges at the heater and air pre-heater requires verification on proper functioning. 18. Check and confirm with an explosion meter for absence of combustibles in the furnace. Carry out all procedures required by the Plant Operating Practices.

Warning : If the heater is not sufficiently purged, an explosion may result causing serious damage to equipment and possible loss of life.

For forced draft start-up open stack damper. Slop the ID-fan. Close the guillotines in the flue gas duct at the stack and combustion air duct at the APEXTM (see 5.3.2--Operating Conditions--Operation of the guillotines should be performed). Open the air by- damper.

B. Start-Up Of Pilot Burners

1. Balance the draft level (negative pressure) at the arch at approximately 5 to 7.5 mmH2O, by adjusting the inlet vanes of the induced draft fan (balanced draft start-up) or open stack damper fully (forced draft start-up).


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 192




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

2. Once the combustion chamber pressure has been stabilized, the draft control and high pressure alarm systems shall be re-instated. 3. Insert the portable igniter using the designated opening at the bottom of the burner wind box. if the air supply to the pilot as per requirement. 4. Open local pilot gas valve at the burner, ignite the pilot. flame visually through burner sight door. 5. Light pilots of all burners one by one. All pilots should be in operation period to start main flames.

6. Adjust pilot gas back pressure and/or air inlet opening to the pilot to improve flame, if necessary. 7. In case of restart of the main burners, furnace purging is only required when all pilots have been extinguished. Before restart confirm that all pilots are still burning. 8. Consideration may be given to introduce the process flow (on turn-down) before igniting the main burners. Alternatively this step can be delayed until furnace and tube metal temperatures are comparable to the incoming feedstock temperature.

C. Igniting The Main Burners On Fuel Gas

1. Set the fuel pressure controller for about 40% liberation rate (see burner performance curves for fuel gas pressure) 2. If fuel oil firing is not foreseen shortly after start-up with fuel gas, then a small, steam flow should be routed through the oil gun of all burners for cooling purposes. Alternatively the oil gun may be retracted from the burners. 3. the combustion air pressure upstream the burner does not exceed 50 mmH2O. 4. Open local valve fully. Should the burner not ignite within 3 seconds, close valve. Allow at least one minute before another attempt.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 193




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

5. Keep the need for even heat distribution in mind whilst proceeding to light multiple burners in the burner circle. Once all burners are lighted and conditions stabilized, the heat release rate/fuel gas pressure may be increased. 6. if the arch pressure control acts on the inlet vanes of the ID-fan, when the flue gas temperature to the ID-fan increases. The arch draft level should be maintained at between 3 to 8 mmH2O during the firing rate increase. 7. Do not operate the burners below the minimum firing rate shown in the burner data sheets. If the heater needs to be operated below the specified minimum firing for all burners (i.e. dry-out or high turndown), then some of the burners should be shut off. The remaining burners can be operated at or above the minimum firing rate.

The maximum flue gas temperature increase at the arch should not exceed 300C per hour during the initial start-up (see Dry-Out Procedure). For subsequent start-ups after 72 hours of normal heater operation (fully dry-out condition) 500C per hour flue gas temperature increase can be used. For dry-out, and for start-ups after major refractory repairs, follow the temperature increase rate in the Dry-Out Procedure. During the heating up period the process outlet temperature increase should not exceed 300C per hour.

With all burners in operation, the combustion air quantity/flue gas oxygen level should be controlled to between 4 to 6% for the start-up period. Observe the CO reading which should be negligible at 10 to 80 ppm.

Warning : Never move the burner dampers, increase the combustion air flow, or shut off a burner when the firebox is short of air; an explosion may result. Decrease the fuel rate in steps not to exceed 10%, allowing the oxygen level in the firebox to stabilize between each step, until the required excess air level is achieved.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 194




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

All changes in the heat release of the burners should be preceded by a firebox oxygen check. When increasing the heat release of the burners, the excess oxygen level must be increased before increasing the fuel rate. When decreasing the heat release of the burners, the fuel rate must be decreased before decreasing the excess oxygen level.

Observe the flue gas temperature level leaving the air pre-heater. When this temperature has reached 1850C, the air by damper should be closed gradually, in small steps, in order to keep this temperature around 175--1850C.

Once the heater has reached a constant load level, set the arch pressure to approximately 3.0 mmH2O and the oxygen level in the flue gas to the design conditions (see point 6.28) by adjusting the combustion air flow. Check the unburned combustibles (CO) reading which should remain negligible at between 10-80 ppm. Prolonged higher CO reading, at 100-200 ppm with the above oxygen level would indicate to air mal-distribution, with one or more burners not receiving sufficient combustion air. By observing the flames, the affected burner can usually be singled out through its longer visible (possibly even smoky) flame. Check the burner damper settings of the burner. In case CO readings are still beyond acceptable levels, increase the total air quantity to give 0.5 to 1.0% higher flue gas oxygen reading. (see also 5.3.2—Operating Conditions---The burners are low-NOx type by means of staged air supply)

At this stage the furnace firing control can be switched over to automatic.

Warning : If the burners are operated without a sufficient air supply, a build-up of gas may occur resulting in an explosion. Care should be taken to assure more than sufficient air for combustion is flowing through each burner at all times and to allow the same flow of combustion air to each burner in operation.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 195




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

D. Igniting The Main Burner On Oil Firing

1. Open steam tracing valves and allow piping to warm up. Start fuel oil circulation and monitor local oil temperature level in the return line. This should gradually rise to approximately 1700C to obtain an oil viscosity of 20 or less. In case the oil type is more heavy then a higher temperature should be used to achieve proper firing performance. 2. Open both burner atomizer steam and steam purge lines for one burner to warm up the oil gun and to clean the internals. 3. Repeat this operation for each burner. that all parts of the supply lines are free of condensate. Check steam traps accordingly. 4. If the selected oil gun is at operating temperature (above 1700C) and the atomizing steam is dry then the purge by- valve can be closed. 5. Set the fuel pressure control valve at an approximately 40% heat release setting (see burner performance curve for the related pressure). 6. Set the steam/oil ratio differential controller at the burner between 1.75 to 2.0 bar. 7. the combustion air pressure upstream the burner does not exceed 50 mm H2O. 8. Gradually open the local oil hand valve at the burner fully. Ignition should follow. Check the flame visually. Adjust parameters to achieve proper combustion. 9. Repeat points of 5.3.6/D--Igniting The Main Burner On Oil Firing for ignition of the remaining burners. Monitor flue gas temperature at arch and process outlet temperature for maximum temperature rise. 10. If ignition still fails within 3 seconds, close hand valve. Open the purge valve to clean the oil gun immediately. Check the cause of the ignition failure. Below a few checkpoints are listed. a. Oil is at too low temperature. Check oil re-circulation rate, steam tracing and steam traps. b. Perform laboratory analysis on oil viscosity on the fuel oil to be fired.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 196




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

c. Atomizing steam is wet. Check steam traps. Blow steam through oil gun for a couple of minutes toheat the oil gun. d. Plugged steam or oil line. presence of flow at flow meters. e. Plugged oil ports or atomizer at oil gun. Retract oil gun. In case of combination firing it is preferably to fire only a selected number of burners in a symmetrical pattern. The remaining burners are fired on gas only. The advantage is to have the oil firing at a higher liberation level relative to the oil firing turndown level. Firing at turndown level requires close monitoring and higher excess air rates. This is not advised for continuous operation. The remaining oil guns need a small flow of atomizing steam for cooling.

Follow points of 5.3.6/C--Igniting The Main Burner On Fuel Gas (from Keep the need to -to the end of the section) for the general notes on firing main burners.

E. Switch From Forced Draft Operation To Balanced Draft

This operation is intended for start-up conditions or non-scheduled wash operations of the APEXTM. The fuel to the heater should be switched to a sulfur free fuel to avoid acid dew point problems as result of the warm-up of the equipment.

Open all guillotines in the flue gases duct at the stack and combustion air duct (see 5.3.2-Operating Conditions---Operation of the guillotines should be performed…). The damper in the by- duct should remain fully open.

Switch arch pressure control and air by- damper control to manual operation.

This

implicates that the inlet vanes of the ID-fan and the stack damper can be operated independently. The arch pressure should be monitored carefully to keep a negative pressure. Alternatively the high pressure alarm of the firebox can be switched to alarm indication only. (no trip action)

Open the stack damper fully to achieve maximum draft.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 197




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Start ID-fan with closed inlet vanes. Switch arch pressure control to act on ID fan inlet vane control. Reinstate automatic control. Monitor vane position and control action will push vanes to its closed position.

Close stack damper gradually. ID-fan inlet vanes opening when arch pressure exceeds its set point value. Allow smoothly opening of ID-fan inlet vanes when dampers approach fully closure position. Monitor the power consumption of the ID-fan and/or APH warm-up rate.

The APEXTM flue gases outlet temperature should be monitored to keep the warm-up rate at

approximately 80 - 100OC /hr. The damper in the by- duct controls the amount of air

through the air pre-heater. Pending the temperature of the flue gas to the APEXTM (either start-up or normal operation) more combustion air through the air pre-heater is required to control the warm-up.

When sulfur containing fuels are fired during the start-up of the APEXTM, then the warm-up should be performed as quickly as possible to minimize acid formation. However higher warm-up rates as indicated above are not advised because of possible material deformation in the APEXTM.

When the flue gases outlet temperature has reached 175OC, then damper control of the by- can be reinstated. stack damper is closed fully. Normal operation conditions can be implemented (see section 5.3.7-- Normal Operation)

F. Switch from balanced draft operation to forced draft

This operation is intended for maintenance of ID-fan or non-scheduled wash operations of the APEXTM.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 198




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Switch arch pressure control to manual. This implicates that the inlet vanes of the ID-fan and the stack damper can be operated independently. The arch pressure should be monitored carefully to keep a negative pressure. Alternatively the high pressure alarm of the firebox can be switched to alarm indication only. (no trip action)

Open inlet vanes position of the ID-fan slightly. Monitor the arch pressure. Switch arch pressure control to dampers and reinstate automatic control. Dampers are still closed. ID-fan is on manual control. control action will try to push dampers to closed position, because of the slightly higher arch pressure caused by the adjustment of the inlet vanes.

Close the inlet vanes of the ID-fan gradually. opening of stack damper if arch pressure control set point value is exceeded.

Stop the ID-fan. air pre-heater flue gases outlet temperature control will push the air by damper to fully open position. Switch control to manual and keep by- damper in fully open position.

Close the guillotines in the flue gas duct at the stack. Close the guillotines in the combustion air duct at the APEXTM (see section 5.3.2--Operating Conditions---Operation of the guillotines should be performe,)

Never cool down the APEXTM using a FORCED DRAFT FAN. Open the access doors at the duct and air pre-heater when temperature is below 100OC. Apply all safety regulations before inspection of internals.

6.3.7 NORMAL OPERATION


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 199




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The following conditions must be checked at least once per shift when a continuous troublefree operation is performed. More regular checks are required in case of varying conditions at process side (feed change-over) or the fuel type is switched.

Confirm that the flame shapes are reasonably uniform.

Check that the negative pressure below the convection section is about 3.0 mmH2O gauge. Check that the oxygen content of the flue gas remains in the range as given below.

Design excess air Fuel gas Fuel oil

10% 15%

O2 in flue gas %vol dry condition

%vol wet condition

2.1 - 2.3 2.9 - 3.2

1.7 - 2.0 2.5 - 2.8

The O2 analyzer should be monitored to achieve above values. Reduction of excess air levels should be performed at small steps and sufficient large settling times. The performance of the flames should be monitored closely to keep all flames in the same shape. If a CO analyzer is available, it is advised to check the CO content of the flue gas to assure each burner has full combustion conditions. In case of combination firing at part of the burners the highest O 2 content should be followed to avoid shortage of air at the oil firing burners.

If burners are out o service for maintenance/malfunction reasons it is advised to close the burner air dampers of the specific burner. Check the air supply to the other burners to equal distribution.

The warm-up of the APEXTM should be performed in a slow manner to avoid

temperature or pressure excursions beyond the constraints. It is strongly recommended to keep the maximum practicable number of burners operating, to provide even heat distribution for the tubes.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 200




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Check regularly the CO content of the flue gases. Should the reading exceed 100 ppm, check if all air damper of the burners in operation.

If the CO content is still high, it is advised to raise the excess air level in the heater. Increase the combustion air flow (inlet vanes at fan) in small steps (+0.3% oxygen at a time), if all burner air dampers are set identically. In case of oil firing, check the atomizing steam/fuel oil differential pressure. The process turndown of the heater is limited to 77000 kg/hr. It is strongly recommended to avoid excursions below this value. It is expected that the coke formation in the process tubes is accelerated due to the resulting low mass velocity. The heater has a two arrangement. Regular checks on the flow per and process outlet temperature and skin thermocouple readings should indicate the fouling conditions of the tubes in the heater. Monitor and document the skin thermocouples readings. Due to fouling in the tubes it is expected that the metal temperatures will increase. The applied P5 material has a limitation of 650OC.

It is advised to decoke the tubes, when following conditions are present.

The skin

thermocouples have reached a 635OC level at part of the tubes and the pressure drop over the coil(s) has increased significantly. A 150C margin is included for measurement inaccuracy of the skin thermocouples.

The flue gases leaving the air pre-heater should be maintained at 175OC or slightly above, when firing sulfur containing fuels. Regular flue gas sampling at air pre-heater outlet should point out the actual SOx in the flue gas for the present type of fuel firing. Monitor the skin-thermocouples closely for the minimum metal temperature

The soot-blowers at the convection section should be operated periodically to remove the soot and other deposits from the coils. The flue gas outlet temperature at the convection collector will rise as result of the fouling. Operational experience and type of fuel should determine a suitable time interval for cleaning. A convection section outlet temperature increase of 10--15OC or an once


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 201




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

per shift cleaning when oil firing is applied, are regularly applied methods to abate the fouling phenomenon.

It is advised to perform regular checks on the formation of acid in the air pre-heater during the first year of the unit operation, when operational experience is built up. This phenomenon is to be monitored closely. Steady operation of the unit is critical for the expected lifetime of the applied materials. A few temperature or pressure excursions beyond its material constraints may damage the unit to that extent as would have been during a long period of normal operation.

The APEXTM can be cleaned on-line if the heater operations is shifted from balanced draft to forced draft (see sections 5.3.6/E and 5.3.6/F). The stack damper should be used for arch pressure control and the air by- duct for air supply to the burners. If this operation modification is applied, then the guillotines at both air side and flue gas side should be closed to isolate the air preheater.

(see section 5.3.2--Operating Conditions---Operation of the guillotines should be

performed…,). It is advised to inspect the air pre-heater first after cool-down to record the degree of fouling. The top part of the APEXTM can be cleaned with warm water sprayed by hose under slightly pressurized conditions, the bottom block can be cleaned by the installed spray system. The drain in the hopper should be opened before the start of the washing operation. The waste water should be drained to safe location. The water may require neutralization due to the removal of possible acid droplets at the APEXTM internals.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 202




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.3.8 SHUTDOWN

The transfer-line of the 410-F-03 heater is connected to the transfer-lines of heaters F-01 and F02. Idea of shutdown procedures considering the combination of these three heaters can be obtained from earlier chapters/sections.

1. All firing controls should be returned to manual operation. 2. Reduce the feed rate to the turndown conditions. 3. Reduce the firing rate gradually, to lower the arch level flue gas temperature at a rate not exceeding 1000C per hour. 4. The heater outlet temperatures shall be allowed to drop at a maximum rate of 3000C per hour. 5. Shut down burners one by one at suitable intervals to achieve above. 6. Lower the combustion air temperature by gradually opening the by- damper. The flue gas air pre-heater outlet temperature may rise to 200OC. 7. Maintain arch draft level between 3 to 8 mm H2O by regulating the induced draft fan inlet vanes and or the stack (flue gases) damper, during the air supply reduction of the forced draft fan. 8. When the flue gases temperature in the arch drops below 300OC, the process feed circulation may be stopped. 9. Purge the coils with sufficient quantities of steam or inert gas for removal of hydrocarbons. 10. Once all main burners are off, close the pilot gas valves. 11. Switch off the Induced Draft Fan, open the stack damper. Continue running one (1) Forced Draft Fan with minimum inlet vane setting. When the temperature of the flue gases leaving the furnace drops below 200OC, the forced draft fan may be stopped. Open stack damper and access doors to ventilate the heater.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 203




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.3.9 EMERGENCY SHUTDOWN OF F-03

The transfer-line of the 410-F-03 heater is connected to the F-01 transfer-line and the F-02 transfer-line. Idea of shutdown procedures considering the combination of these three heaters can be obtained from earlier chapters/sections.

The general procedure given below covers most emergencies but it is impracticable to attempt to cover all combinations and process conditions in these instructions. In all emergencies action should be taken to make the unit safe as quickly as possible.

FURNACE FEED FAILURE :

All main burners should be shut down automatically. If the feed

cannot be restarted within five (5) minutes, the coils must be flushed out with steam to reduce the risk of coke formation in the tubes. The steam or inert gas flow may be stopped when the flue gas temperature at the arch is below 4000C. However flow may possibly be continued to prevent backflow from transfer-line.

GENERAL ELECTRICAL POWER FAILURE :

The heater should shut down immediately (see

Furnace Feed Failure).

GENERAL INSTRUMENT AIR FAILURE : The heater should shut down immediately (see Furnace Feed Failure). FUEL GAS FAILURE : If the fuel gas pressure cannot be maintained, the gas supply should be cut off. All local fuel valves are to be closed.

FUEL OIL FAILURE : If the fuel oil pressure/temperature cannot be maintained, the oil supply should be cut off. All local fuel oil valves are to be closed. Open steam purge valves to clean the oil guns immediately. If sufficiently cleaned, then close the purge valves such to allow a minimum flow through the oil gun. Alternatively the oil gun can be retracted. In case and pilot gas and fuel


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 204




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

gas are still available, then the heater operation can continue on fuel gas only. If not, then heater will be shut down.

ATOMIZING STEAM FAILURE : The fuel oil will be cut off. All local fuel oil/atomizing steam valves are to be closed. The oil guns should be retracted for cleaning immediately. In case and pilot gas and fuel gas are still available, then the heater operation can continue on fuel gas only. If not, then heater will be shut down. FURNACE TUBE FAILURE : For a minor tube leak, a quick controlled shutdown should be carried out. Fires shall not be cut immediately, but should be reduced to a minimum. Process feed flow rate should be reduced to approximately 50%. The feed to the effected coil should be replaced by steam flow to prevent coke formation. A normal shutdown procedure should be continued.

FURNACE TUBE FAILURE : For a major leak or in the extreme case a tube burst, both process feed flow and firing shall be stopped immediately. Smothering steam must be introduced into the firebox by means of the purge/snuffing steam connections. The flushing (steaming out) of the coils shall be delayed, as it may increase the flow of hydrocarbons from the leak into the firebox.

HIGH FURNACE ARCH PRESSURE : If the pressure in the firebox is positive, the main burners should be shut down (see normal shutdown). In order to avoid nuisance trips it is advised to implement a time delay of approximately ten up to 30 (10-30) seconds in order to compensate for pressure fluctuations.

If practicable, try to avoid rapidly cooling down the furnace. 200OC per hour is the normal limit for temperature reduction. Further actions will depend on the specific situation.

6.3.10 DECOKING INSTRUCTIONS


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 205




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Hereafter guidelines are given for a typical decoking procedure. These should be treated as guide line only and may be adapted to local regulations and operational experiences.

The design includes two plug type headers at the last tubes in the radiant section. For these tubes a mechanical turbining is possible for a more rigorous cleaning of the coke at the tube inner surface.

A spalling stage is possible, but should be executed under close monitoring. Excessive spalling may cause plugging in the tubes. Cutting of the tubes is then required.

It is advised to decoke the two es separately (in sequence) to permit close monitoring of the decoking process in one . The other requires a cooling medium during the decoking.

6.3.11 INTERLOCK SYSTEM

1.

During operation at maximum load both the FD fans will run at 50% process load. In the event of tripping of one of the fans, as sensed by a) Low current flow to any FD fan Working fan will attain full process load and the suction damper of tripped fan will close automatically.

2.

FO SUPPLY & RETURN / FG CUT-OFF

Any of the following condition will cut off FO /FG . a) Low feed flow in the furnace coil . b) High furnace coil outlet temperature (transfer line temperature). c) Low air duct pressure .


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 206




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

d) Low FG pressure . e) Low FO pressure . FOSUPPLY & RETURN / FG CUT-OFF

3 . In the event of failure of ID fan as sensed by : a) Low current flow to ID fan . b) High suction pressure to ID. Stack damper will open automatically . If the stack damper fails to open within 30 seconds fuel oil and fuel gas to the furnace should cut off followed by tripping of FD fans .

4.

In the event of fuel cut off to furnace following actions to take place sequentially : a) Stack damper will open . b) ID fan will trip . c) FD fan will trip .

5.

In case of high furnace pressure , stack damper should open .If the stack damper fails to open within 30 seconds fuel to furnace should cut off followed by tripping of ID fan .

Note: ID fan should be started with inlet vanes in closed condition..

6.

In the event of very high temperature at ID fan suction , stack damper will open automatically and ID fan will trip after stack damper is open . If stack damper fails to open within 30 seconds fuel to the furnace should cut off followed by FD fans tripping

7.

In the event of failure of both FD fans as sensed by : a) Low current of both FD fans .

Fuel to furnace should cut off followed by stack damper opening and ID fan tripping . 8 . During turn down operation only one FD fan will operate . At such situation , failure of working fan as sensed by low current flow , standby fan shall start automatically , suction


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 207




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

damper of the tripped fan close and that of standby fan will open simultaneously. If stand-by fan does not start within 30 secs., it will trip furnace . 9.

Each interlock is having individual by option with lamp indication available at main control room .

10. Prior to trip value, alarm will be generated on DCS for all the cases . 11. Automatic damper opening and closing can be done from main control room . 12. All solenoid valves (other than stack damper ) are having reset facilities available at main control room . 13. Parameters actuating interlock .are having indication at DCS available at main control room . 14. Common emergency push button are provided at main control at control room for all trips and stack damper opening even if the interlocks are in by- mode. In addition, local emergency push button is provided 15 meter away from furnace inside a break glass enclosure.

6.3.12 F-03 SOOT-BLOWING

Six no. of soot blowers of retractable type are provided in F3.

A. PRECHECKS BEFORE THE SOOT BLOWER OPERATION (Local/Remote Manual/Auto Sequence) 1.

Switch on the MAIN POWER SUPPLY.

2.

Ensure that the RYB lights of 3 phase supply are available.

3.

If one of the lights is not glowing ensure the supply through the VOLTAGE SELECTOR switch RY, YB, BR. The voltage should be between 390 to 450 volts.

4. Switch on the PLC power supply in the PLC module. 5. Open the MAIN VALVE. When you press the button (green) the VALVE OPEN indicator will glow after 10 to 11 seconds.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 208




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6. Ensure COUNTER in ZERO position, all blowers in ‘HOME’ position, 230V supply available and glowing and FAULT LAMP is not glowing. 7. If the FAULT LAMP is glowing, reset it through the ‘RESET’ push button. FAULT LAMP should go off. 8. Put all the soot-blowers (or the soot-blowers of your preference) in “ON” position.

B. LOCAL OPERATION PROCEDURE

1

Put the SEQUENCE SELECT switch in ‘Not Select’ (NSEL) position.

2

Select the LOCAL/REMOTE switch to local. “LOCAL SELECTED LAMP” should glow.

3

Before going up near the blower ensure by resetting (FAULT LAMP is not glowing)

4

Switch on the individual blowers of interest module . Go near the soot blower that is to be operated.

5

Press the START

push button (green) in the blower of interest. The blower will go inside

furnace and retract automatically to HOME after full insertion. 6

By any chance if you want to retract, press the RED push button (retract), the blower will be retracting instantly & will reach HOME position.

C. REMOTE MANUAL OPERATION

Points 1 to 8 of section A. should be complied with 1

Put the REMOTE /LOCAL switch to “REMOTE” position. REMOTE SELECTED lamp will glow

2

Put the Sequence Selector switch to NSEL (not selected)

3

Check the fault indication lamp. It should not glow. If it is glowing press the RESET

push

button, it will go off.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 209




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

4

Power supply of the blower which is of interest and to be operated, should be on.

5

BY/AUTO/ MANUAL switch is to be in “AUTO” position.

6

Give a pulse to above switch clockwise i.e. towards the MANUAL side, the blower will start insertion showing the particular RED lamp glowing. The switch will automatically return to AUTO position through spring mechanism. After full insertion the blower will be retracting automatically to the HOME position switching off the particular blower’s indication.

7

By any

chance if you want to pull out the blower in the

“EMERGENCY RETRACT” push button is to be pressed.

middle of insertion

The blower will retract instantly

and the alarm bell will go on. Cancel the alarm by pressing “ALARM ACCEPT” push button. 8

Press the RESET push button after the blower reaches HOME position( the red lamp will go off).

C. AUTO SEQUENCE OPERATION

Points 1 to 8 of section A. should be complied with 1

Put the REMOTE / LOCAL switch to “REMOTE” position. REMOTE SELECTED lamp will glow.

2.

Put the SEQUENCE SELECTOR switch to ‘SEL’ (sequence selected).

3. Check the fault indication lamp. It should not glow. If it is glowing press the RESET push button, it will go off. 4. Power supply of the blowers which are of interest and to be operated should be on. 5. If you wish to by any of the blowers, you should do it by operating AUTO / MANUAL / BY switch to the BY position. Even though byed, the respective blower’s power supply should be on. 6. Press the SEQUENCE START push button.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 210




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

7. If more than one blower in sequence is byed, the SEQUENCE INTERRUPTED lamp will be glowing after 1 minute . Reset the push button.

The next blower which is ready (

not byed) will insert and automatically retract and will proceed to the next one, if any. 8. If

soot-blowing in all six blowers are over then the

“SOOT BLOWER SEQUENCE

COMPLETED” lamp will flash and the bell will go on. Alarm accept and reset push buttons are to be pressed. 9. In “AUTO SEQUENCE”

mode also you can retract,

if

there is any problem ,

by

pressing the EMERGENCY retract push button. 10. It is to be noted that the complete reset will be effective only after the completion of blowers that are selected for auto operation.

After Completion of Soot Blowing The Following Should Be Ensured 1

Switch off the individual blower’s power supply.

2

Close the MAIN VALVE and positively ensure through the ‘VALVE CLOSED’ indication.

3

Switch off the MAIN POWER SUPPLY.

Note :

The individual yellow lamps in the respective blowers and valves are for motor over-load

which are hooked up to FAULT INDICATION lamp at the PLC module. It should be reset with a delay of 1 minute, if the FAULT INDICATION LAMP in PLC is due to ‘yellow lamps’( motor overload). By The PLC During during Any Failure Of PLC To Operate Locally

Bying the PLC is not recommended. In case of emergency, points given under may be followed (with full responsibility of IOCL) . 1. Please check the voltage “R” phase (control voltage) at terminal 3 of that particular sootblower. 2. If it is available after extending the line (“R” phase) by shorting the 3&5 (blower1), 8&10 (blower 2 ),13&15 (blower 3 ), 18&20 (blower 4), 23&25 (blower 5), 28&30 (blower 6), at JB-2, terminal 5 of that

particular soot-blower should get phase extension and “CF”(Forward


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 211



) should pick up. If not,


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

put a link between 4&5 of individual soot blowers. Now

the blower can be operated locally. If the “R” phase is not available at terminal 3, put a link between 1&19 of that particular blower.

Cautions : 1.

Terminal 3 connection from PLC T-3 to TB-3 of soot-blower-1 should be isolated before carrying out point-3 of above.

2. Main steam valve should be opened to ensure the steam flow during blowing.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 212




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER-7 TASKS TO BE PERFORMED BY OPERATORS 7.1 Pump Operator Pump Operation : Check healthiness of running pump like the following: Sl.No

Chapter 3 Action

Observation

1. a

Low LO level on oil cup . LO color / contaminated with water / product

2. b

LO leak from cup / bearing housing

3. c

Vibration / high bearing temperature

4. d

Suction/discharge PGs not functioning

5. e

Suction pressure low& pump load not increasing

6. f

Bearing CW flow low

7. g

High amperage of pump

8. h

Uneven amperage of pumps running in parallel

9. i 10. j

Seal flush cooler of hot pump leaking / CW line chocked Seal flush cooler-spherule leak

11. k

Leakage from pump gland / seal

12. l

Heavy leakage from pump gland / seal

13. m 14. n

Seal quenching steam for hot pump is low / high Leak from suction and discharge flanges / valve gland etc

Make up & ensure oil level in bearing. Drain & replace it. Inform S/I or maintenance Inform PNE for attending the same by maintenance Inform S/I. If abnormally high, C/O the pump & inform S/I. Inform PNE for attending it by maintenance C/O pump, after informing to PNE/ Operator. Inform PNE for attending it by maintenance Throttle discharge after consulting operator Adjust load by adjusting discharge valve Inform PNE for attending it by maintenance  If leak is more, immediately C/O the pump  If leak is less, report to PNE for attending it. Inform PNE for attending it by maintenance. Keep steam lancer if required Immediately C/O the pump & isolate the leaky one. Inform Opetator & S/I , take the help of others. Adjust the quenching steam flow rate Keep steam lancer & inform PNE for attending it by maintenance


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 213

. Indian Oil Gujarat Refinery 15. o 16. p 17. q 18. r 19. s 20. t 21. u 22. v 23. w

24. x 25. y 26.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Coupling guard is not properly fixed

Inform PNE for attending it by maintenance Abnormal sound from pump/motor Inform S/I for attending it by maintenance Poor illumination in pump house Inform PNE for attending it by maintenance Earthing of motor is not proper Inform PNE for attending it by maintenance Seal quenching steam b/v gland leak Inform PNE for attending it by maintenance Unit Start up/Shut down As per procedure, laid down in the operating manual Emergency Handling As per procedure, laid down in the operating manual LPG pump seal pot level low Inform PNE for suspected seal leak Check readiness of stand by pump in respect to proper line up (In case multi-service pump), Proper warm up, shaft rotation, bearing CW flow, lube oil quality and seal quenching steam flow is normal. Schedule change over of pumps as specified. Release of Pumps/Motors to maintenance following standard procedure. Collection of routine & non – routing samples.

27.

Checking of run down products samples as per schedule in normal operation and also during unit start up and shut down.

28. 29.

Checking of any hydrocarbon leaks in the plant. Off-site tank farm area jobs such as :  Receiving hot oil in Tk.No.212/213 ex. AU-3/FPU-II Unit and continuous supply to Udex for furnace Operation.  Receiving slops ex AU-3 as and when required in Tk.No.214 and tank preparation and processing in AU-3 Unit.  Operation of Raffinate ( FGH feed tanks) tanks 209/210/211 as per standard operation. Release of tanks to M&I as and when required as per normal procedure Logging of abnormalities and filling of pump house log book

30. 31.

During energisation and de-energisation of motor, motor to be checked by switching ON along with S/S technician and subsequently TAGGING to be done

32.

While getting pump strainers and seal flush coolers cleaned, complete isolation and depressurization to ensured, and operator not to leave work place till


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 214




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

completion of job 33.

Other jobs as and when asked by Shift In charge.

7.2 Field Operator Sl.No Observation / Task 1. Check all unit rundown position 2. Any change in product rundown to be informed to operator before and after C/O 3. Check product colour 4. Chemical dozing tank level becomes low 5.

Chemical dosing tank level is steady

6.

Chemical dosing tank level is raising

7.

Preparation of Ahuralan solution:

8.

Preparation of Ammonia solution.

Action log book / display in board Update log book and display board

Inform operator for any abnormality.  Change over the tank with full one.  Top up / prepare solution in the empty tank.  Check the performance of running pump/motor  If it not pumping, start the stand by pump and observe change in tank level  Check discharge PSV is popped up  Report to PNE to attend it by maint.  Check whether the pump is developing a required pressure or not  If it is not developing, check discharge b/v NRV ing  Start the stand by pump, as per procedure and observe tank level  Report to PNE to attend it by maintenance  Inform S/I to arrange to connect Ahuralan (CI-corrosion inhibitor) drum.  Transfer required amount of CI to tank  Dilute with Naphtha (1:2 CI/Naphtha ratio)  Circulate solution for 3-4 hr.  Adjust dozing to respective column top as per requirement.  chemical .  Take required quantity of DM water in the tank.  Dissolve one cylinder of Ammonia (40kg)) in it.  Sprinkle water on ammonia cylinder for


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 215



9.

Preparation of caustic solution:

10. 11.

Check PH of sour water. Water level in column over head accumulator drum. All rundown temperature & pressure to log. Inlet / outlet TG / PG of heat exchanger / cooler / condenser not working Heat exchanger / cooler by valves are open Heat exchanger and coolers commissioning/decommissioning

12. 13.

14. 15.

16. 17.

Leak from floating head cover / flanges / block valve flange/gland Excessive leak in heat exchanger

18.

Abnormal change in HE inlet / outlet


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

fast condensation.  When cylinder exhausted, mark it & inform S/I to replace with maintenance help.  chemical .  Adjust dozing to respective column top to maintain PH, as per requirement  If fresh caustic tank is empty, line up the tank & inform LPG S/I to start transfer pump.  After receiving required amount, inform LPG S/I to stop the pump.  Transfer required amount of fresh caustic in the tank depending on the strength to be prepared.  Dilute / top up the tank with DM water up to the required level.(Ammonia to DM water Ratio= 3:7)  Circulate the solution for 4 hrs.  Collect the sample & inform S/I for strength checking.  Adjust dozing or replace spent caustic as per requirement  chemical . Adjust chemical dozing, if PH deviated Drain water. (Do not leave the place till draining is over) If any gauge is not working, inform to S/I. Inform S/I to attend it by maintenance

Close the by valve after consulting S/I As per procedure/checklist, heat exchangers/coolers are to be commissioned/decommissioned Keep steam lancer & inform S/I to attend it by maintenance Take assistance of others and by/isolate the heat exchanger. Inform to S/I


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 216


VOL-I: Addendum

20.

temperature Abnormal change in HE pressure drop. Over head reflux drum pressure high

21. 22.

Any leak vessel & its piping, valves PSV ing

23.

Desalter desludging

24.

Desalter taking high amp- low voltage

25.

Check brine color / oil in brine

26. 27.

Desalter brine is clear & demulsifier dosing rate is high Desalter brine PH is high

28.

Liquid level in Flare KOD

29.

31.

Defective pressure/temperature gauge Check proper tracing steam flow in Pre- fractionators & main fractionators level instrument Unit Start up/Shut down

32.

Emergency Handling



Any hydrocarbon leaks in the plant

  

19.

30.

33.



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Inform to S/I. Divert PCV outlet to flare by coordinating with operator. Inform S/I to attend it by maintenance Take stand by PSV inline. Isolate the ing PSV. Inform S/I to attend it  1 hr in A – shift  1 hr in B – shift  Check inter face level from tri-line  If level is more, inform to reduce level  Or, do de-sludging for more time.  Increase demulsifier dozing rate.  Increase Mixer delta P.  Check inter face level from tri-line  If level is low, inform to increase level  Increase demulsifier dozing rate.  Reduce mixing valve delta P.  Inform PNE  Reduce dosing rate.       

Check the variation in stripper water PH Reduce caustic dosing to pre-desalter Inform to PNE/ operator about the variation in stripper water PH Inform to operator Drain out liquid in CBD. If draining in OWS, Keep running water on it. Inform S/I to replace it.



Inform S/I to attend if not sufficient.



As per procedure/check list, laid down in the operating manual As per procedure/check list, laid down in the operating manual As directed by operator / shift in-charge Inform to S/I Keep a steam lancer at the location, if required


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 217


Operating Manual for JR AU-III VOL-I: Addendum 

Fuel gas header pressure low

Product / feed / gas sampling

36.

During energisation energisation of motor,

37.

Other job

and

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Increase oil firing by coordinating with operator, if any margin exists. Adjust circulating refluxes to raise the preheat

 35.


A per procedure product / feed / gas sampling to be carried out

de- motor to be checked by switching ON along with S/S technician and subsequently TAGGING to be done As & when asked by shift in-charge.

7.3 Furnace Operator Sl.No 1.

Observation Furnace hazy, smoky burner.

 

2.

COT is low

3.

Flame impingement

4.

Skin temperature high at particular point COT & Skin temperature are high Dripping of oil from burner

5. 6.

 

   

7.

FO return line is cold/congealed

8. 9.

Convection zone / stack temperature high. Soot blower not running/stuck up

10.

Oil / gas burner not getting lit

Action If total furnace is hazy, ask to increase combustion airflow from . If 1 or 2 burners are smoky, adjust the burners by adjusting air s, atomizing steam or by stack damper. Take more burners by consulting operator. Adjust flame of particular burner. Inform S/I to attend the burner. Check/adjust burner at that point. Inform S/I Reduce firing, if required cut off furnace Cut off oil, Flush with steam. If fire is there, extinguish with steam & keep steam lancer there. Take the burner in gas firing. Inform to S/I to attend it. Open more return valve. Keep steam lancer on return valve. Do repeated soot blowing. Switch off SB . Inform S/I to attend by Maintenance Inform S/I to attend by Maintenance. Oil and


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 218


11.

12. 13. 14. 15.

16.


19. 20.

VR temperature high / low Soot blowing of furnaces

1st Sep,2016

0

1st Sep,2016

Ask to reduce steam pressure, if it is high. Isolate the ing PSV & Take spare one in line. Inform S/I to attend by Maintenance        

21.

Raise in furnace arch temperature

    

22.

Check burner flame pattern

   

Check / record furnace draft

Rev. Date

Keep steam lancer on it. Inform S/I to attend by Maintenance Inform to S/I



23.

Rev. No.

Inform S/I

Furnace-refractory bricks are falling down PSV of soot blowing steam ing

18.

17.

Issue Date

gas burner properly flushed and isolated before releasing for cleaning Inform S/I to attend by Maintenance

Local temperature, Feed inlet / outlet PGs & draft gauges are not functioning Hot spot in the tube or hanger broken Leak from flanges / valve gland

Stack damper / air is not getting operated Any hydrocarbon leaks in the plant VR not getting received




Inform to S/I Keep a steam lancer at the location, if required Inform PNE Check line up / its tracing steam If problem persists, line up RCO to surge drum Adjust steam to heater coil by furnace operator In morning & evening shift. Inform man to open STD before starting soot blowing If soot blowers are not functioning, inform S/I to attend by respective maintenance group. Check stack damper opening Check for any air ingress inside the furnace Reduce the fuel gas consumption, if possible Adjust air Adjust fuel oil burners

Adjust air, oil, steam etc wherever required. Check / keep close all peepholes. Inform S/I to rectify the defective one. Check for any hot spot on the tubes. Report if any. Check for any abnormality on furnace roof (hole etc). Report to S/I for corrective action. Adjust stack damper after consulting S/I


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 219


24. 25.


gauges Check / record furnace inlet & outlet pressure. IFO tank

    

26.

ID/FD fan Start/Stop



27.

Unit Start up/Shutdown



28.

Emergency handling



29.

ID/FD fan gear box lube oil top up



30.

ID/FD fan gear box lube oil dripping from lube oil cup/gear box



 31.

32.



ID/FD fan abnormal sound from fluid coupling chamber  Lube oil leak from fluid coupling chamber ID/FD fan abnormal sound from motor





 33.

ID/FD fan lube oil circulation temp. is high

  


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

wherever applicable. Inform S/I to rectify the defective PGs Check record IFO tank level Check healthiness of IFO pump If VR system fails, take IFO system in line (For AU1/AU2) Line AU5 RCO to VR drum in case of VR receiving fails from GHC As per procedure, laid down in the operating manual As per procedure/check list, laid down in the operating manual As per procedure/check list, laid down in the operating manual If lube oil level is low in gear boxes, top up lube oil If leak is more, inform to PNE/ operator and take other FD fan in line. Incase of ID fan, inform to PNE/ operator and asked operator to open stack damper and stop the ID fan If leak is less, report to PNE to attend it by maintenance If abnormal sound/ lube oil leak is severe, inform to PNE/ Operator and take other FD fan in line. Incase of ID fan, inform to PNE/ operator and asked operator to open stack damper and stop the ID fan If it is severe, inform to PNE/ Operator and take other FD fan in line. Incase of ID fan, inform to PNE/ operator and asked operator to open stack damper and stop the ID fan If not, go for frequent rounds till maintenance crew look at the problem Compare local indication (temperature gauge) with DCS indication Check water circulation in lube oil cooler. If it is low, raise the cooling water


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 220




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

flow/Arrange for external cooling  

34.

ID/FD fan lube oil cooler gasket leak

  

 35.

ID/FD fan lube oil contamination in fluid coupling chamber

 

If stand by FD fan is available, take it in line by coordinating with operator Incase of ID fan, stop ID fan by coordinating with operator Report to PNE to attend it by maintenance Report to PNE/ Operator If stand by is present, took other FD fan in line immediately to avoid damage to equipment/furnace tripping In case of ID fan, stop ID fan by coordinating with operator. Check the lube oil quality in fluid coupling chamber (water carry over) Report to PNE for any tube puncture in the lube oil cooler

36.

During energisation and de- motor to be checked by switching ON along energisation of motor, with S/S technician and subsequently TAGGING to be done

37.

Cleaning of FO/FG strainers

38.

Draft gauges healthiness

39.

Other un expected job

If strainer choked, change the filter and inform to shift in charge to get it cleaned Draft gauges to be get checked if any suspicion arises 

As per guidance of shift in-charge

7.4 Operator Sl.No 1.

Observation Desalter inter-phase level high and amperage high

  

Action Bring down the level by opening LDIC. If required, open HIC. If water ingress is through crude, reduce DM water injection. Inform crude control operator to drain water


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 221



  2.

Desalter pressure low, high crude flow & pre-topping column level going down

     

3.

Desalter effluent is not clear



   4.

5.

Voltage Is low & amperage is high

Desalter temperature too high

        

6.

Desalter temperature too low

 

7.

High salt content in desalter outlet

 

8.

Desalter tripped

 


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

from tank. Monitor column top pressure for any pressurization As soon as level comes down, normalize water injection. Check crude booster pump suction pressure Check the functioning of desalter pressure controller Reduce jump over opening of furnace. Ask pump operator to start 3rd feed pump. Check desalter PSV for ing. Normalize jump over opening after sometime. Ask field operator to check the inter-phase level from tri-line. If level is low & amperage is low, increase level. Increase demulsifier dozing if required. If amperage & level are on higher side, ask field operator to reduce Dp across mixing valve. If crude inlet temperature is too low, inform PNE to arrange to increase it. Stop DM water injection. Reduce inter-phase level. Ask field operator to check level from tri-line. Check effluent if level falls below 0.If crude starts coming out, stop draining. Wait till voltage is normal. Resume water injection. Inform PNE to check from electrical angle by E/M Inform PNE. If it is by particular crude, reduce T’Put after consulting PNE. Check / close post desalter. Close all by if it is opened. Inform PNE. If it is by particular crude, open post desalter heat exchanger by. Increase water injection rate, if it is low. Ask field operator to increase Dp across mixing valve & to increase demulsifier dozing. Inform to PNE/sub-station to reset it If substation crew can’t identify the problem, inform


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 222



  

9.

Brine water PH is high

  

10.

Brine water PH is low

  

11.

High water content in desalted crude

 

12.



13.

Maintain desalter outlet salt content 1 – 1.7 ptb.  Oil content in brine < 50 ppm.  DM water injection 4 to 6 % of crude  Desalter temperature 130 – 140 deg C Fractionating column Column level low

 



   


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

to Elect. Maint. In the mean while, reduce the DM water injection Keep a watch on desalter interphase level and column top pressure If problem is not solved and unbearable situation arises (raise in column top pressure and naphtha coloration takes place), then unit to be kept in circulation, as per procedure. Asked operator, to check stripper water PH Reduce caustic dosing to pre-desalter Inform to PNE about the variation in stripper water PH Asked operator, to check stripper water PH Increase caustic dosing to pre-desalter Inform to PNE about the variation in stripper water PH Reduce water injection rate, if it is high. Ask PNE to reduce Dp across mixing valve.

Check Level control valve malfunctioning. Reduce rundown flow till level starts holding If crude (feed) flow is low, check feed pump. If pump tripped, take stand by pump in line. Inform PNE / substation to reset the tripped pump. If the pump not delivering proper pressure, ask pump operator to change over the pump. Inform PNE to clean the suction strainer of the pump. If battery limits feed line pressure is low, Inform crude control for corrective action. Reduce T’put by reducing J/O opening / flow If crude flow is more then requirement, check desalter PSV for ing. Normalize T’put after stabilization.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 223



Column level high

        



          

15.

Column bottom temperature high

16.

Column bottom temperature low

17.

Column bottom pressure high

18.

Column bottom pressure low

     

19.

Column top temperature high

  


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Check Level control valve malfunctioning. Increase rundown flow till level starts holding / reducing. Inform PNE to check rundown tank line up in OMS. If bottom pump tripped, take stand by pump in line. Ask substation to reset the tripped pump. If rundown flow still restricts, reduce T’put till normalized. If suction strainer of bottom pump is choked, take stand by pump in line Check the desalter PSV Check the malfunctioning of any circulating reflux c/vs In case of main fractionating column- check HSD, SKO color. If colored ask to divert it in slop / or a new low dip rundown tank. Incase of pre-topping column, ensure that sufficient furnace feed flow is there in all es. If not, cut off the furnace. Check coking up of es. Inform shift in charge for corrective action Reduce reboiler / furnace COT. Optimize furnace flow Increase column bottom level. Increase reboiler / furnace COT. Optimize furnace flow Reduce column bottom level to normal. Check desalter PSV Check any malfunctioning of circulating reflux c/vs Check water carryover with feed/reflux (in case of stabilizer) Reduce column level.. Inform S/I to check level by instrument maintenance I Check desalter PSV (for fractionating columns) Check any malfunctioning of circulating reflux c/vs Check water carryover with feed (in case of stabilizer) Increase top reflux flow. If flow limiting (For fractionating column) Increase / adjust all pump around flow. If flow limiting (For pre-topping, stabilizer etc)


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 224



 

20.

Column top temperature low

    

 21.

Column top pressure high

     

22.

Product draw temperature high or low

    

23.

Main fractionators column flash zone temperature high / low

   


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

check reflux temperature. Inform PNE to reduce reflux temperature by taking more condensers in line or by lowering CW supply temperature from water block. Where air cooler is there, switch on one or two air coolers. Reduce T’Put or light crude processing (in case of mix crude processing. Inform S/I. Reduce top reflux flow. For fractionating column adjust all pumps around flow. Check any malfunctioning of circulating reflux c/vs For pre-topping, stabilizer etc, checks reflux temperature. If it is too low, inform PNE to increase reflux temperature by isolating a condensers If air cooler is there, switch off one or two air coolers. If controller malfunctioning, take it on manual mode & control manually. Inform PNE to attend it. If required, in some cases, open controller / PSV by. Check any malfunctioning of circulating reflux c/vs Reduce COT / cut off re-boiler if column bottom temperature is too high. If air fin cooler exists, switch off one or two air coolers. If column level is full, bring down level either by reducing t’put or increasing bottom product flow. Increase top temperature. Adjust product draw flow (Increase or decrease) as per laboratory result. If product draw temp is low, check for flooding If flooding takes place, draw off more amount of lighter product from the tray above the flooded tray. If product draw temperature is high, drop the product from the top tray exactly above the dry tray. Adjust Kero / HSD pump around flow / temperature. Adjust furnace COT if required. Check desalter PSV (for fractionating columns) Check any malfunctioning of circulating reflux c/vs


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 225



VOL-I: Addendum

24.

Stabilizer feed temperature low / high

25.

RCO yield

          

26.

LPG recovery

27.

Furnace soot blowing

   

28. 29. 30. 31. 32.

ID /FD fan start up/stop Unit start up & shut down Emergency Drum level low / high VR not getting received

33. 34.

VR temperature high / low Drum pressure low / high

35. 36.

Steam flash drum pressure high Steam flash drum level high

37.

FG header pressure low

                 


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Check control valve malfunctioning. If required take the C/V on hand wheel. Inform PNE to attend it by maintenance. Check the stabilizer bottom temp. Check any raise in feed flow/reflux drum level Maintain stripping steam flow/raise in reboiler temp. maximum possible with respect to T’put. Recover maximum HSD and keep product quality ok. Raise COT, if any margin exists. Maintain low over flash. To minimizing RCO yield. Adjust reflux temperature 40 to 45 degC Adjust stabilizer bottom temperature so the reflux ratio is maintained between 2 to 2.5 Open stack damper Take ID fan opening HIC in manual mode After opening stack damper, inform to furnace operator for soot blowing After completion of soot blowing job (ensured by furnace operator and himself), close the stack damper Asked the field operator to check the furnace. Take ID fan opening HIC in cascade with O2% As per procedure laid down in the operating manual As per procedure As per emergency handling procedure. Check controller malfunctioning Inform PNE Inform GRE/GHC If problem persists, line up RCO to surge drum Adjust steam to heater coil by furnace operator Check vessel split range control valve/level controller Take on manual mode Inform PNE to attend it by maintenance Isolate MP steam to flash drum outlet LP steam header if it is lined up. Check controller malfunctioning Check about its line up in AU1 DM water tank. If any margin exists in oil firing, increase oil firing and reduce gas firing If not, consult S/I & RSM and line up LPG vaporizer by field operator.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 226


38.


LPG reflux drum boot water draining

   

39.

Quality Control LPG weathering high / low

 

40.

SKO flash point low/ high

41.

SKO IBP low/ high

42. 43.

SKO FBP low/ high HSD flash point low / high

         

44. 45.

HSD pour point low / high HSD 95% recovery low / high

46.

Sour water PH is high/low

47.

RCO Recovery is high (1525%)

    

 

48.

Product colored

  


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Maintain gas header pressure, as per requirement Open boot water SDV After completion of draining (ensured by field operator), SDV automatically gets closed. Counter check with DCS and field. Decrease / increase stabilizer top temperature after consulting PNE Check reflux ratio. If it not optimum, adjust stabilizer bottom temperature. Adjust Kero stripping steam Adjust main fractionators top temperature as applicable Adjust top CR flow Adjust H.Naphtha draw Adjust Kero CR flow Increase / decrease SKO draw Adjust HSD stripping steam Adjust main fractionators top temperature as applicable. Adjust HSD CR Increase/decrease SKO draw (if permissible), after consulting PNE Increase / decrease HSD draw Increase / decrease HSD draw Adjust HSD CR flow Reduce/increase ammonia injection to column over head line If any margin exists in main column stripping steam (with respect to T’Put), increase column stripping steam flow Raise COT, if margin exists. Raise HSD with draw rate by keeping the required quality Keep minimum over flash flow Ask pump operator to check color at draw pump vent. If it is colored at pump, ask instrument to check fractionator bottom level. Taking RCO R/D controller on manual mode, pump out more to reduce level. Ask pump operator to check RCO


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 227



 

49. 50.

Logging of parameters

51.

Monitoring of abnormality of rotating equipments DCS system

52.

Gas detectors

53.

Pump change over

54.

Exchanger hand over/take over

55.

Monitoring of furnace

56.

Interlocks

57.

Coordination with RSM/ Offsite

58.

Data preparation and communication

59.

Other job

 


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

pump load, if required start 2nd pump. Divert the colored product to slop tank. If color is normal at pump, ask to check color at each heat exchanger outlet. Identify & isolate the leaky heat exchanger. Any deviation to be informed to shift in charge Any alarm of high vibration of any rotary equipment , High seal pot pressure of pump appears on DCS, pump/field and S/I to be alerted Any DCS/PLC system alarm appears S/I and concern ITE to be alerted If any gas detector alarm appears, concern area operator and S/I to be alerted Total attention t be given to concern parameters while getting pump change over done Clearance to be given for take over& hand over after adjusting the parameters(if required). Abnormal change in any other parameter to be reported to S/I All critical parameters like skin temperature/ box temperatures are to be monitored closely. Any deviation to be informed to S/I. Heat load to be adjusted to keep all parameters in within limit

All Inter locks shall be kept in line, In case of emergency and unit upset interlock can be byed in consultation with S/I. Secondary measures to be taken for byed interlocks. Closed monitoring shall be ensured regarding parameters which are related to byed interlocks In case of water ingression in crude RSM/GR crude C/R to be ed for action at their end. During product routing RSM/OMS(R) to be ed Daily material balance and utility balance sheet to be prepared as specified, The same to be communicated to PNM/RSM/NM 

As & when asked by shift in-charge.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 228




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 229




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER – 8 NORMAL SHUT-DOWN PROCEDURE 8.1 INTRODUCTION In this section, procedure for normal i.e. planned shutdown is discussed. While shutting down all process units simultaneously or any section of the process unit, care should be taken not to it air into the system until all hydrocarbon vapours have been removed. Care should be taken for any sharp drop in temperature to avoid thermal stresses in piping and equipment. All related process units, utilities and of sites should be kept informed well in advance about the shut down planning. It is to be ensured that a slop tank and one crude tank having sufficient space are available to receive the slop/off spec material. Closed blow down drum should be emptied out and should be kept ready to receive hydrocarbons draining/flushing from equipment. Flushing oil should be made available in adequate quantity and adequate pressure. Ensure ivation solution availability. The following steps are involved for carrying out the normal shutdown safely:           

8.2

Preliminary preparation Throughput Reduction Bying of Desalter & decommissioning Discontinue chemical Injection Cooling of Furnaces Shutdown stabilizer Pumping Out Gas Oil Flushing Depressurization & Steaming ivation Of heater tubes & Coking as per requirement Opening Of Equipments.

PRELIMINARY PREPARATION The following prerequisites for normal shutdown are to be fulfilled. JOB DESCRIPTION

Action By

(a) Top up SRGO in intermediate tank TK-212 for flushing.

Pump Operator Field Operator

(b) Ensure column drains are clear from down-stream of drain valves


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 230




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

JOB DESCRIPTION

Action By Pump Operator

up to open ends.

(c) Keep intermediate tank TK-214 empty for holding off grade Shift In-Charge material during shutdown. Shift In-Charge (d) Inform FPU-I to prepare 125 M3 of ivation solution (2% Sodium Carbonate & 0.5% Sodium Nitrate solution). Field Operator (e) Ensure 300 NM3 Nitrogen availability from GRSPF for ivation of the heater tubes and transfer lines. Shift In-Charge (f) Keep the underground tank empty and ensure its inlet line from equipments clear. Check performance of underground vessel pumps H-18/H-19 and offer it to M/M for functionality. (g) Inform OM&S to line up a separate tank for AU3 as to receive off grade RCO, crude & slop oil & flushing oil during the shut down procedure. (h) Inform RSM, AU-I, AU-II, CRU, GRE, GRSPF, GHC, OM&S, Shift In-Charge Crude Control, TPS, SS-4, Water Block and Laboratory about shutdown timing.

8.3

DECOMMISSIONING OF DESALTERS

1.

2.

3.

JOB DESCRIPTION Action By Wide open the mixing valves at desalter inlet by manually operating 3MV1001 & 3MV1002 so that steady desalted crude pump suction pressure is ensured. Raise desalter inter-phase level up to 80% and by the desalters / just before starting the throughput reduction. While raising the Field inter-phase levels turn off the desalter (transformers) at 40% level. Operator *Note- Get the desalters electrically isolated by SS-4. Then start draining desalters. Inform CETP and RSM prior to this Drain desalter in close blow down system(CBD). Desalter can be kept filled with Gas oil and can be isolated after draining. Keep desalter pressure around 0.3 kg/cm 2 when it is idle.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 231




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

8.4 THROUGHPUT REDUCTION JOB DESCRIPTION

Action By

(a) Stop imported crude processing, if any, and start reducing throughput Crude in steps to the level of 4500 MTPD. Cont Opt. *Note-2. Make adjustments on all operating variables so that normal pressure and temperature conditions are maintained.

/

(b) Line up to route E-2 Naphtha, K-4 bottom to General Naphtha/GOP Field Opt Naphtha via AU1/AU4.

(c) During throughput reduction reduce hot stream flow through E-106 / reboiler as feed flow to K-4 reduces to maintain bottom temperature at Field Opt K-4. (d) Take furnaces F1, F2 on Natural draft & F-3 on forced draft. /Furn. Opt (e) Reduce the throughput further to about 4000 MTPD in two hours adjusting firing in furnaces. / *Note-furnace interlocks to be byed during T’put reduction. Furnace Operator (f) During throughput reduction, product shall go off. Route the product as follows : 1. SK to SK or HSD as per colour Field 2. HSD to intermediate tank /OM&S Operator 3. E-2 naphtha, K-4 bottom to General Naphtha/GOP Naphtha via AU1/AU4. 4. RCO to OM&S.

8.5 COOLING JOB DESCRIPTION

Action by


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 232




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

JOB DESCRIPTION (a) Stop Kero and SRGO circulating reflux (when T’put is 4000 MTPD).

Action by / Pump Opt

(b) Start reducing F-1/F-2 /F-3 COT @ 40 0C per hour slowly to 300 0C. / (c) At 300 C COT, cut off gas firing and close the individual B/V to Furnace furnaces. Keep pilot burner on and depressurize gas header through a Opt burner whose oil burner is still on. Get blinds inserted on FG lines to / F-1/ F-2 and F-3 after FG control valves for individual furnaces. Furnace Opt 0

(d) When K-1/K-2 bottom temperature comes to 240 0C, cut off stripping steam to K-1,K-2,K-6A/B and K-3A/B & K-3C. Isolate 4-ata steam PRC 3PC3205 and 3-ata steam PRC 3PC3701. / Field Opt (e) Stop injection of all chemicals. *Note-1. Stop Caustic injection pumps H-25/26 & isolate caustic injection to desalted crude. Field 2.Stop Demulsifier injection pump H-29/29A & isolate the valve to crude Operator inlet. 3. Stop Ammonia injection pump H-30/31 & isolate the ammonia injection to overhead vapour lines of K1/K2. 4.Stop Corrosion inhibitor pump H-21A/B/C/D after stopping the ammonia injection pumps & isolate injection to K1/K2/K4 vapour lines. 5.Isolate the vessels including cylinders & drums, which contain chemicals. Depressurise & drain pumps including calibration pots. (f) Bring the route H2/2A/2B/2C  HE trains  K-1  HE ckt  F1/F-2/F-3  K-2 on hot circulation after ensuring that RCO coolers outlet temperature is around 50--55 0C and not above. For hot circulation close battery limit isolation valve on crude line and simultaneously open circulation line valves on RCO line. Field Operator (g) The firing in F-1/F-2/F-3 is gradually being reduced, E-1 and E-2 gasoline make shall start decreasing and feed to K-4 will come down. Put K-4 on close circulation through thermo-siphon reboiler E-106 using pump H-14. Any excess material built up in K-4, route it to General Naphtha. Also route E-2 gasoline to General Naphtha/GOP Naphtha via Au1/Au4. Furnace/Pum p Op


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 233




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

JOB DESCRIPTION Action by (h) Continue reduction of COT in all three furnaces and when the same /Furnac is 200 OC, cut off firing. Flush out each burner with steam soon after e Op stopping oil. Keep the flue gas dampers and air s open, and keep the fuel oil return valves of each header crack open so that fuel oil circulation through each side is still on. (i) Purge the fireboxes thoroughly with steam for at least fifteen minutes Furnace Opt in the furnaces. Field / Pump *Note-Continue the circulation for about 2 hours after cutting off firing Operator (cold circulation). 8.6 SHUTDOWN OF NAPHTHA STABLIZER (K4) JOB DESCRIPTION 1. 2.

3. 4.

5.

6. 7. 8.

Action By

Inform LPG downstream unit about discontinuing LPG production During T’put reduction reduce hot steam to E-106 to maintain bottom temp as the feed to K-4 reduces. Also reduction to F1/F2/F3 COT will further decrease the feed to K-4 column.

Shit InCharge / Field Opt

Decascade atmospheric reflux drum level controller (3LC3202) from stabilizer feed controller (3FC3203) Decascade stabilizer column top temperature controller (3TC3603) from reflux flow controller (3FC3601). Increase top reflux to stabilizer & cut off LPG R/D (3FX3604) from reflux drum level controller (3LC3602). Reduce the column top pressure very gradually by operating 3PC3601. *Note-Care must be taken to reduce the pressure very slowly to avoid lifting of heavy ends to the top and sudden release of heavy components to fuel gas system, which may condensate in fuel gas system afterwards. Reduce further the heating medium to K4 bottom reboiler (E106) by operating 3TC3605. Pump out stabilizer top reflux drum liquid to stabilizer till reflux pump looses suction. Keep receiving feed to stabilizer till atmospheric column (K1) starts operating on total reflux in course of shut down & then cut off feed to stabilizer. Close the isolation valve in the stabilizer feed line.

Opt


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Opt

Opt

Opt Opt /Field Opt

Vol-I (Addendum)

Page 234




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

JOB DESCRIPTION 9.

10.

11.

12.

Action By

By utilizing the available pressure empty out the stabilizer bottom to slops storage tank & maintain stabilizer bottom level. Keep a watch on run down steams, as it may contain lighter compounds, which may create problem in slop tank. To facilitate emptying out, top pressure control valve of the column may be closed or loss of pressure can be made up form external FG supply. Heating up bottom contents can also be done if necessary to build up pressure for this purpose. Care must be exercised to prevent gas break through from stabilizer column to storage tank due to sudden loss of level in stabilizer bottom while emptying out.

/Field Opt

/Field Opt

Reduction in stabilizer column pressure, naphtha flow and /Field stabilizer bottom level will all indicate completion of the Opt emptying out of the column. After emptying out, isolate the column by shutting off valve on the inlet and outlet streams and then depressurize slowly by releasing to flare through depressurizing valve. After depress rinsing, residual liquid in column, piping exchanger Field Opt will be drained to CBD or OWS. *Note- LPG should not be drained to CBD or OWS in large quantity, as it may flash in the way.

8.7 PUMPING OUT JOB DESCRIPTION

Action By

(a) Empty out reflux vessels in respective columns

Field / Pump opt (b) Stop cold circulation. Field / Pump Opt (c) Empty out K-1 with the help of H-41A/B/C to K-2 till pump loses Field/ suction. Pump opt (d) Empty out K-2 with the help of H-11/H-11A/42 to Separate RCO Field / Pump Tank in OM&S. Opt * Empty columns till their bottom pump lose suction.

Pump opt


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 235




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

8.8 GAS OIL FLUSHING JOB DESCRIPTION (a) Carry out gas oil flushing of crude and RCO circuits as follows.

Action By All Operators

i. Gas oil from TK-212 Pump H-101 crude pump suction preheat exchangers (crude side) with desalters byed K-1 up to(100% level) H-41 A/B/C. ii. H-41ABC F-1/F-2/F-3 K-2( 30 min for F-1, keep u/s b/v’s of F-2/F-3 c/v’s closed and then 30 min in turns for F-2 & F-3 in a similar manner)  [ F-1/F-2 Jump-over  K-2 (10 min) ]. iii. K-2 H-11/11A/42  RCO heat exchangers/T-16/A/B/C/D/E coolers circulation line OM&S Tank *Note-During gas flushing of crude & RCO line E1/E2/E4/K4 to be Field / Pump emptied & depressurized. Opt (b) Check the sample at RCO sample point near CBD vessel pit. If it is Pump clear gas oil, route flushed gas oil through: Operator i. RCO to OM&S ii. RCO to FPU-I hot and cold iii. RCO to FPU -II hot and cold iv. IFO to AU-4 & Job-50 (c) Empty out K-1/K-2 till pump loses suction. *Note- 1. The better the displacement /dilution of heavy oil from the All system, the better and quicker will be the subsequent steam /water Operators flushing of columns. Hence, this flushing should be properly done. 2. By valve of all control valves including furnace flow C/Vs, heat Field/ exchangers and coolers in the system under flushing should be kept crack Furnace open to flush out by loops also. Operator

8.9 DEPRESSURISATION AND STEAMING

JOB DESCRIPTION

Action By

(a) Get blinds from column vents and drains removed.

M/M


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 236




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

JOB DESCRIPTION Action By (b) Get blind from furnace F-1 radiation section interconnection M/M / removed and get hose connection done from this to drain the Furnace Opt material. Do it for F-2 and F-3 also. (c) Depressurise the columns K-1 into fuel gas system, then to the flare / system and finally to the atmosphere by opening column vent valves.

Field Opt

(d) Depressurise K-2 first to flare and then into the atmosphere through vent valve. (e) Pump out products from all vessels to minimum level till pumps lose suction and then drain out rest. Depressurise vessels to flare and then

Field Operator Field/Pump Opt

to atmosphere. (f) Close all overhead condenser (T-7A/B, T-8A/B/C/D, T-9A/B) inlet Field

B/Vs.

Operator *Note- Get Blinds from Purging /Service steam line of K-1/K-2/K-4 & E1/E2/E4 removed & also from vent & drain lines. (g) Keep F-1 flow C/V d/s B/V and by B/V closed. Start coil purging in F-1 only. Displace gas oil to K-2. Stop steaming in F-1.

All Operators

Empty out K-2 by running H-11/11-A/H-42 till pump loses suction. Start steaming of F-1 coil again. Check for any level builds up, empty out K-2 after stopping steaming till pump loses suction. Open F-1 coil drain B/V, start steaming of coil and continue steaming till clear steam comes out from coil drain. Now start steaming

F-2 coils and

displace gas oil to K-2. Empty out K-2 simultaneously by H11/11A/42 till pump loses suction. Continue steaming of F-2 coils till clear steam appears from transfer line drain. Now start steaming F-3 coils and displace gas oil to K-2. Empty out K-2 simultaneously by H11/11A/42 till pump loses suction. Continue steaming of F-3 coils till clear steam appears from F-3 transfer line drain and K-2 column


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 237




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

JOB DESCRIPTION

Action By

drain.

With the steam on, light pilot burners and main burner on each side of the furnace (open gas to Unit valve) and maintain a COT of 2000C to avoid condensation of steam inside the coils. Open service steam in K-1, K-4, and stripping steam into K-2 and K-3A/B, K-3C & K-6A/B.

Note : i. Keep K-1 bottom pumps (H-41A/B/C) suction valves closed and discharge valves drains open. Due to ing of NRVs (if they are

Pump Operator

ing) steam is expected to come out from the pump drains. ii. Keep K-1 and K-2 vents full open and steam flushing should be regulated so as to maintain a pressure around 1 kg/cm2(g) in K-1 and

Field Operator

0.5 kg/cm2(g) in K-2. (h) Keep furnace coil drain valves and transfer line vent valve open. When clear steam comes, put off firing in furnace. Depressurise fuel gas line through burner and blind main gas line valve at battery limit.

Furnace Operator

(i) Proceed for ivation as per the procedure given under that head. Once coil purging with steam is stopped, close K-1 bottom pumps Pump

discharge valves to avoid loss of inert gas during ivation. (j) Carry

out

steam

and

air

decoking

as

per

standard

Operator

procedure.(Available in Chap.- 5.2.12 , 5.2.13 for F1/F2 & Chap.5.3.10 for F3)

/

(k) After emptying out all the vessels, columns, close all rundown block Furnace valves and get all run down lines blinded as listed below:

Operator Field

i. LPG ii. GOP/General naphtha line to OM&S via Au1 & Au4 & also raffinate


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Operators

Vol-I (Addendum)

Page 238




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

JOB DESCRIPTION

Action By

ex UDEX line. iii. Kero line to OM&S iv. HSD/SKO after E-315 v.

Cold RCO to OM&S (6”), Hot RCO to FPU-I and FPU-II, Cold RCO to FPU-I & II.

vi. Gas away line at battery limit. vii. Flare line (battery limit) l)

Drain out individual exchangers and other equipments into underground vessel E-8 and prepare equipments for handing over to Field maintenance as per standard procedure. Temperature of material Operator being drained should not be more than 50-55 OC . Keep both shell and tube side vents of exchangers open for proper draining.

m) Empty out underground vessel E-8 with the help of pump H-18 and H-19 and give clearance to OMS to close RCO R/D tank valve Pump Operator

8.10 IVATION OF F1/F2/F3

1. 2.

JOB DESCRIPTION Action By Line up Inert gas (IG) Ex CRU up to F1/F2/F3 es Field Opt After confirming that dry steam is coming from K-2 transfer line Field Opt HPV, start taking IG & displace in F1/F2/F3 keeping only one ring of HPV open. *Note- Allow IG to come out from HPV for 15 minutes


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 239


3. 4. 5. 6. 7.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

JOB DESCRIPTION Blinding of K2 feed entry in Presence of IG Fill F1/F2/F3 coil with ivation solution one by one. Allow ivation solution to come out of HPV for 5 –10 minutes. Let F1/F2/F3 coils soak with ivation solution. Drain ivation solution exit F1/F2/F3 coil from coil bottom drain If Needed steam spalling & coking to be as per procedure

Action By MM Field Opt

Field Opt Field/Fur/ Opt

*Note-

NORMAL STARTUP PROCEDURE FOR : 1.M&I – Follow steps from 6.2 to 6.10. 2.Bottle up condition- Follow steps from 6.2 to 6.9


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 240




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER - 9 NORMAL START UP PROCEDURE INTRODUCTION Start up and shut down are the most critical periods in operation of any process unit. It is then that the hazardous possibilities for fire and explosion are highest. Start up and normal operating procedures are described in this section. The hazards encountered most frequently in start up and shut down of units are accidental mixing of air and hydrocarbons and ing of water with hot oil. Other hazards primarily associated with start up are excessive pressure, vacuum and thermal/mechanical shocks. These can result in flares, explosions, destructive pressure surges and other damages to unit as well as injury to personal. Fires occur when oxygen and fuel vapour or mists are mixed in flammable proportions and come in with an ignition source. They may run out of control or touch off devastating explosive. Pressure surge from unplanned mixing of water and hot oil may cause damage of equipment and/or loss of valuable production. Preparation for start-up begins with a complete review of the start-up procedure by the operating crew. Start up of the unit involves the following consecutive phases.  Preparation of the unit  Removal of air for the process systems  Tightness testing to prevent leakage  Backing in fuel gas to prevent air ingress  Cold circulation for removal of water  Hot circulation

 9.1

Bringing the unit on stream PRELIMINARY PREPARATION

The following prerequisites for normal start-up are to be fulfilled. SrNo 1 2

JOB DESCRIPTION

ACTION BY

Check all the equipments for mechanical completion All Operators Check that blinds are installed/removed as per master blind list except All Operators for fuel oil and fuel gas lines, which will be de-blinded before furnace firing


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 241




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

3 Ensure that all PSV’s are boxed up properly & lined up as per P& ID

All Operators

stipulation. *Note- For K1 & K2 all PSV’s are to line up. All other column & vessel at least one PSV is to be lined up. 4 All instruments should be in position and calibrated All Opt./IM *Note- All Control Valve should be kept on Manual Mode as far possible 5 Try out individual pumps without load, after routine check-up of the Pump pump and the motor. Ensure correct direction of rotation of the Operator motors. Keep all motors energized 6 All fire fighting equipments like fire extinguishers, steam hoses should be in position

All Operators

7 Commission all the utilities. Circulation water to be commissioned keeping individual cooler/condenser isolation valve closed

Field Operator

8 Flare, closed blow down, oily water sewer and flushing oil systems are to be in operable condition

Field Operator

9 All related agencies as detailed below should be informed about start Shift up: In Charge    

TPS Water Block/CETP RSM/Fire Station GRE/GR Crude Controls/OM&S/GHC

 Laboratory 10 Surface drain of the Unit should be routed to OWS, and towards open Fur/Field channel should be closed Operator 11 Area should be cleared of debris, scrap material etc

All Opt./ Maint. Group

12 Commission steam to all steam tracers.

All Opt./IM

13 Receive slop cut/ VR in unit fuel oil tanks VR drum/E-6/E-7 to keep these full. Establish IFO circulation.

Furnace Operator

14 Prepare caustic, ammonia and demulsifier solutions and keep the same ready.

Field Operator

9.2 AIR REMOVAL & PRESSURE TEST Air from various equipment piping etc. is eliminated by steaming of various sections of the unit to expel air can be carried out simultaneously or in a convenient sequence. The following basic points should be taken care during steaming of the equipment systems:


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 242




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



Cooling water to the condensers and product coolers to be isolated and water should be drained out from the condensers, coolers etc. (This is to avoid condensation of steam in large quantity in these equipment due

to flow of

cooling media, i.e. cooling water. It may lead to frequent hammering in unit equipment)   

Keep waterside vents and drains of condensers/cooler opened. Keep instrument tapping like PT, FT etc. isolated from main process piping. Electric supply to the desalter should remain cut off.

SrNo 1

1.1 1.2

1.3

JOB DESCRIPTION

ACTION BY

Keeping all vents and drains at columns, furnaces and HEs open introduce steam at following locations: a) Crude pumps' common discharge line *All the CVs by B/V to be crack opened to remove air from by line. b) Service steams for K-1, K-4, E-1, E-2 and E-4 c) Stripping steam to K-1, K-6A/B, K-2, K-3A/B and K-3C *Note: 1.Steam to be introduced at a slow rate to avoid any damage to column internals. 2. Vigorously steam for at least 4 hours and then shut off crude column vent. Allow steam to vent from atmospheric column reflux drum d) Purging steam to furnace coils *Note: Pilot burners and if required gas burners can be lit to maintain heater box temp around 200OC to avoid steam condensation and hammering in furnace coils e) Hoses at Heat exchangers Open fire box purging steam and purge for at least 15 minutes. Simultaneously get the blinds from fuel gas line removed Light all the pilot burners in F-1/F-2/F-3, one by one. For this, switch on the igniter for 5 to 10 seconds and open pilot gas valve of the same. Ensure that the first burner gets ignited immediately, otherwise close the gas valve, switch off the igniter and purge the furnace again The low point drains of pipes and equipment should be kept open to remove condensate. *Note- 1.During initial steaming, line rust etc. may frequently keep coming and chocking the drains. Special care should be taken to ensure that none of the drain points are chocked due to accumulation of foreign material. High point vent should also be opened for air removal 2. No steam condensate should be allowed to accumulate inside unit equipment.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Fur/Field Operator

Fur/Field Operator Fur/Field Operator

Field Operator

Vol-I (Addendum)

Page 243


4



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Pressurize K-1, K-4, E-1 and E-4 up to 1.0 kg/cm2 (g), and K-2, and E-2 up to 0.5 kg/cm2 (g) for 2 hrs. Check all the columns, vessels from top to bottom for any leakages (Including flanges, nozzles & instrument tapings). If any leaks observed get it attended Steam Following Circuits:

Field Operator All Operators

Fur/Field Operator

I. Crude pumps' discharge to K-1 bying desalters Pump H-2/2A/2B/2C3PC3101 3TV3125AE102A/B(S)E103A(T)/E103B(T)HM3A/B(T) E104A/B(S))-*DS-O 3TV3125BE301A/B(S)E302A/B/C(T)E303(S)E305(S)-----------  (Desalter is to be kept byed)

DS-N

*3TV3102A/3TV3102B E320(T)HM3E/F(T)HM3C/D(T)HM3A/B(T)-------- 3FC3110K1   E306A/B(T)E307(S)E308A/B/C(T)-------- * Note- Desalter air removal & pressure testing will be done separately by connecting steam hose to crude outlet line. II. F-1/F-2/F-3 to K-2 H-41A/B/C E317A/B (S)E309A/B/C (S)F1/F2/F3K2 III. SK, HSD and RCO run-down circuitSKO + Kero-1 R/D circuitPumpH-10/10AE303(T)3FC3111E301A/B(T)T-14AR/D 3FC3208 P-305A/B Pump HSD + K-3A Nap + K-6A Nap R/D circuitPump H-4/5AE306A/B(T)E305(T)E311(T)TC31313FC3135 E102A/B(T)E315(S)R/D 3FC3210P304A/B/C pump RCO R/D circuitH-11/11A/H-42E09C(T)E309A/B(T) HMA/B (S)HMC/D (S)HME/F (S) E320A/B (S)* E308A/B/C (S)E302A/B/C (S)---HV1001B---- *HM3A/B ((S)E103B (S)/E103A (S)—HV1001A--------------------- R/D Hot T16/16A/B/C/D/ER/D Cold


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 244




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

IV. CR-I to K-1 & CR-II (SKO), CR-III (SRGO) to K-2 circuitCR-II CircuitPump P-302A/BE104A/B(T)3TC31303FC3502K-2 CR-III + CR-1 CircuitPump P307A/B3TC3505E317A/B(T) E307(T)----K-2 E313(S) K-1CR-1 CR-1K1 *Note- 1.Steaming is to be done in one direction & steaming to be continued till last vent point temp reaches 1000C or till clear steam starts coming out from all vents (clear steam venting for at least four hours shall be an indication of fairly good air removal). 2. Eliminate air through all exchanger vent points and drain out condensate from all exchanger low points. 5 Close all vents and adjust pressure to 0.5 kg/cm2.

Field Operator

9.3 GAS BACKUP

SrNo JOB DESCRIPTION 1 Throttle steam and start backing fuel gas into system to E-1, E-2 and E-4 (from by of C/V) & to columns from reflux drums *Note- Pressure surges during fuel gas backing-up should be avoided. Ensure that all vents are closed and properly capped before FG back up. 2 Stop steam completely and ensure no vacuum is generated 3

Stop main gas burners in all furnaces & keep all pilot burners on.

4

7

When gas starts coming from drains close all the drain valves. *Note- All the drain points to be monitored and not to be left unmanned. As soon as gas comes from the drain close the drain valve. Continue condensate draining (repeat every ½ hour) of system from all low point drains till system is free of condensate. Ensure that system pressure does not exceed 0.5 kg/cm2 for K2 & E2 & 1.0 kg/cm2 for K1, E1, K4 & E4 Get all vents blinded/capped

8

Stop gas back to system & line up C/Vs to gas away/flare.

5 6


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

ACTION BY Field/ Operator

Fur/Field Operator Fur/Field Operator Field Operator Field Operator Field Operator Field Operator/M M Field

Vol-I (Addendum)

Page 245




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Operator

9.4 COLD CIRCULATION

SrNo JOB DESCRIPTION 1 Commission all instruments, alarms and control valves & check the interlock wherever possible. 2 Get one tank lined up at Crude Control exclusively for AU-3 3

4

5

6

7

8

Line up equipments as follows: Crude Tank  Crude Pumps  crude preheat Exchangers  Desalters with vents open. Fill up desalters completely. Expel air from vents completely. Settle water and drain keeping vent valve open. Again receive the crude and top up Desalter. *Note- Keep Desalter in line as surge vessel. Desalter not to be energised. Keeping Desalters in line receive crude and fill up K-1 slightly below 100% level shown by bottom LC. Settle water and drain it from column bottom drain and H-41 A/B/C drains Start H-41A/B/C, transfer crude from K-1 to E-317A/B E309A/B/C F-1/F-2/F-3 (one by one in turn for 15 minutes each and then all) to K-2 for about 45 minutes and build up 70% level in K-2 and make up crude level in K-1 by crude pumps H-2/2A/2B/2C. Then stop both crude pumps and K-1 bottom pumps. Settle water; drain the same from K-1/K-2 bottom drains and H-41A/B/C as well as H11/11A/42 pumps drains Close crude battery limit valve. Start H-11/11A/42 and pump through RCO circuit, circulation line, crude pump suction, crude preheat exchanger trains to K-1. During this keep heat exchangers T-2C T-3 and E-308A/B/C RCO side drain valve open till crude comes out. Settle crude in K-1 and drain- for 2 hrs (If required make up K-2 level by running H-41A/B/C again). Establish cold circulation as following Crude pump (H2/2A/2B/2C)  Crude preheat exchangers  K1H-41A/B/C  E-317A/B E-309A/B/C  F-1 + F-2 + F-3  K2H11/11A/42 RCO heat exchangers/coolers  Circulation line  Crude pump(H-2/2A/2B/2C)

ACTION BY Operator Shift In Charge Field/Pump Operator Field/Pump Operator

Field/Pump Operator All Operators

Field/Pump Operator

All Operators

9.5 HOT CIRCULATION


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 246




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

SrNo JOB DESCRIPTION 1. Open the shutdown valves on main fuel gas lines as per shutdown valve opening procedure given in interlock system, and light main burners as and when necessary to raise temperature in F-1/F-2/F-3. 2. Raise COT at the rate of 40OC per hour up to 120OC. Initial lighting of the burners should be evenly distributed and frequent checks are to be conducted since at the initial stage, burners may tend to get extinguished. 3. When K-2 bottom temperature reaches 80OC and K-1 bottom temperature slightly lower (~ 60OC), drain free settled water from columns. From time to time drain water from K-1, K-2, E-1, E-2 4. If at any stage vapour locking of K-1/K-2 bottom pumps occur remove it through vent coolers. 5. Hold COT at 120-150 OC or bottom temp >100 OC for 4 hours. By holding the temperature, the remaining portion of water from the entire circulating crude is expected to boil off in K-2 mostly and K-1 partly and shall get condensed in E-2 and E-1. Drain water from E-1 and E-2 at regular intervals. *Note- At this points columns to checked from top to bottom for any leakages 6. Raise COTs of F-1/F-2/F-3 at the rate of 40OC per hour and hold common COT at 200OC. Get column manhole/ heat exchanger covers and flanges, condenser covers and flanges hot bolted. Take complete round of Unit to see if any flange is fuming. Get it hot bolted. 7. Increase COT @ 40OC/hr up to 300OC *Note- Light oil burner in F1/F2/F3 as per requirement 8. When level appears in E-2, drain out water thoroughly and start refluxing in K-2. When K-2 pressure tends to go up, commission K-2 top PRC. 9. Hot bolting to be done again when COT reaches 300OC. 10.

11.

ACTION BY /Fur Operator /Fur Operator

Field Operator /Pump Operator /Field Operator

Fur Operator/MM

/Fur Operator All Operators

Fur/Field Operator/MM /Field Operator

When K-2 bottom temperature goes up to 240OC, open column bottom stripping steam, after commissioning 3 ata steam header and thoroughly draining out steam condensate. While going up on temperature, watch carefully the following: a) Maintain the rate of rise of COT at a steady rate of around 40OC. This is important to avoid thermal shocks to equipments ALL Operator and pipelines. b) While on hot circulation, RCO cooler outlet temperature should not be allowed to go beyond 50 - 55OC so that the crude feed pumps do not get vapor-locked. Adjust cooling water as necessary. In case of huge vapour lock, water hose can be used


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 247


12.

13.

14.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

on H-2/2A/2B/2C on temporary basis c) Maintain minimum flow – 60m3/hr in 410-F-01,90 m3/hr in 410-F-02, 10mt/hr in 410-F-03 d) Maintain maximum skin temp – 450 Deg C in 410-F-01/F-02 & 475 Deg C in 410-F-03. Any possible leakage should be detected in time and immediate remedial action is to be taken so that the same does not result in any fire or any other emergency situations. Once stripping steam is introduced at K-2 bottom open SRGO drawoff TRC 3TC3505 manually and slightly, to avoid flooding in this zone. As level builds up in stripper K-3B, start SRGO (HSD) run-down pump and route the off-spec product to intermediate tank-214. *Note- At least 1 hour prior to stripping steam introduction to column thorough condensate draining to be started & to be continued till stripping steam commissioned. When K-2 bottom temperature is above 250OC, take the Unit out of hot circulation. This is done by taking in fresh crude and breaking the circulation, routing the RCO ex cooler to RCO R/D system Flush circulation line with diesel

/Field Operator

/Field Operator Field Operator

9.6 BRINGING UNIT ON STREAM SrNo JOB DESCRIPTION 1. With the ission of fresh crude, start ammonia injection to K-1 and K-2 overhead lines and caustic injection to desalter outlet at dosage commensurate with low throughput and also start Ahuralan injection to K-1/K-2 overhead lines 2. In case K-6A/B is to be taken on line, water draining from the strippers through P-305A/B and P-304A/B (as per flexibility) pumps is to be done. Start the pumps. Start drawing heavy naphtha to K6A and kero-I to K-6B by opening respective LCs. Commission CR-I line and start CR-I to K-1 at a slow rate later when draw-off temperature is going high. 3. Keep on raising the COTs till they reach the normal level. 4.

5.

ACTION BY Field Operator

/Field/ Pump Operator

/Fur Operator /Field/ Pump Operator

Open side-cut heavy naphtha-II draw-off TRC 3TC3506 to get required tray temperature. Adjust SRGO TRC also, to get required tray temperature. Withdraw Kero-II to maintain tray temperature. Start stripping steam to the strippers, if required, after thorough draining of steam condensate. Start pump P-304 and inject heavy naphtha to SRGO. Route products to intermediate tanks. Establish Kero-II CR when E-2 gasoline reflux flow goes up beyond All Operators


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 248


6. 7. 8.

9. 10.

11.

12.

13. 14.

15. 16. 17. 18.

19. 20.



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

normal value as follows, keeping 3TV3130 fully open. Pump P-302A/B E-104A/B 3TV3130K-2 Commission K-2 split range controller on E-2 When continuous flow from E-1 and E-2 is available route it to OM&S in MS pool via AU-4 or AU-1 Start P-307A/B SRGO CR pump and route hot stream flow to E-106 through TV-3605 and slowly increase K-4 bottom temperature and divert balance SRGO to K-1 bottom residue HE E-317A/B. Commission K-4 bottom LIC and maintain level by routing bottom material to MS pool by pumps H-14 With increase in temperature, pressure will start building up in K4. Build up pressure up to 8.0 kg/cm2. Start continuous make up of E-1 gasoline to K-4 and route K-4 bottom to MS pool. Stop H-14 as K-4 bottom naphtha shall flow by K-4 system pressure Commission K-4 top PRC and divert gas-to-gas away system

As level starts appearing in E-4 drain water from E-4 and start K-4 reflux pump H-15/15A. Adjust reflux flow and SRGO CR through E-106 to make on-grade LPG. Route on-grade LPG to OM&S via caustic wash in GRE and K-4 bottoms to General Naphtha via Au-4 or AU-1/2 for reprocessing after bying cooler T-18A. Get blinds inserted on all columns' vents, transfer lines' drains and columns' drains Check products' colour frequently at sampling point and send the first set of samples for laboratory analysis as soon as K-1/ K2 section stabilises. Make necessary adjustments, based on results reported by laboratory Route all products to regular run-down systems when results are OK Start Ahuralan injection to K-4 overhead line Get crude booster pump started at Crude Control and start raising the throughput gradually, without upsetting Unit conditions Start demulsifier injection into crude, desalter current and DM water injection into crude (take DM heaters on line), to bring desalter up to normal operation conditions Drains and bleeders, which are not required for periodic routine check-up or operation, are to be plugged off/blinded Reprocess material in slop tank-214 at the earliest, so that the tank is always available for handling emergencies


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

/Field Operator All Operators All Operators

All Operators /Pump Operator

/Field Operator /Field Operator

Operator/MM /Field Operator

Field Operator Field Operator /Field Operator /Field Operator /Field Operator/MM /Pump Operator

Vol-I (Addendum)

Page 249




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER - 10 EMERGENCY PROCEDURES 10.1

GENERAL GUIDELINES

Outlines of procedures to be followed in case of emergencies arising out of failures like power, steam, water and heater tubes failures are given in this section. However, emergencies may be of many more types than can be outlined in an operating manual. An emergency may call for quick adoption of some alternative steps, reduction in T’put, sectional circulation or sectional shutdown, complete unit circulation or complete unit shutdown, shutdown as per normal shutdown procedure or emergency shutdown procedure etc. depending on the type, extent and duration of the failure. Hence judicious spot decision is required to be taken. However, the general guidelines given below are to be ed while deciding and acting: i.

The product inside the heater coil should not get excessively heated, to avoid coke formation. Heater coils should not run dry. Cut off oil firing and gas firing before putting off the pilot gas burners. Close the unit limit gas and unit B/V and depressurize the gas line to flare line. Firebox purging steam should be opened immediately after cutting off pilot gas burner. Heater coil pressure must be lower than available steam pressure, when coil-purging steam is opened.

ii. iii. iv. v.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 250




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

vi.

If coil purging in F-1, F-2 and F-3 becomes necessary, no condensation of steam inside the coils is permitted, since the last tubes are of stainless steel. vii. The ivation solution should be prepared at the earliest, since the same may be needed for ivation of F-1, F-2 and F-3 coils. viii. Steam flushing of individual oil burners, is required to keep the tips free for subsequent light up. ix. Fuel oil BPC by valve is required to be opened in time, so that BPC pressure does not exceed 6.0 kg/cm2. x. No excessive pressure surge or level build up in columns, vessels etc. are to be allowed. Attempt is to be made to avoid any safety valve popping. xi. No off grade materials is to be allowed to go into on grade tanks. Hence, timely closing of rundown valves or diverting product rundowns should be ensured. Inform concerned sections about stopping/diversion. xii. Crude feed line battery limit isolation valve is to be closed before establishing circulation. xiii. While on hot circulation, LSHS/RCO cooler rundown temperature should not exceed 50-55OC, to avoid feed pump losing suction. (Temp. is to be controlled by pinching water to LSHS/RCO coolers) xiv. While pumping out any material from the unit pump out temperature has to be low enough. xv. Timely closing of stripping steam isolation valves must be ensured, to avoid pressure surges in the column or product backing up into steam line. Keep bleeders on the steam lines, mainly on 3 Ata steam line opened to avoid back up of product. xvi. Crude oil and LSHS circuits must be flushed with diesel at the earliest convenient time to avoid congealing. xvii. Proper vigilance in the plant to be observed by operating personnel to avoid near fire or fire likes situations. Timely actions like blanketing by opening steam lancers may help avoiding near fire situation to develop into a fire situation. The major emergencies encountered are:  Power failure  Steam failure  Water failure  Instrument air failure  Crude feed failure  All utilities failure  Failure of heater coils  Failure of heater interlocks  110V DC supply failure  24V DC supply failure  UPS failure  US failure  Fire in the plant


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 251




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Failure of Critical equipments (Pump, Exchangers, Coolers, Condensers etc) / important control valves & critical process indication. Furnace Oil Failure

 

The general emergencies are being described hereunder: 10.2 POWER FAILURE 10.2.1 PARTIAL POWER FAILURE Partial power failure may be due to power dip, cable fault/short circuit or fault in sub station. a.

In case of power dip quickly identify the tripped equipments and restart the same. In some cases resetting in the substation may be needed. Start the standby equipments and call for help from SS-4. In case standby equipment also cannot be started, call for urgent help from sub-station 4 and sustain operation, if possible, on reduced T'put and downgrade products to off spec tanks. Normalize as soon as resetting is done. Failure of supply to one set of equipments receiving supply from one common source located in substation. Start all standby equipments immediately, and proceed as in case (a). Failure of supply to equipment due to cable or any other electrical failure related to that equipment only. Start the stand-by equipment.

b.

c.

10.2.2 TOTAL POWER FAILURE This may be due to: i.

Load shedding as per load shedding scheme,

ii.

Overloading or tripping or malfunctioning of transformers or any other problem with equipments common for supplying power to all equipments.

iii.

Failure of supply from TPS, due to various reasons including possible

cable fault.

EFFECTS OF POWER FAILURE The immediate effects of total power failure are: a.

All motors will stop, resulting in: i. ii. iii. iv.

No flow through heater coils. Hence possible overheating inside the coil, resulting in coke formation. No flow through fuel oil circuit. No reflux to column top, which may result in top temperature and pressure shooting up. Increase in vapour load from column top temporarily due to which reflux accumulator’s levels may tend to go up. Some vessels safety valves may pop. No flow through heat exchangers, resulting in thermal shocks, which in some cases may result in exchanger leakage and fire.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 252

. Indian Oil Gujarat Refinery v.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

b. c.

No flow through pipelines and other equipments may result in leakages due to thermal shock anywhere in the unit and thus may result in fire. There will be no illumination in the plant (except emergency light). DCS system may get affected as follows:

d.

DCS will be on battery back up for 4-6 hours If battery backs up also fails No indications of process variable in Screens will be blank C/V will go to fail safe position No controlling action Shutdown interlocks will be actuated Heater refractory may get thermal shock. Refractory bricks may fall.

Such a total power failure may again be of short duration or long duration. 10.2.3 TOTAL POWER FAILURE SHORT OR LONG DURATION Actions To Be Taken : In case of a total power failure of short or long duration, proceed as follows: JOB DESCRIPTION 1

2

3 4 5 6

7

Action By Cut off heater firing completely. Since the fuel oil pump /Furnace has stopped with power failure, cut off gas firing by shutting Operator off main gas valve at furnace. Close individual gas burners valves. Close individual oil burner valves and flush out oil burner guns with steam. Stop pilot burners. Open firebox purging steam. Close stripping steam to K-2 and K-3, by closing control valves, isolation valves and by valves. Leave the bleeders open to avoid oil backing up into steam line. Stop water to LSHS coolers to avoid congealing. Close discharge valves of all pumps. Keep watch on pressure of vessels and release the same to flare whenever needed. Check up throughout the unit area for possible near fire or fire situations. Take immediate steps.

/Furnace Operator Field Operator Pump Opt Field Operator All Operators

Unit to taken on cold/hot circulation. If possible, otherwise All Operators keep the unit under shut down condition. After power resumption unit to be started as per normal procedure.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 253




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

FAILURE OF ALL UTILITIES TOGETHER

Another probability is total power failure throughout the refinery, which will result in failure of power, water, steam and air (since the circulating water pumps as well as the air compressors are all electricity driven). EFFECTS OF ALL UTILITIES FAILURE a.

All motors will stop, resulting in : i. ii. iii.

No flow through heater coils No reflux to column top, i.e. rise in top temperature and pressure. Excessive increase in vapour load from column top, resulting in popping of columns' and vessels safety valves' popping. iv. No flow through heat exchangers and pipelines, resulting in thermal shocks, which may result in huge, smoke and fire. b. There will be no illumination in plant/refinery area. c. No cooling water flow will be available; thereby condensers, coolers and vessels will also get subjected to thermal shocks. Also this will further increase the vapour load in the overhead system, which will result in popping of safety valves in vessels and columns. Also, there may be lot of hammering at various locations. Pipe rupture or leakages can also take place d. Alarm signals will not function. All instruments, including indications, will stop functioning. e. Heater refractory will get thermal shock and chances of bricks falling are there.

Action To Be Taken JOB DESCRIPTION 1 2 3

4

5 6

Action By Cut off heater firing completely. Shut off main gas line Furnace/Field battery limit valve. Operator Close individual valves on gas burner and oil burners. Purge Furnace Optr oil burner tips momentarily with available steam. Open all primary air ducts wide, to avoid any possible Furnace Optr pocket formation inside the furnace. This operation may be done after some time to avoid thermal shock. Close stripping steam to K-1, K-6, K-6 and K-3 by closing Field control valves' isolating valves and by valves. Open Operator bleeders in between to prevent oil backing up into steam. Close discharge valves of all pumps. Pump Operator Since a large number of safety valves may pop, ask to check Cru Field Operator up and control liquid level in flare knock out drum.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 254




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

7 8

Release pressure from reflux vessels into the flare system. As soon as water supply is available, condensation and cooling will start. Stop water flow to RCO cooler, to avoid congealing, watch for levels in condensers, which may or may not rise abnormally, depending on the amount of vapour still available. 9 As soon as steam supply is available, open purging steam into heater fireboxes. Open small amount of steam into F-1, F-2 and F-3 coils, displacing oil into column K-2, in case power supply is still not available. 10 Survey the Unit conditions and find out possible time of availability of power supply. 11 Reload the HM for DCS system on resumption of power. Based on the Unit conditions and time lag before power is made available, decide on the further course of action which may be any one of the situations mentioned earlier.

Field Operator Field Operator

Furnace / Field Operator

I/M

10.4

STEAM FAILURE Effects Of Steam Failure Will Be As Under : a. Atomising steam to oil burners will not be available. Due to improper atomisation, the burners will initially be smoky and with further drop in steam pressure, there is the risk of oil spraying in the hot surfaces of the furnaces (fire/ explosion hazard). b. Stripping steam to K-1, K-6, K-2 and K-3 will not be available. If this is not isolated immediately, oil may back up into the steam line. c. Fire fighting and other utility steam will not be available. d. No steam through steam tracers will be available. This is not of any immediate consequences, but in case of prolongation of steam failure, RCO/FO lines may get congealed. e. No steam for mechanical seals of hot pumps will be available causing fire back-up of HC on steam lines requiring stoppage of such pumps and isolation of steam lines. If the steam supply is expected to be restored quickly, proceed as follows : Action To Be Taken JOB DESCRIPTION 1

2

Action By Stop K-1, K-6 ( in case in line ), K-2 and K-3 stripping steam Field Operator by closing control valves, isolation block valves and by- valves. Open bleeders to avoid product backing up into steam line. Stop fuel oil pump, close individual oil burner's valves, Furnace Operator momentarily purging the oil burners tips with available steam. Close steam valves. Simultaneously close individual gas burner valves and close gas line valves at TRC-s and at battery limit. Open primary air ducts after some time.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 255


4

5



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Reduce the t'put and bring the Unit on circulation as quickly as possible. Continue with Feed pump--K-1-- K-2 circulation. Keep watch on RCO cooler outlet temperature, which should not be more than 50--55OC. Keep bleeders on steam lines open at suitable locations so that possibilities of oil backing up into steam line get eliminated and condensate drains out easily on resumption of steam supply. As soon as steam supply is restored, open purging steam into the fireboxes of the furnaces and after thorough purging, light up burners as required, and following normal start up procedure bring the Unit on stream, as quickly as practicable. Thorough draining of condensate is to be done before opening stripping steam.

All

Field Operator

All Operators

10.5

WATER FAILURE Effects of water failure will be : 1 No water flow through condensers and coolers. Columns' and vessels' pressure will shoot up and refluxing into columns will suffer. Products' outlet temperatures and circulating reflux 2 temperature will rise abruptly. 3 Pump glands and bearings will not get the required cooling water, after some time. 4 Thermal shocks and hammerings at various locations are expected. Action To Be Taken JOB DESCRIPTION 1

2 3

4 5

Action By Cut off firing infurnaces immediately. Stop oil as well as gas Furnace Operator firing. Open firebox purging steam into all three furnaces. Close each burner valves. Steam-flush the tips of oil burners after closing the same. Simultaneously reduce t'put quickly to minimum, say 3750MTPD. Operator Stop stripping steam to K-1,K-6 ( in case in line ), K-2 and K- Field Operator 3. Close control valves' isolation valves and by valves. Establish K-1 -- K-2 circulation and allow the furnaces to cool down. K-1 -K-2 circulation may require repeated All Operators attention initially, due to higher temperature of circulation in absence of water in RCO coolers. This may be done as long as some water for pumps' bearing cooling is available. Field Operator Watch columns' and vessels' pressures, excess being released to flare system. Pump Operator Stop all pumps before water pressure fall down to zero. On resumption of water supply, depending on Unit conditions


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 256




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

at that moment, the Unit may be started up as per normal start up procedure after proper checking of line-up.

10.6 INSTRUMENT AIR FAILURE Instrument air is supplied to the Unit at a pressure of about 6.7 kg/cm 2(g) from the TPS compressor house. It is taken to an air receiver E-11 and from there it is taken to the Unit. PRC on this line maintains the supply pressure at 3 kg/cm2(g) in the header. Each instrument is supplied with air at a constant pressure of 1.4 kg/cm2(g). In case of failure of running compressor, when the other is under maintenance, air compressor at CRU/FCC is started immediately. There may be time gap of about 5--10 minutes. Air receiver in the Unit can supply air for this time interval. If due to some reasons, air supply cannot be restored within this period, then the supply line header pressure will fall below 3.0 kg/cm2(g). EFFECTS OF INSTRUMENT AIR FAILURE i.

All heater FO/FG control valves will get closed, i.e. firing to heater will get cut off. Column top TRCs will open fully. ii. Fuel oil BPC will open, resulting in drop of FO pressure. iii. All FRCs will open fully, i.e. all levels will tend to go up. iv. All LICs will open fully, i.e. all levels will tend to drop. v. Main steam PRC will open fully. vi. Stripping steam to columns will open fully. vii. K-2 top PRC split range control valves will close from the make up side and will open to the flare side. Rest all PRCs will open. viii.E-1 and E-2 inter-phase level control valves will close. ix. Three-way valves will line up in the following ways : a. 3 TV3129 at P-301A/B discharge will line up flow towards E-313A/B keeping by closed.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 257




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

b. 3 TV3131 at E-311 tube O/L will line up flow towards E-102A/B keeping by closed. c. Byes of 3 TV040 and 3 TV3135 will close. d. 3TV3605 at E-106 will open by. E-106 will not yet get any hot medium. Pressure, flow, temperature indications will be available while level indications will not be there. SOV will go to safe position.

x. xi.

Action To Be Taken

1

2

3 4

5

6 7

JOB DESCRIPTION Proceed as follows : If industrial air supply is still on, take industrial air into instrument air receiver, after thorough draining of condensed moisture. Continue this draining by leaving the drain valve crack open. If industrial air supply is not readily available, or if instrument air supply is not expected to resume soon, cut off heater firing completely. Open firebox purging steam and steam flush individual oil burners after stopping the same. Close stripping steam to K-1,K-6 ( in case in line ), K-2 and K-3. Take column top TRC-s on by. Stop flows from E-1 to K4, E-4 to rundown by closing valves. The reflux pumps will then be refluxing alone into the columns. By manual adjustment of the discharge valves of the reflux pumps, maintain a small flow of reflux into columns so that the top temperature does not shoot up and the column pressures remain within limits. Once top temperatures start dropping, cut down refluxes to maintain reflux accumulators' levels.

Action By Field Operator

Furnace Operator

Field Operator All Operators

Establish K-1--K-2 and K-4--K-4 circulations. Close All Operators rundown valves and stop all pumps not connected with heater circulation and column refluxing. Maintain levels in vessels and columns. All Operators In case air supply is not expected early, shut down the Unit All Operators as per normal shut-down procedure. After establishing cold circulation and cooling the system down adequately, all pumps may be stopped. Unit may be started up as per normal start up procedure when air is available. Flush RCO rundown line with gas oil.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 258




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

10.7 CRUDE FEED FAILURE This may be due to crude booster failure, choking of suction strainer of crude booster, etc. Its effects will be rapid loss of level in K-1, which if not tackled immediately, may result in K-1 bottom pump losing suction. Chain effects would follow. JOB DESCRIPTION Proceed as follows : 1 Quickly and drastically reduce t'put, maintaining the operating conditions. Take flow switch on by mode. 2 Check up with crude control station for possibility of resuming of gravity flow immediately. If so, run the Unit on reduced t'put, till corrective action is taken at crude control station. 3 If gravity feed arrangement cannot be made immediately, bring the Unit on hot circulation, with routine care. NOTE: If K-1 bottom pump loses suction due to rapid drop in level in K1, cut off firing in F-1, F-2 and F-3 immediately. Open purging steam in firebox and re-light when K-1 bottom pump takes suction with F-1, F-2 on Natural Draft and F-3 on Balanced / Forced Draft. 4 Continue with K1-K2 circulation. Maintain conditions of all sections as close to normal as possible, if early resumption of crude supply is expected. 5 If supply is expected to be delayed, reduce the COTs to 200OC and circulate. Close stripping steam to K-1, K-6 ( in case in line ), K-2 and K-3. If indefinite delay is expected, shut down the Unit as per normal shutdown procedure. 10.8

Action By Operator

Shift In charge/ Operator

All Operators

All Operators

All Operators

FAILURE OF HEATER TUBES IN F-1, F-2 & F-3

The leakage may be a small one or may be major one. In case of a small leakage (say a small flame, continuous or otherwise), it may be possible to bring the Unit down quickly, going through the normal shutdown steps. During the process, keep constant watch on the extent of leakage and if the same increases, emergency shut-down may be required. 10.8.1 SMALL LEAK Action To Be Taken


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 259




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

JOB DESCRIPTION Action By 1 2

3 4

5

Proceed as follows: Reduce t'put and reduce firing in F-1, F-2 & F-3. Route the products to off grade tanks. Cut off stripping steam to K-6 and K-3. When K-2 bottom temperature is around 240OC stop stripping steam to K-2 and when K-1 bottom temperature is around 180OC stop stripping steam to K-1. Leave some three or four burners in the furnace; continue firing at a low rate and open coil purging steam. When steam comes out through leaky tube, or when fire at leaky point remains extinguished for some time, cut off burners and open fire box purging steam immediately. Proceed further with normal shut-down procedure. Proceed in the remaining sections as per normal shutdown procedure.

/Furnace Operator Field Operator

Furnace Operator

Furnace Operator

All Operators

10.8.2 MAJOR LEAK In case of major leakage, it may be ed that the Unit has to be brought down quickly. Also oil falling through heavy leakage may not necessarily get completely burnt, but may vaporise after falling on hot surface, resulting in formation of possible explosive mixture, with the heat available from hot refractories that may cause explosion. Hence fire must not be extinguished before the oil is displaced with steam past the leaky point of the tube. Action To Be Taken

1

2

3

JOB DESCRIPTION Proceed as follows : Stop feed. Cut off all burners except 3 to 4 and immediately open coil purging steam. Steam into the coil containing the leaky tube should be put in such a way that the leakage does not increase uncontrollably and the main column's safety valves do not pop. Inform crude control station about stopping of feed and ask for gravity line-up. Shut off individual furnace fuel gas line's main valve soon as all but one gas burners are put off, the line being depressurized through the last one which should be at the same location as a lighted oil burner. Once steam starts coming continuously through leaky point of the coil, and fire due to oil spillage in the furnace fire box has got extinguished, cut off the remaining burners and open

Action By All Operators

Furnace/ Field Operator

Furnace Operator


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 260



4

5 6 7

8 9

VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

JOB DESCRIPTION purging steam to the fire-box. Route all products to the off-grade tank-214. Stop circulating reflux pump when it loses suction. Simultaneously, stop stripping steam to K-1,K-6 ( in case in line ), K-2 and K-3. Continue top refluxing, as long as reflux accumulators' levels are available. Remaining material from K-1 has to be drained out in OWS, after adequate cooling. Remaining material from K-2 is to be pumped out to a OM&S. Pumping rate and water to RCO cooler is to be adjusted to maintain RCO run-down temperature at 50-55OC and not above. Rest of the sections is to be decommissioned as per normal shutdown procedure. Go as per normal ivation procedure of F-1, F-2 and F-3.

Action By

Field/Pump Operator

/Pump Operator Field Operator Field/Pump Operator

All Operators All Operators

10.9 CONTROL SYSTEM FAILURE 10.9.1 24 V DC FAILURE EFFECTS : 1. No indication of process variable 2. C/V will go to safe fail position 3. No control action ACTIONS : 1.

If 24V DC failure is partial and critical loops are available, then plant can be run at low throughput. If 24V DC failure is total, then shutdown to be taken as per shutdown procedure. Call I/M for attending. Proceed for plant shutdown and start up after normalisation.

2. 3. 4. 10.9.2

110V AC FAILURE

If 110V AC failure is due to inverter, then SVR will come in line and power supply will be restored. If SVR does not come in line then the following are the effects : 1. US failure No screen 2. HM failure No memory 3. AM failure No supervisory level control 4. 24V DC failure


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 261




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ACTIONS : 1. Call E/M and Electrical Testing for attending power supply 2. Call I/M for HM loading 3. Proceed for plant shutdown and start up after normalisation 10.9.3 110V DC FAILURE 110V DC failure is due to Rectifier then battery back-up will come in line for 4--6 hours. EFFECTS : 1. Battery drain after 4-6 hours 2. SOVs will be operated 3. Interlock system will be actuated 4. 110V AC failure 5. 24V DC failure ACTIONS : 1. Call E/M and Electrical Testing for power supply restoration 2. Call I/M for HM loading 3. Proceed for plant shutdown and start up after normalisation. 10.9.4

440V AC FAILURE

440V AC supply comes through two independent feeders. If one feeder fails, then other feeder comes in line automatically. If both the feeders fail, then power failure is total. EFFECTS : 1. Battery back up will come in line for 4-6 hours ACTIONS : 1. Call E/M and Electrical Testing for restarting power supply 2. If E/M is not able to rectify, take plant shutdown while battery power supply is available. 3.

Proceed for plant start up after normalisation.

10.9.5 DCS/PLC FAILURE/FREEZING EFFECTS: 1. DCS screen will freeze and indications will show the last value (or DCS screen may go blank). 2. DCS clock will rest at the time of freezing. 3. Unit will be running but no control action can be taken from control room. ACTIONS: 1. Printer on line/off line should be used after print commands. Then only printer can be switched off.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 262




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

2.

10.10

Call I/M for attending on priority basis as in the absence of DCS it won’t be safer to S/D or take the unit on circulation in case of any other emergency. . 4. Check C/V openings, temperature and pressure indications at field. 5. Proper vigilance in the field to be observed for changes in critical parameters. FIRE IN THE PLANT EFFECTS: 1. The equipment where fire has taken place due to hydrocarbon leakages will definitely affect the normal running of plant. Action will depend on the judicious observation & action to be taken depending on the situation.

ACTIONS: 1. In no way get panic as it may result in some inappropriate decisions. 2. Initial fire fighting is to be started by plant personnel with available fire extinguisher & water hydrants. 3. Immediately call the fire people at 7333 or 6333 for help. 4. Isolate the equipment or hydrocarbon to the equipment if fire is not being controlled. 5. Damage by the fire to be immediately observed & its effect to normal running of plant. 6. If anything abnormal observed T’put reduction to be started so that unit can be taken on circulation (Hot or cold) or shut down in short duration depending on situation. 7. Product colour to be observed continuously 8. If fire gets extinguished immediately unit conditions to be normalized. 10.11 FAILURE OF CRITICAL EQUIPMENTS 



Failure Of K-2 Top Reflux Pump EFFECTS: 1. K-2 top pressure will rise suddenly & safety may pop. ACTIONS: 1. Start stand by pump immediately. 2. If stand by pump is not available decrease the steam to K-2 to control to top temperature & pressure. 3. Increase CR-II & Cr-III if possible. 4. It won’t be possible to run the unit for longer period in the absence of K-2 Reflux pump so immediately it is to be attended by M/M & E/M & to be taken on line Failure of K-1 bottom pump EFFECTS: 1. K-1 Level will rise leading to E1 naphtha getting coloured. 2. Furnace es flow wills decrease leading to high skin temp or coke formation inside tubes. ACTIONS:


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 263




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

1. Start stand by pumps. With one pump its difficult to run the unit at low throughput. 2. Start cutting firing in all the furnaces. First F3 furnace firing to be cut as flow to this furnace decrease first. 3. If the second pump is not available shortly plant is to be taken on hot circulation. 1. taken on line 









Failure of K-2 bottom pump EFFECTS: 1. K-2 Level will rise leading to HSD & SKO getting coloured. ACTIONS: 1. Start Stand by pump. If stand by pump is not available decrease steam flow. 2. Check the color of HSD. 3. If the 2nd pump is not available shortly unit is to be taken on Hot/Cold circulation Failure of K-2 Steam C/V & FI indication EFFECTS: 1. If C/V gets fully opened immediate effect will be rise in K-2 top pressure & temperature HSD will be colored. 2. If C/V is getting fully closed immediately flash zone temperature will decrease. 3. Products may be off in grade ACTIONS: 1. if K-2 top pressure is not coming down & diesel is also heavy in color the check steam C/V. If its not working by it & get it attended on priority. 2. Reduce COT & T’put. 3. If steam C/V is fully closed by it slowly watching top pressure & temp. Failure of K-2 bottom LC/LI & PI EFFECTS: 1. There will not be proper judgment of level & high level will make the diesel coloured ACTIONS: 1. Attend it on priority & if it can’t be attended for a longer period it won’t be safe to run the plant as bottom level will not be controlled resulting diesel to be off grade. Failure of Exchanger/Condenser/Cooler EFFECTS: 1. There will not be proper judgment of level & high level will make the E1 naphtha coloured & low level will dry the furnaces ACTIONS: 2. By it immediately. In the case of condensers vapour load to be decreased by reducing top temp or reducing T’put. 3. R/D coolers for HSD & SKO where stand by is not available Failure of K-1 bottom LC/LI & PI EFFECTS:


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 264




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

1. There will not be proper judgment of level & high level will make the E1 naphtha coloured & low level will dry the furnaces ACTIONS: 4. Attend it on priority & if it can’t be attended for a longer period it won’t be safe to run the plant. 5. If possible go for circulation or shut down the unit.

10.12 FURNACE OIL FAILURE EFFECTS : 1. No fuel to furnace result in lower COT. 2. Products will go off. ACTIONS : 1. Reduce T’put & if the pump is not available for longer period keep unit on hot circulation.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 265




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER-11

STANDARD OPERATING PROCEDURE 11.1

EQUIPMENT HANDING OVER TO MAINTANANCE:

Equipments are required to be handed over during shutdown/normal operations for maintenance purposes. Procedures given below should be followed to ensure their safe release and safe maintenance work. A.

PUMPS

I. For electrical maintenance  Stop motor as per procedure.  De-energise the motor from substation.  Ensure that “DO NOT OPERATE, MEN AT WORK” board is put on the switch.  Give clearance to decouple the motor, if required.  Give clearance for electrical job.  Since MAY’11, LOTO (Lock Out Tag Out) is being followed. II.

For mechanical maintenance

1. Cold pumps  Stop the pump as per procedure.  Close cooling water.  Close suction and discharge B/Vs.  Ensure the B/Vs are holding.  Depressurise/drain the pump gradually. Note : Depressurise LPG pumps to flare if connection is available. Chemical dosing pump should be flushed with water if possible. Heavy material pumps should be flushed with FLO and then are to be drained.  De-energise the motor from Sub-station.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 266




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

 Ensure that “DO NOT OPERATE, MEN AT WORK” board is put on the switch.  Give clearance for maintenance job.  LOTO to be followed. 2. Hot pumps  Stop the pump as per procedure.  Before depressurizing , close warm up B/Vs.  Close gland sealing, flushing oil.  Stop steam to mechanical seal.  Allow the pump to cool.  Flush the pump with FLO if material is heavy.  Drain/depressurize the pump. Note : Keep the water hose running. In case of high pour point materials like RCO, VR, etc open FLO line to suction and run the pump to displace heavy material into discharge circuit. If FLO is not available drain preferably through cooler or drain gradually.  Rest steps are same as those for cold pumps.

B

HEAT EXCHANGER / CONDENSER COOLER / REBOILER  Isolate and decommission the equipment as per procedure.  Flush the equipment handling heavy material with FLO and steam.  Drain hydrocarbons to CBD vessel E-8. Open the vent valves to ensure complete draining.  Provide blinds/wedge opening towards the exchanger on both the side.  Give steam connection on top nozzle.  Carry out steamimg for 4 hours.  Water flush condensers and coolers handling light hydrocarbons.  Release the equipment for maintenance.

C.

FURNACE  Shut down the furnace as per procedure and blind fuel gas lines.  Open the damper and air s fully.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 267




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

 Isolate and flush fuel oil circuit and blind fuel oil lines.  Steam-purge the header coil to displace coil contents to column ( water washing can follow for complete coil flushing if permitted by metallurgy of coil.)  ivate the coil wherever required.  Carry out decocking operation wherever required.  Open the manholes of furnace.  Blind all steam and hydrocarbon lines.  When the box cools down to around 500C, check for presence of any hydrocarbon.  Give clearance for ‘MAN ENTRY’ and maintenance job. D.

VESSEL  Pump out the vessel completely.  Drain out remaining portion of hydrocarbons to CBD/OWS.  For heavy material vessel, flush and then drain.  For caustic, chemical vessels, dilute the contents with water and then empty out.  Close inlet and outlet valves, safety valves and any other connected lines.  Keep the vent open.  All inlet/outlet flanges should be blinded with wedge opening towards vessel side.  Give steam connection.  Thoroughly steam the vessel for 4 hours. For vessel containing heavy hydrocarbons, more steaming will be needed.  Keep the drains and vents of instrument taps open for flushing. Ensure that steam comes out from all the wedge openings.  Give water hose connection and over-flow water from vessel for about 4 hours.  Drain water completely.  Ensure caustic branch nozzles are free from caustic by opening weep holes etc.  Blind water and steam lines.  Open man-way cover.  Test inside for presence of hydrocarbons with explosimeter.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 268




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

 If above gas test is negative, give ‘ENTRY PERMIT’ for maintenance job. E.

COLUMN  Pump out oil / hydrocarbon from the column completely.  Drain out remaining oil to CBD/OWS.  Deblind steam purging line.  Steam the system for 6 hours. Steam will wet the entire column such that flange opening for blinding and wedge opening can be done safely.  Install blinds with wedge opening towards column on all inlet and outlet nozzles except steam and top reflux line.  Keep the drains and vents of all instrument tappings open.  Steam the column for 6--8 Hrs. Note : Ensure that sufficient steam issues from all the wedge openings. Keep the vent open. Do

not exceed working pressure of column while steaming.  Provide water connection to reflux line.  Keep the column drain fully open.  Stop steaming and water wash for about 4 hours. Do not allow water level to build up high in the column.  Repeat steaming and water washing.  Open top man-hole cover.  Carry out gas test by explosimeter.  If gas test is positive, box up man-hole and repeat steaming and water washing.  If gas test is negative give clearance to open rest of the manholes.  Get steam and top reflux lines blinded.  Ensure for proper ventilation in the column.  Provide air hose / fan, if required.  Give clearance for inspection/maintenance jobs.

F.

CONTROL VALVE


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 269




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

 By the control valve.  Close up-stream and down-stream B/Vs.  Isolate gland seal oil / flushing oil.  Drain C/V loop. Ensure isolation valves are holding.  Give clearance for removing the control valve.  End-blind the open flanges. G.

SAFETY VALVES

1. Safety valves with isolation valves  Take spare safety valve on line if provided.  Isolate the safety valve.  Ensure that isolation valves are holding.  Give clearance to open the safety valve.  End-blind the open flanges. [ N.B. : Safety valves without isolation B/Vs should not be removed. ]

2. Safety valves with no isolation valves on flare side  Take spare safety valve on line if provided. Isolate the one which is to be removed.  Give steam connection and open steam to the down stream bleeder, if available.  Give clearance to remove the safety valve on emergency basis.  Immediately end-blind the open flanges.  Keep water hose on the down stream flange while opening/blinding to avoid air entry.  Use non sparking tool.

H.

INSTRUMENTS


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 270




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

 Close the isolation valves.  Isolate flushing oil to the instruments.  Depressurise the instrument. Ensure isolation valves are holding.  Remove the instrument cap or blind from the open end.  Give clearance for maintenance job.

I.

DESALTER  Desludge the desalter, by and isolate.  De-energise the transformer. Disconnect electrical connections.  Flush desalter with FLO along with rest of the Unit if the total Unit is shut down.  Pump out/Empty out desalter.  Deblind LP steam and top vent.  Slowly open the vent valve.  Start desludging water and fill desalter up to 4th try line.  Open steam to desalter bottom ex nearby connection for hot water washing.  Drain content to CBD/OWS.  Fill fresh water up to 5th try line and drain the content to OWS.  Steam desalter for 4--6 hours.  Blind all the nozzles of desalter except vent.  Open manholes, check for gas and give clearance to Maintenance and Inspection.

11.2

EQUIPMENT TAKING OVER FROM MAINTENANCE

If equipment is not properly checked while taking over from Maintenance it may result in accidents or give trouble during start up.

Check the following items while taking over any

equipment from Maintenance.

A. 

PUMP/MOTOR Check that electrical and earthing connections are complete.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 271




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



Ensure the correct direction of rotation.



Ensure mechanical completion. Check coupling guard is in position.



Ensure cooling water, quenching steam and flushing oil lines are clear.



Pressure gauges should be in position.



Ensure that shaft is free to rotate.



Check that associated lines are de-blinded.

B.

HEAT EXCHANGER / CONDENSER / COOLER / REBOILER

Ensure the following :

Tube and shell cleaning is proper.



Leaky tubes are plugged/replaced.



Shell is painted as per Inspection.



Exchanger is properly boxed up with gaskets.



Check for short bolting.



Bull plugs, thermowells, pressure gauge, assemblies, PSV/TSV are in position.



Insulation is complete.



Earthing connections are completed.

C.

FURNACE Ensure the following :



Heater tubes are cleaned properly.



All foreign materials are removed from the fire box.



Skin thermocouples/oxygen analyzer and other instruments are in position.



Man-ways, explosion doors, peep holes, header box covers are boxed up.



Stack damper operation is smooth and damper's open/close position indicators are correct.



Operation of all burner valves is satisfactory.



Blinding/deblinding is done as per master blind list.



Steam and oil connections to individual burner gun are correct.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 272

. Indian Oil Gujarat Refinery  D.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Area around the furnace is clean. VESSEL While taking over vessel from maintenance check and ensure following items :



Vessel is thoroughly cleaned.



No foreign material is left inside.



Drain points and instrument taps are clear.



Vessel internal including instruments are in their respective positions and properly secured.



Vessel is coated/painted as per Inspection report. Take clearance from Inspection.



No person is left behind in the vessel.



If all the above things are satisfactory give clearance to box up the manholes. Note : Manhole should be boxed up on four bolts in presence of Production staff.



Remove the blind as per master blind list.



Connect all the instruments.



Line up safety valves.



The vessel is ready for service.

E.

COLUMN Ensure the following :



Start boxing up from top.



The tray decks below the manhole are clean and free of foreign materials.



Temporary connections are removed.



All instrument tappings, drain points, distributors, down-comers, inlet and outlet nozzles are clean.



All internals are fitted properly.



All inside fittings like distributors, thermo-wells, floats of level indicators etc are in position.



Tray man-way covers are boxed up.



Manholes are to be boxed up on four bolts after ensuring that nobody is left inside.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 273




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Note : Tray man-way and manholes should be box up on four bolts in presence of production staff. 

All man-way covers are boxed up as above.



Blinding/de-blinding is done as per master blind list.



NRV’s are installed in their proper direction.



Column bottom drains are connected properly.



Safety valves are installed and lined up.



The instruments are in their respective position.

☺

The column is ready for service.

11.3 STANDARD OPERATING PROCEDURE : 11.3.1 PUMPS

Pump is used to transfer liquids from one place to other. Pumps are of three types : (A)

Centrifugal pump

(B)

Reciprocating pump

(C)

Rotary/Gear pump.

11.3.1(A) CENTRIFUGAL PUMP These are most widely used. A centrifugal pump consists of following parts : Motor, bearing housing, coupling, pump casing, impeller and shaft, mechanical seal/gland packing, cooling, flushing and quenching systems.

(A) Start-Up Procedure COLD PUMP 

Check the mechanical/electrical completion.



Check the quality and level of lube oil. Change/top up lube oil, if required.



Rotate the shaft by hand to ensure that it is free.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 274




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



Energise the motor.



Commission cooling water if provided.



Commission quenching/flushing medium to seal /gland packing. Adjust pressure.



Open suction valve and fill the casing with liquid. Bleed if necessary.



Press/start button and check direction of rotation.



Check the discharge pressure and open discharge valve gradually.



Check the amperage of the motor. Adjust the load, if required.



Check for any abnormal conditions like vibrations, abnormal sound, leakage, bearing 

temperature etc.

HOT PUMP The procedure is same as that for cold pump except for the following additional points. 

Open warm-up valve (across NRV of discharge line) to heat the pump before starting.



Pinch /close the warm-up valve after the pump is on full load.

(B) Shut down procedure 

Close the discharge block valve fully.



Stop the motor.



Open warm up b/v for hot pump to keep it hot. Ensure that the pump is not rotating.

(C) Change over of the pumps 

Start the stand-by pump as per standard procedure.



Open the discharge valve gradually. Simultaneously close the discharge valve keeping a watch on the discharge pressure gauge/flow-meter.



Switch off the originally running pump.



Open warm up b/v of hot pump to keep it warm up.

11.3.1(B)

RECIPROCATING PUMP


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 275




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

This is positive displacement pump; hence an outlet must be available for the liquid displaced otherwise the system will get over-pressurized. In reciprocating pump liquid is displaced from suction to discharge by the reciprocating movement of the piston or plunger in a cylinder. The pump consists of following parts : Motor, gear-box coupling, pump cylinder, piston/plunger, stroke adjuster, safety valves, suction/discharge valves.

(A)

Start Up Procedure



Check mechanical/electrical completion.



Check the quality and level of lube oil.



Rotate the shaft by hand to ensure that it is free.



Check the minimum flow circuit and discharge relief valve.



Adjust the stroke length in case of dosing pumps.



Start the motor by push-button.



Watch the discharge pressure. If pressure continues to increase beyond normal pressure,



stop pump immediately and check the line-up.



Check for unusual noise, vibrations, and rise in bearing temperatures of motors and



pumps.

Note : Discharge valve of reciprocating pump should never be closed/throttled while the motor is running.

(B) Shut-Down Procedure 

Stop the motor.



Do not close suction/discharge valve unless it is to be handed over to maintenance.

(C) Change-Over Of The Pumps 

Start the stand-by pump as per standard procedure.



Immediately switch off originally running pump as soon as the pressure starts increasing.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 276




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

11.3.1(C.) ROTARY/GEAR PUMP

In this pump rotary vanes/gears/lobes displace liquid from suction to discharge. This is also a positive displacement pump. It consists of following parts : Motor, coupling, pump casing, vanes/gears/lobes, safety valve, bearing housing. The start-up, shut-down and change-over procedures are identical to those of reciprocating pump.

Routine Checks Following checks should be carried out regularly. 

Quality and level of lube oil.



Pump and motor bearing temperatures.



Abnormal sound and vibrations



Leakage



Pressure gauges

11.3.2 ID/FD FANS

FD fan supplies combustion air to the furnace and ID fan maintains the furnace pressure. Main parts of ID/FD fans are: Motor, bearing housing, coupling, rotor, impeller, suction vanes, discharge dampers etc. Pre-Start-Up Checks 

Check mechanical completion.



Ensure free rotation of shaft.



Energise the motor.



Check the quality and level of lube oil in the bearing housing.



Ensure free movement of suction vanes.

Start-Up Procedure 

Close the discharge damper.



Close suction vanes.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 277




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



Line up air duct/flue gas duct.



By FD/ID fan interlocks for furnaces.



Start fan motor.



Check the direction of rotation and any abnormality.



Open discharge damper.



Slowly open suction vanes of FD and ID fans and adjust air flow/furnace pressure respectively.

Shut Down Procedure 

Switch off motor.



Close suction vanes and discharge dampers.

Routine Checks 

Record pressure, flow, current and bearing temperature.



Check lube oil quality and level.



Check for abnormal sound, vibrations or any other abnormal condition.

11.3.3 HEAT EXCHANGERS

These are equipments in which heat is exchanged between hot and cold fluids of the process, to increase process efficiency. It is used to transfer heat from one fluid to another. Exchangers normally consist of tube bundle enclosed in a shell. Shell and tube type of heat exchangers are used in this Unit.

Commissioning Procedure



Get the HE system de-blinded.



Keep the vent valves of both shell and tube sides open.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 278




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Remove air by steaming or filling with flushing oil.

Note : In case of flushing oil filling, provide an extension hose on vent line for safe disposal of oil. 

Line up PSV/TSV.



Close the vents and provide caps.



Carry out pressure test with steam/FLO for any leaks.



Commission cold side gradually.



Open outlet of heating medium gradually.



Open inlet of heating medium gradually.



Close by valve of cold side.



Close by valve of hot side.



Check for any leaks.



Carry out hot bolting.



Put blinds on CBD lines and caps on drains.

11.3.4 COOLERS Coolers are used to cool a liquid normally prior to storage. Commissioning Procedure 

Air displacement on cooling water side is done by water. Rest of the procedure is same as that of heat exchanger.



Adjust cooling water flow to obtain desired product outlet temperature.

11.3.5 CONDENSERS Condensers are used to condense vapours into liquid form.

Commissioning Procedure 

Steam shell side to displace air.



Pressurise and check for leaks.



Open hydrocarbon inlet valve slowly.



Commission water and displace air from tubes.



Open outlet valve of hydrocarbon side gradually keeping a close watch on column pressure.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 279




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



Adjust cooling water flow to get desired condensate temperature.



Plug / cap the vents and drains

Decommissioning Of Exchangers / Coolers / Condensers 

Gradually open by valve on heating medium side.



Close the inlet valve on heating medium.



Close outlet valve on heating medium.



Leave outlet valve open if exchanger is not to be drained/depressurised.



Stop cooling water of coolers/condensers.



Open by valve of cold medium of exchangers.



Close inlet and outlet valve of cold medium side.



Flush the shell/tube side of the HE elements which are handing high pour point hydrocarbons if the



system pressure is higher than FLO pressure, drain the exchanger to CBD and then flush with



FLO to CBD.



If the system pressure is lower than FLO pressure, open FLO to inlet and open the outlet valve of the HE element to displace heavy hydrocarbons into the system itself .



Isolate PSV/TSV.



If the exchanger is not to be handed over to Maintenance, it need not be depressurised/drained.

Routine Checks Of Exchangers / Coolers /Condensers Following checks should be carried out regularly. 

Inlet/outlet temperatures and pressures on both sides to assess the performance and leakage.



Water outlet temperature in coolers should not exceed 45OC to avoid scale formation.

11.3.6 DESALTER


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 280




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

[ See details in Section-5 ] Desalter is provided to remove water and dissolved salts from crude oil. The main parts of desalter are: Desalter-I (old ) is bi-electric and Desalter-II (new) is mono-electric. Desalter Operation Following are some important points for smooth and efficient operation of the desalters. Desalter Pressure & Temperature 

Desalter pressure should be sufficient to keep the crude in liquid form (around 12kg/cm 2



).

Desalter temperature should be maintained between 120-130 0 C to achieve effective desalting. Higher temperature are required for more viscous crude.

Water Injection 

Water to the extent of 2--6 % of feed should be injected in crude to achieve complete dissolution of salts from crude to water.



Pressure drop across mixing valve should be around 0.3 to 1.0 kg/cm 2. Higher pressure results in efficient but tight emulsion. Hence optimum pressure differential has to be maintained.



Water injection should be further adjusted whether feed rate is changed.



Water injection can be reduced while processing slops or when large quantity of water is present in feed itself.

Demulsifier Injection

Demulsifier is added to the extent of 4 to 10 ppm depending upon type of crude to break the emulsion and quality of demulsifier.

Control Of Oil Water Interface Level


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 281




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Normally oil-water interface should be between 80--100 cm below the lower electrode. Optimum interface level will depend upon the type of crude and oil content of desalter brine.

Desalter current Increase in Desalter current may result from high interface level or short circuiting. If lowering of interface level or increasing demulsifier injection does not bring down the current, then check for short circuit.

In case of Desalter tripping, water injection to crude should be stopped immediately. 11.3.7 FURNANCES

Furnaces are used to heat K-2 feed by using fuel oil/gas. In AU-3:(I) F1 and F2 can run on (A)

Natural draft.

(B)

Balance draft .

(C)

Forced draft

(II) F-3 can run on (A)

Forced draft

(B)

Balance draft

Furnace consist of fire box, tubes, burners, air s, dampers, , ID/FD fans, air pre-heater, igniters, chimney / stack etc.

Pre Start-Up Checks 

All mechanical jobs are complete.



All burner pipings are correctly fitted.



Ensure stack damper operates freely.



Air s of individual burners are smooth.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 282




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



De-blind all the lines excluding fuel gas and decoking lines.



Keep torch ready.



Ensure that draft gauges are in position.



Open stack damper fully.



Close all burner valves.



Check availability of ID/FD fans.

Start-Up Procedure (A) NATURAL DRAFT FURNACE



Establish flow through heater coils.



Open shut-off valves on fuel oil and fuel gas lines.



Establish fuel oil circulation and check for leaks.



Ensure that all burner valves are holding .



Start fire-box purging steam.



Steam for about half an hour.



Remove blind from fuel gas line.



Open the air of burner which is to be lit.



Adjust the air flow to pilot burners.



Stop purging steam to fire box.



Light the torch and insert in front of a pilot burner.



Open the fuel gas valve to the pilot burner.



If pilot burner is not lit, shut-off fuel gas and again purge the furnace with steam for few minutes before re-lighting the pilot.



Do not stand under the burner while it is being lit.



Light all pilot burners one by one.



Keep fuel gas pressure at about 1.5 kg/cm2



Light main gas burners one by one by opening burner valve as per requirement.

Lighting Of Oil Burner


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 283




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



Adjust IFO header pressure to 5.5--6.0 kg/cm2.



Set pressure differential between atomizing steam and oil to 1.5--2.5 kg/cm2(Steam pressure is higher than oil pressure).



Open cross-over steam to oil burner and warm-up for 5 minutes till dry steam comes out from the tip.



Close the above steam.



Partially open atomizing steam valve.



Open the valve on fuel oil to burner gradually to get a small steady flame.



Adjust steam and oil valves to get a clean bright flame.



When all burners are lit as per requirement throttle the stack damper to get draft of 2 mm of water gauge at the inlet to convection.



Check O2 % and adjust the air s to get the O2 level of around 3% in flue gases.



When the Unit stabilizes, take all controls on ‘AUTO’ mode.



Adjust differential pressure of atomizing steam/oil to get a clean bright flame.



The temperature control should be on the fuel oil or fuel gas whichever is predominant.

(B) BALANCE DRAFT FURNACE 

Keep all drop out doors open.



Keep all interlocks on by.



Start FD fan and purge air duct and plenum chamber for 15 minutes. Stop FD fan.



Start the furnace on natural draft as per procedure.



Igniter can be used for lighting pilots.

Switching Over To Balance Draft 

Start FD fan.



Establish airflow through ducts.



Close drop out doors one by one.



Start ID fan.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 284




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



Open suction vanes to maintain sufficiently low pressure at hip arch.



Close stack damper keeping watch on hip arc portion.



Adjust FD / ID suction vanes for excess air control and hip arch pressure respectively.



Put all interlocks in ‘AUTO’.

Shut Down Procedure NATURAL DRAFT FURNACE



Close oil valve of burner. Open steam purge to oil side.



Purge oil into furnace and close steam valve.



Close atomising steam to burner.



Cut off all the oil burners one by one in the above manner till all the burners are put off.



Cut off all the gas burners one by one by closing individual burner valve.



Continue oil/steam flow through the furnace coils till the box temperature comes down to 250OC. Open vent valve of steam coil after closing inlet/outlet valves.



Put off pilot burners one by one.



Open snuffing/purging steam to box and purge for about half an hour.



Flush heater coil with FLO.



Install blinds in main fuel and pilot gas lines.



Close the inlet valve of IFO supply header.



Open the flushing oil valve to IFO.



Gradually flush the IFO header with FLO for half an hour.



Close the IFO return header valve.



Close FLO valve to IFO header.

BALANCE DRAFT 

By all interlocks,



Open stack damper.



Stop ID fan.



Open all drop-out-doors one by one.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 285






Stop FD fan after 10--15 minutes.



Now the furnace is on Natural Draft



Shut down the furnace as per procedure

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ROUTINE CHECKS

Following checks should be carried out at the regular interval. Flame Pattern 

Flame impingement over the tube should not be allowed.



Flame should be clean and bright.



Flame should not be very long, smoky, loose or sparkling. In case of any problem associated with the flame pattern, following items are to be checked : Fuel oil temperature, steam pressure, condensate carry over in the steam, burner alignment,

furnace draft, cleaning of burners, opening of air etc.

Excess Air 

Control excess air such that oxygen content in flue gases is about 3%.



Draft at the convection inlet should be maintained at 2 mm of water gauge.



Adjust stack damper to get the desired draft. If the excess air remains on higher side after adjusting the damper then adjust individual air

s to get the desired level of excess air.

Skin/Flue Gas Temperature



Control the skin temperature below the specified limit ( as in Specifications ).



Control flue gas temperature within the operating limit.



Soot blowers should be regularly operated.



Convection inlet / outlet, radiation outlet temperatures should be monitored.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 286




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Check the condition of fire box purging steam lines (particularly near the furnace) for any corrosion.



Check the external surface of furnace shell for any corrosion.



While checking the flame pattern always use face shield / coloured safety goggles.



In no case furnace draft should be below 1mm of water gauge.



If the soot blower gets stuck up inside the furnace, keep the steam on till it is retracted.



Any abnormality observed should be immediately brought to the notice of the Superior.

11.4 TANK OPERATIONS 11.4.1 TANK HANDING OVER FOR MAINTENANCE: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Pump out tank materials to OM&S respective tank till pump looses suction. Get water hose connection from drain or through dip hatch and build up level for pumping out more hydrocarbon. As far as possible hydrocarbon to be pumped out. Get tank's inlet / outlet and other connected lines (except drain) blinded. Drain tank content to OWS. Get sky light cover and manhole opened. Take further water inside the tank for over flowing of rest hydrocarbon through manhole. Overflowing to be continued till all hydrocarbon remove. Check by explosive meter. If OK then water to be drained out. Leave tank for air circulation. Check explosivity. If OK, hand over the tank for cleaning / M & I job. If explosivity. is not OK, then repeat the overflowing by water more.

11.4.2 CHECK LIST FOR TAKING OVER STORAGE TANK AFTER MAINT AND INSPECTION (Common for all types of tanks) 01) 02) 03) 04) 05) 06)

Tk inside has been cleaned thoroughly and all debris has been taken out. Water draw off line has been cleaned and is through. Datum plate is properly fixed and the top surface is cleaned. Dip tape bob is touching the Datum plate properly, when the dip tape lowered from Dip Hatch. The Actual reference height is matching with the calibration chart value (physical checking). Flame Arrestor has been checked for through ness and fitted properly.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 287

. Indian Oil Gujarat Refinery 07) 08) 09)

10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) 32) 33) 34) 35) 36) 37) 38) 39)



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Gooseneck has been checked for through ness and fitted properly and wire mesh has been provided at the mouth of gooseneck to prevent entry of bird etc. P.V. valve has been checked for proper working and fitted in position. Mechanical level indicator float movement (up and down) along with guide strings has been checked and found OK and its zero reading has been checked when the float is kept at the datum plate level. Dial thermometer has been provided. Steam coil pressure testing was done and certified ok by inspection. Side entry mixer shaft propeller is properly fitted inside the tank and the shaft is freely rotating. Jet nozzle / euducator is fitted properly with its tip facing 45 degree upward. The slope of Tk bottom is towards the water draw-off line. Steam coils are properly ed to prevent bending / hanging of the coil. Staircase condition is ok. Tank insulation is in good condition. Roof skylight covers and all manhole covers have been properly boxed up with fresh gaskets and all bolts have been tightened (after ensuring that there is nobody inside the tank). All tank valves have been fitted properly with fresh gaskets and all bolts have been tightened. Drain funnel to underground OWS is clear and dechocked. Tank shell earthing is properly provided. Fire fighting facilities like foam lines etc. are properly fitted. Deluge cooling facility / spray nozzle cooling water ring are pr provided and their performance has been tested. Operating platform for tank valve operation is as per requirement. Tk pad is in good condition. Approach path from the road to the tank dyke and from the dyke to the tank valve manifold, stair case etc. are clear and safe for movement of personnel. All oil spillage / sludge etc. have been removed from tank dyke enclosure and the area has been properly dressed up. Reference height, safe filling height and product name have been painted properly on the tank shell near the entry point of the staircase and also near the dip hatch platform. Opening in the tank dyke has been repaired properly. Rotary jet mixer assembly at the center is through and properly fitted. Tank bottom having concave shape water collecting sump is cleared at the center. All the scrap and unwanted material is removed from the tank farm. All inlet, outlet, jet nozzles are cleaned and through. Lightening arrester is in position. All tank valves, drain valves, steam inlet/outlet valves are revisioned and fitted. Tank automation instruments are fitted properly and zero check is done. Inside / outside painting is done. Base plates if removed for inspection purpose are welded again. Checking of calibration of tank done.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 288




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ADDITIONAL CHECKS FOR FLOATING TANKS: 01) Pontoon boxes have been checked and found to be free of leaks and pontoon box lids have been properly fixed. 02) Floating rooftop has been cleaned and all debris taken out. 03) Roof drain sump on the floating roof has been cleaned and the perforated cover has been fixed on the sump. 04) NRV at the top end of roof drain has been serviced and fitted back properly. 05) Water seal in the emergency roof drain have been topped up properly and cover is fitted. 06) Floating roof foam seal is in good condition and foam seal weather protector is in good condition. 07) Foam seal vents have been checked for throughness, and also the flame arrestor fitted on the seal vent. 08) Emergency vents on the floating roof are in proper working condition. 09) The non sparking guide ring provided between the floating roof and the dip hatch pipe is properly fitted and is in good condition and it's free movement is observed while receiving / draining water. 10) The sliding ladder on the floating roof is in proper working condition. 11) The earthing wires are properly provided from the deck of the floating roof to the roof ladder and also from the roof ladder to the tank shell (two sets of earthing wires are to be provided in each case). 12) Free up and down movement of the floating roof has been checked by filling with water and then draining. 13) Roof drain system was serviced / pressurize tested and approved by the inspection. 14) Foam dam provided on the floating roof is in good condition. 15) Whether floating roof-ing legs have been adjusted to lower position. 11.4.3 COMMISSIONING OF TANK 1. Gravitate, at a slow rate, from another tank filled with same product, into the tank to be commissioned. The rate has to be slow till the suction pipe is completely dipped under liquid. This precaution is needed mainly incase of lighter oils/hydrocarbons, to minimize static charge generation inside the tank. 2. In case of fixed roof tank normal rate of receipt can be resumed after the above mentioned level is reached. 3. In case of floating roof tank, the intake of product has to be maintained low till the roof flats fully. Thereafter normal rate of receipt can be restored to. 11.4.4 DO'S AND DO NOTS OF TANK OPERATION 1. While gauging stand opposite direction of wind so that vapour if any, is carried away. 2. Lower the dip tape slowly, sliding over the reference plate to avoid generation of static charge.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 289




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

3. Avoid floating roof tank operation in critical zone. 4. While commissioning the tank receive material at slow rate till the suction pipe is completely dipped in liquid.

CHAPTER –12 INTRODUCTION TO DCS

12.1 INTRODUCTION The Distributed Control System (DCS) mainly consists of: 1.

Controller System (AMC)

2.

Interlock System

3.

Data Acquisition System (IPC)

4.

Man Machine Interface (US)

5.

History Module (HM)

6.

Application Module (AM)

7.

Communication System

(C)

Advantages of DCS -

Easy/effective Man Machine Interface


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 290



-

Accurate Controlling Capability

-

Integrity due to redundancy

-

Lesser failure rate and lesser maintenance need

-

Security

-

Large data storage and easy retrieval

-

High speed of communication

-

High flexibility

-

Plant integration made possible

-

Advanced control strategies and optimization


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

12.2 Advanced Multi Function Controller (AMC) AMC is a 16 loop controller. The AMC's are used with redundant processor. All control I/O's (Inputs/Out puts) are connected to an AMC using redundant I/O cards. 12.3 Critical Process Controller (C) C is the processor, which controls the process interlock. C supplied by Tata Honeywell is Triconex make with triple processor with three legs in the I/0 cards and incorporates 2 out of 3 voting logic. One printer is connected to C for sequence of event printing. 12.4 Industrial Programmable Controller (IPC) IPC is used for data acquisition system and for open loops. 12.5 Universal Station (US) Universal Station is the man machine interface. It is a node sitting on LCN, which communicates with all other nodes on LCN. US displays continuous process operating data like trends reports sequence, alarms etc. Also process engineer displays like configuration, point building, graphics building, CL programming, log/report building are available. A brief description of the nomenclature used is given under 11.12.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 291




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

12.6 History Module (HM) History Module is the mass storage media with redundant 2 /0 MB disk. HM communicates with all nodes and keeps record of process and system. It also contains event journals, graphic display files and aids in maintenance. 12.7 Application Module (AM) AM is the media for Advanced Control applications. It accepts inputs from multiple process connected devices and provides control outputs to control elements in the proces or to other data points in modules on the LCN. AM implements advanced calculations, advanced control strategies and optimisation programs.

12.8

Communication System

12.8.1.

Local Control Network (LCN)

a. b. c. d.

Co-axial cable with redundancy (each of 300M max) Links US to other nodes e.g. HM, AM, HG etc. Bit serial communication based on IEEE-802 Uses proprietary token ing protocol which includes havy levels of error checking and connection.

e. f. g. h.

Five million bits per second speed Auto swaping every second with redundant LCN. Can a maximum of 40 rodes LCN Segments can be interconnected by using LCN Extender boards and fiber Optic cables (max 2 KM). 12.8.2.

Data Hiway

a. Co-axial cable with redundancy b. Provides communication between process corrected devices (e.g. AMC, IPC, C etc.) and Hiway Gateway.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 292

. Indian Oil Gujarat Refinery c. d. e. f.

VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Bit serial communication 250 Kilo bits per second speed Can have a maximum length of 20,000 feet Each data hiway can a maximum of 28 devices (e.g. AMC, IPC, C etc) 12.8.3.

a. b. c. d. e. f.


Hiway Gateway

Hiway gateway links LCN nodes with devices sitting on data hiway It converts communication protocol between LCN and data hiway It has 1:1 redundancy Synchronizes time keeping Data access from/to AMC/IPC/C from Data base : 3000 points/Hiway gateway

12.9.

UPS System

12.9.1.

Introduction to UPS

DCS functions effectively only if there is an uninterrupted power supply (UPS). Hence UPS alongwith battery back up is installed as a pre-requisite for any DCS system. The main purpose of UPS is to cater supply requirement of all DCS components in HG, AM, HM and all US status and boxes like AMC's and C's. In addition to above, it also requires catering supply to all peripheral supply like printer, PC's and assignable recorders mounted on DCS. In UPS, there are three independent incoming supply of 440V AC coming from three independent power distribution system and are connected to three modules namely Module-1, Module-2 and SVR. Generally Module-1 and Module-2 are working parallel and SVR is working as a stand by system. Each is capable enough to cater total power supply requirement of DCS. All these three are connected to a battery bank, which will be in charged condition continuously. Battery bank will come in line when all the incoming power supply fails or all the above mentioned three modules fail. However in annunciator system, these windows are kept which indicates for any of the module failure and battery in line condition. A simple sketch shows the power distribution network. 12.9.2. Supply Distribution to DCS System


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 293




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

110V AC supply coming from UPS is distributed to all system cabinet supply through power distribution boxes located in DCS control room. All the nodes require direct 110V AC supply whereas input supply of all transmitters and control valves connected to AMC boxes require 24V DC supply. This is achieved through two nos. of 24V supply boxes located in each marshalling box. 12.9.3.

Types of UPS Failures

12.9.3.1. Any incoming 440V AC supply or any module failure DCS system will not be affected and annunciator will indicate the particular module, which has failed. 12.9.3.2. Total Failure of 440V AC During this time entire DCS supply is met by battery bank. This battery bank can cater the system from 30 minutes to 2 hours depending upon the load of DCS. If the supply is not restored within this period, shutdown is imminent. 12.9.3.3. Partial Failure of 110V AC to nodes This type of failure may be due to fuse failure or power supply module failure. HM Failure : Some selected graphics in the screen will be available where all other operations like PV indication, SP/OP indication/changing can be done through " Details point display of that particular Tag No". However, the following displays will not be available in the screen: - Balance Graphics - Free Format logs/reports - History trending - Events History - Process Retrieval In any case process operation will not be affected. AM Failure :


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 294




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

All the advanced control function will be stopped but plant will be running with its basic control loop and its program connected with AMC's. Advance Process Control (APC) was implemented in the year 2008. It is a technology of HONEYWELL named RMPCT (Robust Multiple Process Control Technology). Its server is placed at MIS building.

NOTE: 26 PAGES CONTAINING SKETCH OF TDC 3000 SYSTEM ARCHITECTURE NOT AVAILABLE IN SOFT COPY FORM.

CHAPTER – 13 LINE-UP OF FEED AND PRODCT CIRCUITS

FEED CIRCUIT: A) PREHEAT TRAIN-I


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 295




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

B) PREHEAT TRAIN-II


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 296




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 297




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 298




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 299




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 300




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 301




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 302




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 303




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER - 14


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 304



VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

FIRE FIGHTING FACILTIES WHAT IS FIRE ? “Fire is burning of matter". In technical fire is a chemical reaction where matter reacts with oxygen under certain conditions to release heat and light energy.

Classification of Fire : Class A

Fires involving solid carbonaceous materials e.g. wood, paper, cloths, rubber plastic.

Class B

Fires involving flammable or combustible liquids or liquefied solids, grease etc.

Class C

Fires involving gases or liquefied gases such as methane, propane, butane, LPG etc.

Class D

Fires involving certain combustion metals such as Magnesium, Titanium, Zirconium, Sodium, Potassium.

Causes of Fires :

Sparks from electrical equipment, heat from friction, open flames, smoking and matches, spontaneous ignition, hot surfaces and heated lines, static electricity, lightning, auto-ignition etc.

Methods of extinguishing Fires :

Starvation

: Elimination of Fuel.

Smothering

: Limitation of Oxygen.

Cooling

: Removal of heat.

Chemical interference : Interrupt chain Reaction.

Different Agents used for Fire Fighting


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 305




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Water, Steam, Foam, Dry Chemical Powder, Carbon di-oxide, Sand etc.

FIRE PREVENTION AND PROTECTION

Fire Prevention

1.

Regulation For The Prevention Of Fires



Ban on carrying of a potential sources of ignition.



Ban on lighting fires in battery area.



Ban on smoking.



Ban on carrying lamps.



Use of spark arrestors in vehicles.

2. General Precautions



Maintain good housekeeping.



Follow the laid down procedure strictly.



Sampling and draining of hydrocarbon should be done under strict supervision.



Do not operate an equipment unauthorizedly.



Use only approved type of tools.



Anticipate the hazards during vessel cleaning and take preventive steps in advance.

FIRE PREVENTION ACTIVITES Fire prevention can best be achieved with the application of :

1. SOUND ENGINEERING


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 306




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

DESIGN OF THE PLANT MATERIALS USED FOR CONSTRUCTION, MEANS OF ESCAPE ETC. 2. GOOD HOUSEKEEPING CLEANLINESS OF THE PLANT, METHODS OF STORAGE. 3. GOOD HABITS OBSERVATION OF FIRE PREVENTION RULES ETC. 4. COMMON SENSE NO SMOKING NEAR INFLAMMABLE MATERIAL ETC.

5. INSTRUCTION TO PERSONNEL 

KNOWLEDGE OF THE JOB.



SAFE PRACTICES.



ACTION IN CASE OF FIRE.



KNOWLEDGE OF FIRE EXTINGUISHERS ETC.

6. REGULAR TRAINING OF EMPLOYEES 

Introduction training programme



Refresher courses



Specialised training programmes

SAFETY AUDITS 

Internal



External

VARIOUS SAFETY STUDIES Ex. Risk Analysis, Hazop, Hazan etc prior to commissioning of any plant or equipment.

COMPLIANCE OF STATUTORY REQUIREMENTS

INSPECTIONS


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 307




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

To check for proper placement and operation of fire protection equipment and seek correction of common fire causes, such as poor house keeping, improper storage of flammable materials, smoking violations and excessive accumulations of dust or flammable material.

FIRE EMERGENCY DRILL An emergency manual can be prepared to outline procedures and drills and detail responsibilities of each individual involved. 

Training



Valuable check on the adequacy and condition of exiting alarm system instills a sense of security among the occupiers if careful plans are made.



Exit Drills



Plant Drills (Mock drills in plant area)



Mutual Aid Drills



On-Site / Off-Site Drills etc.

FIRE STATION Our refinery has two fire stations, each equipped with all modern equipment and trained manpower.

COMMUNICATION E.g. Telephones : Fire call numbers 7333 & 6333; Hotlines for communicating mutual aid member; P.A., Paging Walkie-talkie system; Fire Alarm : By breaking the glass of any of the alarms located in the refinery area : At GR 62 nos. & At GHC 53 nos.; Sirens :11 nos. at various locations.

FIRE PROTECTION Following fire protection facilities provided depending upon nature/risk of the installation :

FIRE WATER SYSTEM:


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 308



VOL-I: Addendum

1) Fire Water Storage

: 22,400 M3

2) Fire Water Pumps

: 8300 M3/Hr.

3) Distribution Piping Network

: Approx. 50 Km.

HYDRANTS

MONITORS

(around 1000)

(around 400)


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

WATER SPRAY SYSTEM (Oil Tanks & Hydrocarbon Pump house) LPG area as per OISD -116.

FOAM SYSTEM Semi-fixed : Provided on oil storage tanks. Railway gantry no.6 Mobile

: Foam tenders 5 nos. & Foam Nurser : 1

MOBILE FIRE FIGHTING EQUIPMENTS Foam Tender

:5

D Tender

:1

Emergency Tender

:1

Foam Nurser

:1

CARBON DIOXIDE PROTECTION SYSTEM : Turbines and Generators in power plants.

FIRST-AID FIRE FIGHTING EQUIPMENTS

First team comprises operation / maintenance staff at site and any other refinery person available at site. These persons will handle the situation till the arrival of trained fire fighters with the help of :

Portable Fire Extinguishers 

DRY CHEMICAL POWDER (D)



FOAM


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 309




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



WATER TYPE



CO2



HALON 10 Kg : 2000 nos. ; 25 Kg trolley mounted : 100 nos.



D -- trolley mounted 75 Kg : 175 nos.



FOAM--type trolley mounted 45 lit.: 30nos.

FIRE FIGHTING TEAM First Main Team : It comprises of Shift-in-Charge of Fire stations and Fire operators on duty with fire fighting equipments & Officers from Fire and Safety Department & CISF personnel.

Second Main Team : Fire operators ( Reinforcement ), CISF staff ( reserve as well as on-duty except for gate staff ), Fire fighting team from external sources ( like neighbouring industries, BMC etc. )

PRE-FIRE FIGHTING PLAN FOR AU-III UNIT Pre fire fighting plan is an important aspect of fire protection and helps to review the major fire hazards and possible emergency scenarios of a unit vis-à-vis the fire protection facilities available to deal with the various possible emergencies. It also helps in making a pre-plan on the methodology of approach to fire and actions required for effective fire fighting and mitigation of emergency. With the above objective, a t survey and study was carried out by Fire & Safety and AU-III production to identify critical fire hazards and facilities available to deal with such emergencies.

The following methodology was adopted:

(A) Identification of possible emergency scenarios (B) Developing preplan for each scenario with following parameters: (i) Consequence of scenario (ii) Identification of critical equipments w.r.t scenario


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 310




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

(ii) Identification of Fire protection facilities available to deal with the emergency. (iii) Approachability of fire tenders to scene of emergency (iv) Action to be taken in emergency (C) Identification of deficiency in the existing system and remedial action.

(A) IDENTIFICATION OF POSSIBLE EMERGENCY SCENARIOS Based on the criticality of equipments, hazardous material handled by the equipments and experience of production and Fire & Safety the possible emergency scenarios envisaged in AU-III units are:

SCENARIO-1

Mechanical Seal Failure of pumps resulting in fire

SCENARIO-2

Leakage & fire in heat exchangers

SCENARIO-3

Leakage of flange leading to fire in top of column.

SCENARIO-4

Furnace fire due to liquid carry over into firebox or tube rupture

SCENARIO-1: MECHANICAL SEAL FAILURE OF PUMPS

I.

CONSEQUENCE: Vapours leading to Fire due to autoignition/ other source of ignition.

II. CRITICAL EQUIPMENTS: PUMP NO.

SERVICE

410-H-2C/2B/2A/2

MIXED CRUDE PUMP

410-H-10, 410-H-10A

KERO-II RUNDOWN

410-H-42

RCO RUNDOWN PUMP

410-H-11/11A

RCO RUNDOWN PUMP

410-H-4

HSD RUNDOWN PUMP

410-H-9

NAPHTHA II & K-2 REFLUX PUMP

410-H-5A

HSD RUNDOWN PUMP


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 311




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

410-H-8

NAPHTHA II & K-2 REFLUX PUMP

410-H-8A

K-1 REFLUX PUMP

410-H-6

K-1 REFLUX PUMP

410-H-14

NAPHTHA RUNDOWN PUMP

410-H-15/15A

K-4 REFLUX & LPG RUNDOWN PUMP

410-H-41A/41B/41C

K-1 BOTTOM PUMP

III. FIRE PROTECTION FACILITIES AVAILABLE: (i) M.V.water spray system available in all above pumps. (Valves on West side of pump gallery near

)

(ii) Double headed Hydrants at ground level: West side (west side of K-1)

:5

(iii) Water monitors (ground level) : West side (west side of K-1)

:2

South side (south side of K-1) : 1 (iv) HVLR (South west side of K-1 & North of K2)

:2

(v) D Fire extinguishers, 10 Kg, 75 Kg.

IV. APPROACH FOR FIRE TENDERS In case of any emergency in pumps, one fire tender should enter through approach road between AU-III1 and UDEX from road no. 1. The other fire tender should enter through approach road from road no. 11 near AU-III, UDEX Control Room. The tenders should be parked in suitable location depending upon location of pumps.

V. ACTION TO BE TAKEN IN EMERGENCY: (a) Start MV water spray system for pumps.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 312




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

(b) Isolate the supply to pump by closing the suction. (c) Attack the fire from two sides with D extinguishers of 10 kg or 75 kg capacity depending upon severity of situation. (d) If fire is big, attack from two sides with hand held nozzles from D tender.

SCENARIO-2: LEAKAGE & FIRE IN HEAT EXCHANGERS (NORTH SIDE & SOUTH WEST SIDE). I.

CONSEQUENCE: Fire due to autoignition of hot oil.

II. CRITICAL EQUIPMENTS: Following heat exchangers

EXCHANGER NO.

SERVICE

EXCHANGERS ON NORTH SIDE 410-E-305

CRUDE / SRGO

410-E0303

CRUDE / KERO-II

410-E-302C

RCO / CRUDE

410-E-302A/B

RCO / CRUDE

410-E-301A/B

CRUDE/KERO-I KERO-II

410-E-102A/B

CRUDE / SRGO

410-E-103A

CRUDE / SRGO

410-E-320A/B

CRUDE/RCO

410-E-103B

CRUDE/RCO

410-E-104A/B

CRUDE/CR-II

410-HM3A/B

CRUDE / RCO

410-HM-1A/B

CRUDE / RCO

410- HM-1C/D

CRUDE / RCO

410- HM-1E/F

CRUDE / RCO

410-E-308C

CRUDE / RCO

410-E-307

CRUDE /CR-II


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 313



410-E-306A/B


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CRUDE / SRGO

EXCHANGERS ON SOUTH WEST SIDE 410-E-317A/B

K-1 BOTTOM / CR-III HSD

410-E-309 A/B

RESIDUE / RCO

410-E-309C

RESIDUE / RCO

III. FIRE PROTECTION FACILITIES AVAILABLE: NORTH SIDE EXCHANGERS (i)Double headed Hydrants at ground level: West side (in plant area)

:2

(ii) Water monitors (ground level) : North side (in plant area)

:2

West side (in plant area)

:

1

(iii) D Fire extinguishers, 10 Kg, 75 Kg.

SOUTH WEST SIDE EXCHANGERS (i) Double headed hydrant on South of exchangers :

1

(ii) Elevated water Monitors on west side of Exchangers : 1

IV. APPROACH FOR FIRE TENDERS: (a) North side Exchangers: In case of any emergency in any of the exchangers on North side, one fire tender should be parked on road no. 4 opposite north side exchangers in AU-III. The other fire tender should enter through approach road from Road no.4 and parked on the approach road.

(b) South Side Exchangers: In case of any emergency in any of the exchangers on South side, one fire tender should enter through approach road between AU-III and UDEX from road


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 314




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

no. 1 and parked near South West side of furnace F-1. The other fire tender should approach from Road no.11 and parked near AU-III, UDEX control room.

V. ACTION TO BE TAKEN IN EMERGENCY (a) Attack the fire with water / foam from monitors and hand held nozzles from fire tender. (b) If possible attack the fire with D extinguishers from close range. (c) Isolate the source of leak by closing the valves. (d) Remove smouldering insulation material by cutting GI sheets.

SCENARIO-3: LEAKAGE FROM FLANGE NEAR TOP OF COLUMN

I. CONSEQUENCE: fire in top of column

III. CRITICAL EQUIPMENTS:

EQUIPMENT NO.

DESCRIPTION

K-1

PRE-TOPPING COLUMN

K-2

MAIN REACTOR COLUMN

K-3A

HEAVY NAPHTHA II STRIPPER

K-3B

SRGO COLUMN

K-3C

KERO-II STRIPPER

K-4

NAPHTHA STABILISER

K-6A

HEAVY NAPHTHA STRIPPER

K-6B

KERO-I STRIPPER

II. FIRE PROTECTION FACILITIES AVAILABLE: (i) Double headed Hydrants at ground level: West side (West of pump gallery)

:

5

South West side (Near fuel oil tank)

:

1


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 315




(iii) Water monitors (ground level)

:

South side (South of columns) :

2

West side (West of pump gallery)

:

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

2

(iv) Water Monitor Elevated On condensor plaform

:

On reflux drum platform South side of columns (v) HVLR Elevated

1 :

:

2

:

1

1

(vi) D Fire extinguishers, 10 Kg, 75 Kg.

III. APPROACH FOR FIRE TENDERS: In case of any emergency in any of the columns, one fire tender should enter through approach road from road no. 4 and parked near sub station. The other fire tender enter through approach road from road no.1 between UDEX and AU-III and should be parked near AU-III Furnace F02.

IV. ACTION TO BE TAKEN IN EMERGENCY: (a) Cool the column with water monitor. Start MV water spray system for pumps by opening valves. (b) Do not extinguish the fire unless leak is isolated. (c) Isolate the source of leak by closing the valves. (d) If isolation is possible attack the fire with water monitor. (e) If isolation cannot be obtained, continue thorough cooling of the column and let the fire burn at controlled rate.

SCENARIO-4 : Furnace fire due to liquid carry over into firebox or tube rupture

I.

CONSEQUENCE: Header box fire / tube rupture fire

II. CRITICAL EQUIPMENTS:


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 316



EQUIPMENT NO.

SERVICE

F-1

FURNACE

F-2

FURNACE

F-3

FURNACE


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

III. FIRE PROTECTION FACILITIES AVAILABLE: (i) Double headed Hydrants at ground level: West side (Near Fuel oil tanks) :

1

South Side (along road no.4)

:

1

:

2

(ii) Water monitors (ground level) : East side (in plant area near furnace)

West side (near North west corner of furnace F-3)

:1

(iii) Water monitor (elevated) South East of columns :

1

South West of columns :

1

(iii) D Fire extinguishers, 10 Kg, 75 Kg.

IV. APPROACH FOR FIRE TENDERS: In case of any emergency in Furnace, one fire tender should enter through approach road between AU-III and UDEX from road no. 1. The other fire tender should be parked on road no. 1. V. ACTION TO BE TAKEN IN EMERGENCY: i.

Use fixed and portable water monitors from East, West, North and South side to contain the fire.

ii.

If fire is big, attack from two sides with hand held nozzles from D tender.

iii.

Cool structural threatened by flames with water spray.

iv.

Cool overhead flare line with water monitor and handlines.

Do not use foam, as it is ineffective. Second HVLR facility commissioned recently in at the north side of unit. This will help to deluge water and pour foam upto K2 column should the need arise.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 317



VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Description on HVLR

WORK PERMIT


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 318




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

WHAT IS PERMIT TO WORK? Work Permit is a written document that categorically spells out  The Task  Equipment involved & its condition  Location of equipments  Personnel involved  Time limitation  Precautionary measures to be taken together with likely hazard to be encountered if any.  Act as a predetermined checklist for various safety precautions.  Services as a media of information.  What instills a sense of security from accident. WHAT IS THE OBJECTIVE OF THE SYSTEM? 1) To make the work method or the procedure of the work foolproof leaving nothing to chance. 2) It is a guarantee against accidental starting of machinery or entry of any hazardous liquid or gas into a vessel whose jobs are proposed. WHY IT IS REQUIRED? 1) Sec. 7 A (2a) SSW 2) OISD- 105 3) Rule 172 of petroleum rules, 1976. WHAT ARE THE TYPES OF WORK PERMIT? There are three types -1) Hot Work Permit 2) Cold Work Permit 3) Excavation Permit WHAT ARE HOT WORK & COLD WORK?


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 319




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Hot Work : Hot work is an activity which may produce enough heat to ignite a flammable substance. Cold Work : Cold work is an activity which does not produce sufficient heat to ignite a flammable hydrocarbon mixture or a flammable substance. WHEN VESSEL ENTRY SHOULD BE GIVEN? 

No hot work shall be permitted unless the explosivity meter reading is zero.



Vessel entry where no hot work is to be carried out may be permitted if combustible gases are up to 5% of lower explosive limit (LEL).



Entry with an air-supplied mask may be permitted with LEL of up to 50%.



The oxygen level should be at least 19.5 vol % and the concentration of toxic gases below the threshold limit.

WHO WILL BE THE SIGNATORIES?

List of Gas Safety Inspectors, Fire Permit Signatories distributed to Units. Hot Work/Vessel Entry : For any Holiday/Sunday and Extended Hours, Chief Manager/HOD of the concerned area. Clearance is to be obtained from RSM in each shift.

Cold work/Excavation Permit : For Extended Hours & Holiday, Manager/Sectional Head. Dyke Cutting : Chief Manager / HOD WHAT IS THE VALIDITY OF PERMIT?

1) One week only & renewal is to be done if the same job needs to be continued. 2) In instances like plant turn-around or an activity where work is of continuous nature involving round the clock activity, Blanket hot work permit could be given if the owner-in-charge is fully satisfied that the conditions are totally safe for the multiple jobs to be performed. 3) Even when construction activity has to be undertaken in non-operating areas in integrated Units, it is recommended that approval be obtained from designated Senior management for issuing Blanket Hot Work Permit.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 320




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

WHO WILL KEEP THE COPIES OF PERMIT?

1) With Person doing the jobs and shall be available at site. 2) Area in-charge. 3) Fire Station. 4) After completion or stoppage of the job the person to whom the permit was issued should thoroughly check the area for clearing of debris, removal of temporary electrical installations etc. and then shall sign the work permit and return it to the issuer.

WHAT POINTS ONE SHOULD ENSURE WHILE GIVING CLEARENCE?

1) Equipment / Area Inspected. 2) Surrounding area checked/cleaned. 3) Sewers, Manholes, CBD etc. and hot surfaces covered. 4) Considered hazard from other routine/non-routine operations and persons alerted. 5) Equipment electrically isolated and tagged. 6) Running water hose/portable extinguisher provided. 7) Equipment blinded/disconnected/closed/isolated wedged open. 8) Equipment properly drained/depressurised. 9) Equipment water flushed. 10) Gas/Oxygen deficiency test done and found OK. 11) Shield against sparks provided. 12) Proper ventilation and lighting provided. 13) Proper means of exit provided. 14) Precautionary tags/boards provided. 15) Portable equipment/hose nozzles property Grounded. 16) Standby personnel provided for fire watch from process/maintenance/contractor. 17) Iron sulphide removed/kept wet.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 321




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

18) Area cordoned off. 19) Precaution against public traffic taken. 20) Clearance obtained for excavation /road-cutting from Technical Services/Fire /Concerned Department.

Chapter 4 ACCIDENTS-ISTRATIVE PROCEDURES A. REPORTING OF THE ACCIDENTS

1

Any employee who meets with an accident during his duty hours, however slight it may be, shall immediately report the same to the Engineer-in-charge or any other supervisory staff duly authorised for this purpose by the Departmental Head. When the injured person is not in a position to report him, any employee who may be present at the site of accident must make such report.

2

In all cases where accidents occur resulting in serious injury to personnel, the first action to be taken by the Shift-in-charge is to ensure the welfare of the injured persons and the next action is to inform his Sectional-Head / Plant Manager and the Fire & Safety Department. His next step will be in restoring operational conditions to normal. If no supervisory staff happens to be present at a place where an accident has occurred, it is the duty of the senior person present at the spot to do the functions detailed above.

3

The Engineer-in-charge or any other person duly authorised by the Departmental Head shall at once prepare an 'Accident Advice' in the prescribed form number A-1 and ensure that the employee who has met with an accident reports to the company's medical officer either at the First Aid Post or at the Hospital with the said form number A-1. In case of serious and fatal accidents the Personnel Department shall be informed immediate on telephone or by a messenger. The Medical Officer to whom the injured employee report with 'Accident Advice'


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 322




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

(form number A-1) or a letter in an emergency, shall examine the injured employee. If the injury is of such nature that the employee requires rest, the Medical Officer will prepare an 'Injury Report' (part I of form number A-II) and send the same in quadruplicate to the Fire & Safety Department. The Medical Officer will indicate the probable days of the rest required by the injured person. On receipt of Medical Officer's 'Injury Report' (part I of form number AII), the Fire & Safety department will fill up part II of this form, and send one copy each to the personnel department, and the concerned department. (If necessary the personnel department will report the accident to the Factory Inspector. The concerned department will fill up part III of this form and send it back to Fire & Safety Department for information and further action, if any.

B. ENQUIRY On the occurrence of an accident, the Manger / Deputy Manger / Senior Fire & Safety Officer will visit the scene of the accident as soon s possible and fully enquire in to the cause of the accident. For this purpose he may put questions to the injured employee or his supervisor or any other employee and record the statements of the witness, if required. If the accident causes some loss of time he will prepare an accident report in consultation with the Engineer-in-charge and the concerned Departmental Head. This report will be submitted to the Deputy General manager / Departmental Head. Manager / Deputy manager (Fire & Safety) Senior Fire & Safety Officer and the concerned Departmental Head will decide tly whether a formal inquiry is required. In case any court of inquiry is instituted the detailed accident report will be prepared after the completion of such enquiry.

C. MEDICAL FITTNESS CERTIFICATE (FORM NO. A-III)

1

In case the injured person is fit to resume duty immediately after first aid or after taking rest for some time (before the end of the shift) he shall be allowed to resume duty accordingly.

2

In case the injured person is likely to become disabled for 24 hours or more he shall be marked as on 'accident leave' and shall be allowed to duty only on production of 'Fit for duty


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 323




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

certificate' on Form A-III for the Medical Officer authorised for this purpose. The Medical Officer concerned shall send the copied of Form A-III to the Fire & Safety Department, Personnel Department and the concerned department. If the employee has developed some permanent disability, the Medical Officer shall also arrange to assess the disablement of the injured person on form number A-IV. The copies of this form shall be sent to the Personnel department, Fire Safety Department. s Department and the concerned department. 3

The Personnel Department, on receipt of the ing report of the injure person, the recommendation of the Department head and the report of the Medical Department on form number A-IV, shall take action for the payment of leave wages and compensation, if due, by issuing necessary memos to the s Department.

D. INVESTIGATION REPORT

In case of any accident, whether minor or 'lost time' nature, the supervisor will arrange to send an investigation report to the Fire & Safety Department and the concerned Departmental Head on form number A-V within 48 hours of the accident. Accident Investigation: Purpose: 1

To learn accident causes so that similar accident can be prevented by improvement of working conditions, actions and supervision. This helps in deg accident prevention strategies.

2

To make the hazard known to the management workers and supervisors to direct their attention to accident prevention.

3

To find facts to determine legal liability and information for preventive purposes. (An investigation should be for the preventive purposes to disclose facts and not faults)

4

To establish procedure to combat damage claims under compensation laws.

5

To determine the change or deviation that produced an ‘error’ that in turn resulted in an accident.

6

To find out injury rates to compare safety performance.

7

To use record for the purpose of job safety analysis.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 324




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

To develop safety rules, procedures.

Procedure for conducting Accident Investigation:

1. Put at ease: We, if possible, interview the employee involved . We should go out of our way to PUT THE EMPLOYEE AT EASE and help him to feel relaxed.

The best way to do this with accident investigation interviews is to fully explain to him the purpose of the interview " to find out what happened so as to prevent future occurrences ". One easy way to put at ease is to encourage participation and involvement. Show an interest in his ideas about prevention measures. A friendly and understanding manner is a necessity in gaining co-operation.

2. At the Scene of Accident: When carrying out the interview at the scene of the accident it is much easier for those involved to communicate effectively. The victim and other people involved will be able to explain much more clearly what happened if they can point to specific geographic locations. It also prevents his observations and ideas from being influenced by the opinions of others.

3. Get His Version: On interviewing the person most directly involved, be sure that he understands that you want his version just as he saw it and not "dressed up" for your benefit. Above all do not disagree with him, and do not make judgements or judgmental remarks. This will only put him on the defensive and defeat the whole purpose of the interview.

4. Ask Any Necessary Questions: Find out

(a) What Happened? (b) What was done? AND (c) How it was done?

Questions starting with what, how, when, where and who should get all of the facts of the case before you look for why opinions.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 325




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

5. Repeat History, as you understand it: this will do two things. First it will assure good communication by allowing the employee to be sure that you understood what he meant and not just what he said. Second it gives him a chance to hear back what he said and to fall in any point that were not clear or that he may have overlooked.

6. Close the interview on a positive note: -Prevention The best way to wind up the accident investigation interview with those directly involved is by getting their ideas and discussing these and other possible actions that actions that can be taken to prevent the accident from happening again.

Interviewing A Witness : Above technique should also be used in interviewing a witness to an accident.

Investigation Report: Should include the following broad information:



Who had the accident



When the accident happened



Where the accident happened



The occupation of the person involved



What inflicted the injury or damage



Who had the most control



What happened



What things caused the accident



How the accident can be avoided in the future.

The first requirement for the injured person is to provide medical treatment. It is a mistake to make him upset by questions.

INJURIES CAUSED BY AN ACCIDENT


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 326




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Types of injuries The injuries from accidents are classified as follows: o

Minor Injuries

o

Serious Injuries

o

Fatal Injuries

A. MINOR INJURIES

1

In case of injury, even if it seems to be a minor one, first aid should be rendered at the spot and the causality shall be sent to the first Aid Post for medical attention. In the case of an injury other than minor cuts and abrasions, it must not be left to the man to decide whether the injury is simple or serious. This is the business of company's Medical Officer.

2

If an ambulance is required, the First Aid Post or the Hospital should be ed in telephone advising the nature of the injury. The Medical authorities will decide subsequent action in regard to the welfare of the causality.

3

In rendering first aid, particular care must be taken so that there is no adverse effect on the injury. Normally first aid should be rendered by a trained person, but in an emergency anybody may have to render the first aid.

B. SERIOUS INJURIES

1

In case of serious injury first aid will be rendered at the spot, if applicable and the same time, the First Aid Post / Hospital will be requested for ambulance giving precise nature of injuries.

2

Manager / Deputy Manger (Fire & Safety) or his representative and the concerned Departmental Head will be informed on telephone or by messenger and they should proceed at once to the spot for any such action as the circumstance may require.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 327




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

C. FATAL INJURIES 1

In case of fatal injury, the statutory obligation requires that the situation where the accident occurred should remain as far as possible undisturbed. Therefore, with the exception of removing the causalities from the scene of accident or fire etc., this requirement must be strictly observed.

2

The Medical Officer at First Aid Post, Chief Medical Officer, General Manger / Deputy General Manger, Chief Production manger, Manager / Deputy Manger (Fire & Safety) / Senior Officer, Senior Personnel-cum-istrative manger will be informed immediately of any fatal injury. The personnel Department will take early action to inform the relatives, police the Factory Inspector.

3

An enquiry will be held by a committee, constituted by the Management, in all cases of fatal injury.

FIRST AID TRAINING

The Medical Department will arrange instructional classes in first aid and a reasonable proportion of the personnel employed in the Production, Electrical and Engineering Departments should undergo instructions in this important subject to render necessary first aid as and when necessary. Shift rotation should be so arranged that, as far as possible, persons qualified in first aid are present in all shifts. Refresher courses for first-aiders should be carried out from time to time by the Medical Department. FIRST AID BOXES

First aid boxes will be located in each building of a plant group and in the Maintenance sections, sub-station etc. The concerned department should inspect the contents of each first aid box at least once in every month and ensure that supplies of the necessary medicines in the first aid box are maintained.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 328




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ELECTRIC SHOCKS

General Guidelines 1

Act at once - delay is fatal

2

Death from electric shock is rarely instantaneous.

3

Patient may become unconscious only due to interruption of breathing system due to severe shock therefore life can be saved by immediate artificial respiration.

4

Send for; but never wait for, a doctor.

5

Continue artificial respiration until a doctor pronounces death.

REMOVAL FROM ELECTRICAL 1

If the person who has received the shock is still in with the apparatus / circuit, immediate action should be taken to remove him.

2

Switch off the current immediately or send someone to do so.

3

If it is not possible to switch off the current immediately and render the apparatus / circuit dead, steps must be taken to remove the injured person keeping in mind THAT THE CIRCUIT IS ALIVE.

4

Care should be taken to ensure that the rescuers do not themselves become casualties. through bare skin of the person to be rescued and the rescuer with a age to earth must be avoided.

5

Do not attempt to remove a person from with high voltage without using articles suitably insulated for the system voltage. When attempting to free a person from with low or medium voltage use rubber gloves, boots, mats, or insulated sticks, but if these are not available use a loop of rope or a coat to drag the person free. Whatever is used should be dry and non-conducting.

ACTIONS AFTER RENOVAL FROM ELECTRICAL 1

If the person's clothes have caught fire, extinguish the fire by smothering.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 329




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

2

Get the patient into fresh air.

3

In cold weather, avoid exposure of the casualty to cold. If possible use blankets.

4

If the patient is unconscious, immediately check and remove all foreign matter like tobacco, false teeth etc. If any, in his mouth and throat. Now start ARTIFICIAL RESPIRATION AT ONCE according to the instructions given in the Resuscitation chart. Continue it until the doctor arrives or breathing has been restored to normal.

5

If the patient recovers before medical assistance arrives, regulate your artificial respiration to the rate of patient's breathing and when he has sufficiently recovered made him comfortable and gives him hot tea. Do not allow patient to exert himself even by walking until he has been seen by a doctor as the shock may have affected his heart.

6

On the arrival of the Medical Officer, he will take charge and issue further instructions, as may be necessary. If the patient is required to be sent to the hospital for treatment or to be kept under observation, the Medical Officer will make necessary arrangements

GAS POISIONING 1

Get the victim into fresh air quickly.

2

Do not enter the area without a gas mask. A handkerchief ties over the nose and mouth is no protection.

3

Inform the Medical Officer on duty immediately. The causality should be brought under expert medical aid as quickly as possible.

4

If cold, keep the patient warm with blankets, coat, hot water bottles etc.

5

The patient must not undertake any physical activity; he should perfectly be put to bed.

6

If the patient has become unconscious Carry him to the fresh air. o

Lay him with head lower than the rest of the body.

o

Loosen clothing around neck and ensure that he is getting plenty of fresh air.

o

Rub his limbs towards the body, if it is summer and the weather is too hot, sprinkle cold water on his face.

o

Put smelling salt to the patient’s nose.

BURNS


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 330


1



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

In case of burns from corrosive fluids, get the patient under a shower or if a shower is not available in the vicinity, wash the area of burn with copious quantity of clean water.

2

In case of burns from fire, hot metal or from with electrical apparatus, do not wash with water.

3

On the burn keep several layers of sterilised gauge soaked in 5% solution of Tannic acid or burn-ointment whichever is available in the first aid box, and do the bandage lightly. Application of dressing, which is surgically unclean, is more dangerous than no dressing. Strong antiseptic like Bi-chloride of Mercury or Carbolic Acid should not be used. Send the patient to First Aid Post / Hospital.

4

In cold weather keep the patient warm with blankets or coats.

5

IF the patient has become unconscious:

6

o

Carry him to fresh air.

o

Lay him with head lower than rest of the body.

o

Loosen clothing around his neck.

o

Rub his limbs towards the body.

o

Further treatment will be decided by the Medical Officer.

If the patient's breathing is interrupted, start artificial respiration at once according to the instructions given in Resuscitation chart and continue until breathing has been restored or doctor arrives and takes charge of the patient.

7

ister oxygen from an oxygen inhalator is conjunction with manual artificial respiration. If the breathing is normal, there is no need to apply artificial respiration.

8

On the arrival of the Medical Officer he will take charge and if the patient is required to be sent to the hospital for treatment or to be kept under observation, the Medical Officer will make the necessary arrangements.

9

If the patient has sufficiently recovered before medical assistance arrives make him comfortable and give him hot tea or coffee. Do not allow the patient to exert himself even by walking until a doctor has examined him.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 331




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

TELEPHONIC COMMUNICATIONS IN CASE OF ACCIDENTS

In all cases of telephonic communication in regard to accidents, the message will be prefixed by the words 'Accident Report, Clear the line'. On receipt of this message, the telephone operator will brake off all other calls to the medical or other authorities to be informed and ensure speedy connection with the person communicating the accident report to the officer required to be informed. A copy of this instruction will be made out on a card and pasted in a prominent position above the switchboard of the exchange.

ARRANGING VEHICLE FOR TAKING THE INJURED TO HOSPITAL If ambulance is not available, the person dealing with accident cases has priority to call for any ing transport for removal of the injured person to First Aid Post / Hospital.

DANGEROUS INCIDENCES In the event of any dangerous occurrence the section concerned should submit the report immediately to the Fire & Safety Department who will take further action as required under the company's rules / local laws. ** For details do refer “SAFETY MANUAL (SEQ/FS/SI/8.5.2/2 )” http://sabarmati/fire_and_safety/c_o_n_t_e_n_t_s.htm


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 332




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER – 15

SAFETY SYSTEM & PROCEDURE FOR ACCESSING ROOF OF FLOATING AND FIXED ROOF STORAGE TANKS  Safety Shower – 2 nos Location: 1. Near Ammonia Tank 2. Near Ammonia cylinder shed.  Hydrocarbon Gas Detector – 5 nos Location: 1. LPG pumps (H15/H15A)- 1nos 2. Near H8 – 1nos 3. Between E1 & E4 – 1nos 4. Near E2 –1 nos  Sprinkler system Au3 pump house is provided with sprinkler system. Its isolation valve is provided in between H41C & V4  Deluge System TK 209 TK210 TK211  Emergency Light Old Substation- 2 nos Main Pump House – 4 nos K1 column bottom area- 2 nos Intermediate platform – 2 nos Platform – 1 nos Near H-41 C motor –1 nos K-6B column- 5 nos K-3A column – 4 nos


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 333




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Heat exchanger area- 2 nos F1 – 2 nos F2 – 2 nos F3 – nos Control room – 4 nos

 Public Address system points (Gaitronic Talkback ) 1. Near F2 furnace 2. Between F1 & F3 furnace 3. Pump House area 4. Condenser platform area 5. Between old & new Desalter 6. Column Ladder Platform no 6 7. Column ladder platform no. 9  Fire Monitor Total 15 nos Plant area – ground level- 10 Plant area –platforms- 2 Plant area- E1/E2 platform –2 TK farm – (main road) – 1

Procedure for Accessing Roof of Floating and Fixed Roof Storage Tanks 1.0 Program Description The purpose of this program is to specify safe procedures while inspecting/ working on Floating and Fixed Roof Storage Tanks. Employees who are required to inspect/ work at Roof in Floating and Fixed Roof Storage Tanks are required to attend training on fall protection, Permit system and skill training in respective work area. 2.0 Scope This program applies to all employees who perform duties or required to access on Floating and Fixed Roof Storage Tanks.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 334




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Contractors working on Floating and Fixed Roof Storage Tanks are required to comply with all applicable factory rules related to workplace safety and shall have their own fall protection program in addition to this procedure. 3.0 Procedure for accessing roof of Floating roof tanks 3.1 All concerned persons required to access the roof of a floating roof tank, for inspection, project and maintenance activities, have to take a work permit in the prescribed format for Confined space entry permit. 3.2 Following process/procedure to be ensured before issuing Permit to access the roof of a floating roof tank :3.2.1 Gas test to check presence of H2S & Hydrocarbon. Gas concentration should be below 10% of the lower explosive limit and H2S concentration to be nil in the ambient. 3.2.2

One man shall be standby at the top of platform with a canister mask / breathing apparatus.

3.2.3 A lifeline with safety belt is to be used for the man going on the roof. The other end of the line held by the standby person at the top platform. 3.2.4 No inspection and maintenance of tanks should be undertaken during abnormal weather, thunder or hail storms and insufficient illumination. 3.2.5 Conductive footwear e.g. leather soles or electrically conducting rubber soles, should be worn while gauging, sampling or taking temperatures. Nylon rope shall not be used for lowering sample bottles in the tank. 3.2.6 Check for deck plate internal corrosion: For safety, before accessing the roof, Check with ultrasonic instrument or lightly use a ball peen hammer to test the deck plate near the edge of the roof for thinning. Corrosion normally attacks the deck plate at the edge of a fixed roof & at the rafters in the center of the roof first. (API STD. 653, Tank Inspection, Repair, Alteration & Reconstruction - Refer Section C 1.4) 4.0 Procedure for accessing roof of fixed roof tanks 4.1 All concerned persons required to access the roof of a fixed roof tank, for inspection, project and maintenance activities have to take a work permit.

4.2 The following Checks/ procedures are to be ensured before accessing a fixed roof tank are given below.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 335

. Indian Oil Gujarat Refinery 4.2.1

4.2.2

4.2.3 4.2.4



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Planks/ grating long enough to cover at least two rafters as bottom shall be laid and used as walkways for safety reasons. Corroded roof plates may be a safety hazard for people to walk. A person shall not go alone on the roof of storage tanks for inspection. For repair/maintenance/testing, the entry to the roof deck shall be allowed through a work permit. No walking shall be done on the roof plates where thinning/ perforations are observed. Necessary planking may be provided for walking on such roofs. Ultrasonic thickness measurements shall not be carried out when the tank is receiving or dispatching.

4.3 Following process/procedure to be ensured before issuing Permit to access the roof of a floating roof tank: 4.3.1

4.3.2 4.3.3

4.3.4

4.3.5

4.3.6

Gas test to check presence of H2S & Hydrocarbon. Gas concentration should be below 10% of the lower explosive limit and H2S concentration to be nil in the ambient. A lifeline with safety belt is to be used for the man going on the roof. No inspection, maintenance, gauging or sampling of tanks should be undertaken unless any emergency during abnormal weather, thunder or hail storms and insufficient illumination at the area. Conductive footwear e.g. leather soles or electrically conducting rubber soles, should be worn while gauging, sampling or taking temperatures. Nylon rope shall not be used for lowering sample bottles in the tank. Check for deck plate internal corrosion: For safety, before accessing the roof, check with ultrasonic instrument or lightly use a ball peen hammer to test the deck plate near the edge of the roof for thinning. Corrosion normally attacks the deck plate at the edge of a fixed roof & at the rafters in the center of the roof first. (API STD. 653, Tank Inspection, Repair, Alteration & Reconstruction Refer Section C 1.4). Wherever the roof is found perforated /fragile by Inspection dept., a board depicting “Fragile / perforated roof – Entry prohibited” to be displayed at the approach staircase and access to such tank roof should be prohibited. However the permit can be given in special circumstances like M&I job by the area manager after ensuring that fall protection system along with suitable crawling boards, roof ladders, guardrail for edge protection is in place. In addition to above, the following precautions are to be ensured before issuing permit: -


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 336




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

a. All covers for openings in roofs should be of substantial construction and be secured in position. b. Sufficient and suitable crawling boards or roof ladders should be provided and firmly secured in position. c. During extensive work on the roof, strong barriers or guardrails and toeboards should be provided to stop a person from falling off the roof. d. Where works have to be carried out at or near the edge, a simple barrier consisting of crossed scaffold tubes ing a tubing guardrail may be provided. e. No walking shall be done on the roof plates where thinning/ perforations are observed. Necessary planking may be provided for walking on such roofs a minimum of two boards should be provided so that it is not necessary for a person to stand on a fragile roof to move a board or a ladder, or for any other reason.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 337




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER 16 LABORATORY SAMPLING SCHEDULE S.NO.

STREAM

1

LABFS/SK

2

HSD

3

E1 / E2 water

4

Desalter Inlet/Outlet of Crude Oil

5 6 7

TEST

FREQ.

Density Distillation Flash Point Pour Point (Winter) Flash Point Recovery 95% pH Iron

One/Day One/Day One/Day

TEST LOCATION Shift Shift Shift

One/Day

Shift

One/Day One/Day One/Shift One/Shift

Shift Shift Shift Shift

Density

One/Week

General Shift

One/Week

General Shift

On Required On Required One/Week

Shift General Shift General Shift

Salt Content/BS&W Orsat RD pH, Oil Content

Flue Gas Gas Away/ Gas To Brine Water


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 338




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER - 17 MASTER BLIND LIST

SL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

DESCRIPTION STEAM TO UNIT FUEL GAS TO UNIT ISOLATION B/V FUEL GAS TO UNIT C/V BY B/V GAS AWAY FROM UNIT FLARE LINE OLD INERT GAS TO UNIT C/W SUPPLY TO UNIT C/W TO RETURN LPG R/D TO CRU LPG R/D TO GRE LPG R/D NEW LPG PUMP DEPRESSURISE LINE IVATION SUCTION TO H-8 IVATION PUMP H-8 DISCHARGE IVATION PUMP SUC/DISBY NITROGEN /IVATION TO F-1 F-1 FC3301 F-1 STEAM HEADER FO SUPPLY TO F-1 FO RETURN EX F-1 FG TO F-1 F-2 STEAM HEADER FG TO F-2 FUEL OIL SUPPLY TO F-2 FUEL OIL RETURN EX F-2 F2 1 FC3402 F2 2 FC340 N2/ IVATION TO FC3402 N2/ IVATION TO FC3403 STEAM HEADER TO F3 FUEL GAS TO F3

SIZE RUNNING 6 3 3 3 6 2 20 20 2 2 2 1 4 3 3 2 6 6 2 2 4 6 4 2 2 6 6 2 2 6 4

" " " " " " " " " " " " " " " " " " " " " " " " " " " " " " "

OUT OUT OUT OUT OUT IN OUT OUT IN OUT IN IN IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT IN IN OUT OUT


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

S/D IN IN IN IN IN OUT IN IN OUT IN IN OUT OUT OUT OUT OUT IN IN IN IN IN IN IN IN IN IN IN OUT OUT IN IN

TYPE TAIL SPECT SPECT TAIL SPECT TAIL TAIL TAIL TAIL SPECT SPECT SPECT SPECT SPECT SPECT TAIL SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT TAIL TAIL TAIL SPECT Vol-I (Addendum)

Page 339

. Indian Oil Gujarat Refinery 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67



FUEL OIL SUPPLY TO F-3 F3 1 FC3003 F3 2 FC3005 PURGING STEAM TO K1 PURGING STEAM TO K4 STEAM TO E2 VESSEL DM WATER TO T-8 ABCD FLARE LINE ON WEST SIDE K1 BOTTOM DRAIN LINE K2 BOTTOM DRAIN LINE K4 BOTTOM DRAIN LINE K1 TOP VENT K2 TOP VENT K4 TOP VENT K3A TOP VENT K4 BOTTOM TO GOP R/D E-1 R/D TO GOP E-2 GASOLINE TO GOP AU3 SLOP TO TANK TK 209/210/211 O/L TO PUMPS WATER TO SLOP LINE RCO R/D TO FPU1 COLD/OM&S IFO EX JOB 50 TO E6/E7 RCO TO VBU TANKS AU3 RCO TO IFO SYSTEM RCO COLD TO FPU1 RCO COLD TO FPU2 RCO HOT TO FPU1 RCO HOT TO FPU2 RCO TO VBU HSD R/D BLIND BETWEEN AU3/AU1 HSD SKO R/D SKO TO HSD BLIND BETWEEN AU3/AU1 SKO SKO TO RCO(FPU1 COLD)

2 6 6 3 2 2 1 10 2 3 2 2 3 3 2 4 4 3 4 6 6 6 4 8 4 8 8 6 6 4 4 4 4 4 4 4

" " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " "

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

OUT OUT OUT IN IN IN OUT OUT IN IN IN IN IN IN IN OUT OUT OUT OUT IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT IN OUT OUT OUT OUT


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

IN IN IN OUT OUT OUT IN IN OUT OUT OUT OUT OUT OUT OUT IN IN IN IN IN OUT OUT IN IN IN IN IN IN IN IN IN IN IN IN IN IN

SPECT TAIL TAIL TAIL SPECT SPECT TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL SPECT TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL Vol-I (Addendum)

Page 340




SKO TO RCO(VR) SKO TO RCO(OM&S) LV K4 BTM R/D TO AU1/2 UNSTABLISED NAP EX GRE DRAG STREAM EX CRU K4 BTM R/D TO GENERAL NAP FLO TO RCO TO GHP COLD FLO TO RCO TO GHP HOT FLO TO RCO TO COLD FPU1 FLO TO RCO TO HOT FPU1 CRUDE TO UNIT B/L FLO TO RCO COLD (VR) FLO TO RCO TO VBU FLO TO RCO TO OM&S FLO TO DESALTERS BLD. BET. CAU & DEMUL NR. H26 FLO TO H41A SUC FLO TO H41B SUC FLO TO H41C SUC C/W TO E1 O/L TO PUMPS FO TO UDEX SUPPLY FO RETURN EX UDEX FLO TO FO SUP. NR. H20/20A FLO TO FO SUPPLY TO UDEX FLO TO FO RETURN EX UDEX IFO EX JOB 50 TO AU3 FLO TO H11A SUC FLO TO H11 SUC FLO TO H42 SUC STEAM TO F1/F1 APH NORTH STEAM TO F1/F1 APH SOUTH C/W TO F1/F2 APH NORTH C/W TO F1/F2 APH SOUTH 45EE003A/B I/L DRAIN 45EE003A/B O/L DRAIN 45EE003C/D I/L DRAIN

2 2 4 2 2 4 2 2 2 2 10 2 2 2 4 1 2 2 2 8 4 4 2 2 2 3 2 2 2 2 2 2 2 2 2 2

" " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " "

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

OUT OUT OUT OUT OUT OUT IN IN IN IN OUT IN IN IN IN IN IN IN IN IN IN IN IN IN IN OUT IN IN IN IN IN IN IN IN IN IN


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

IN IN IN IN IN IN OUT OUT OUT OUT IN OUT OUT OUT OUT IN OUT OUT OUT OUT IN IN OUT IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT

TAIL TAIL TAIL TAIL TAIL TAIL SPECT SPECT TAIL TAIL TAIL TAIL TAIL TAIL TAIL TAIL/PB SPECT SPECT SPECT TAIL PB PB SPECT PB PB TAIL SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT Vol-I (Addendum)

Page 341




45EE003A/B I/L FLO 45EE003C/D I/L FLO VR DRUM O/L TO PUMPS FLO TO 45PM002A FLO TO 45PM002B VR DRUM O/L FILTER A FLO VR DRUM O/L FILTER B FLO VR HE O/L FILTER A FLO VR HE O/L FILTER B FLO VR DRUM O/L FILTER A DRAIN VR DRUM O/L FILTER B DRAIN VR HE O/L FILTER A DRAIN VR HE O/L FILTER B DRAIN FLO TO VR RECEIVING LINE FLARE KOD TO CBD HP/MP STEAM TO VR HE LP STEAM TO VR DRUM IFO EX V6/V7 TO VR REC LINE STEAM HEADER TO E6/E7 E317A/B TUBE FLO E317A/B TUBE DRAIN E317 A/B SHELL E309A/B TUBE FLO E309A/B TUBE DRAIN E309A/B SHELL DRAIN E309A/B SHELL FLO E309C SHELL DRAIN E309C SHELL FLO E309C TUBE DRAIN E309C TUBE FLO T16A RCO SIDE FLO T16A RCO SIDE DRAIN T16B RCO SIDE FLO T16B RCO SIDE DRAIN T16C RCO SIDE FLO T16C RCO SIDE DRAIN

2 2 6 2 2 2 2 2 2 2 2 2 2 2 2 4 2 2 6 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

" " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " "

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

IN IN OUT IN IN IN IN IN IN IN IN IN IN IN IN OUT OUT OUT OUT IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

OUT OUT IN OUT OUT OUT OUT OUT OUT OUT OUT IN IN OUT OUT IN IN IN IN OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT

SPECT SPECT TAIL SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT TAIL TAIL TAIL TAIL SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT Vol-I (Addendum)

Page 342




T16D RCO SIDE FLO T16D RCO SIDE DRAIN E105 CRUDE SIDE FLO E105 CRUDE SIDE DRAIN E303 CRUDE SIDE FLO E303 CRUDE SIDE DRAIN E302C CRUDE SIDE FLO E302C CRUDE SIDE DRAIN E302C RCO SIDE FLO E302C RCO SIDE DRAIN E302A/B CRUDE SIDE DRAIN E302A/B CRUDE SIDE FlO E302A/B RCO SIDE FLO E302A/B RCO SIDE DRAIN E301 A/B CRUDE SIDE FLO E301 A/B CRUDE SIDE DRAIN E102 A/B CRUDE SIDE FLO E102 A/B CRUDE SIDE DRAIN E103A CRUDE SIDE FLO E103A CRUDE SIDE DRAIN E103A RCO SIDE FLO E103A RCO SIDE DRAIN E320A/B RCO SIDE FLO E320A/B RCO SIDE DRAIN E320A/B CRUDE SIDE FLO E320A/B CRUDE SIDE DRAIN E103B RCO SIDE FLO E103B RCO SIDE DRAIN E103B CRUDE SIDE FLO E103B CRUDE SIDE DRAIN HM3A/B RCO SIDE FLO HM3A/B RCO SIDE DRAIN HM3A/B CRUDE SIDE FLO HM3A/B CRUDE SIDE DRAIN HM1A/B RCO SIDE FLO HM1A/B RCO SIDE DRAIN

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

" " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " "

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT

SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT Vol-I (Addendum)

Page 343

. Indian Oil Gujarat Refinery 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199



HM1A/B CRUDE SIDE FLO HM1A/B CRUDE SIDE DRAIN HM1C/D RCO SIDE FLO HM1C/D RCO SIDE DRAIN HM1C/D CRUDE SIDE FLO HM1C/DCRUDE SIDE DRAIN HM1E/F RCO SIDE FLO HM1E/F RCO SIDE DRAIN HM1E/F CRUDE SIDE FLO HM1E/F CRUDE SIDE DRAIN E104A/B CRUDE SIDE FLO E104A/B CRUDE SIDE DRAIN E308C RCO SIDE FLO E308C RCO SIDE DRAIN E308C CRUDE SIDE FLO E308C CRUDE SIDE DRAIN E308A/B RCO SIDE FLO E308A/B RCO SIDE DRAIN E308A/B CRUDE SIDE FLO E308A/B CRUDE SIDE DRAIN E307 CRUDE SIDE FLO E307 CRUDE SIDE DRAIN E306 CRUDE SIDE FLO E306 CRUDE SIDE DRAIN

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

" " " " " " " " " " " " " " " " " " " " " " " "

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN IN

OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT

SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT SPECT

CHAPTER – 18



Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 344




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Corrosion Inhibitor 1.

CHEMICAL IDENTITY

Chemical Name

Corrosion Inhibitor

Synonyms

Corrosion Inhibitor

Formula

R1NHR2NHR3RH4

Regulated Identification

Chemical Classification

Long chain fatty amine derivative

Trade Name

C.A.S. NO.

Shipping Name

5285-60-9

Ahuralan ESK 50

UN NO.

Ahuralan ESK 50

Codes/Label Hazardous waste I.D. No. Hazchem Code

2.

HAZARDOUS INGREDIENTS

C.A.S. NO.

1. Ahuralan ESK 50

5285-60-9


C.A.S. NO.

PHYSICAL AND CHEMICAL DATA


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 345


VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Boiling Point/ Range oC

150 - 300

Physical State

Liquid

Appearance

Viscous, Yellowish brown

Melting/ Freezing Point oC

<10

Vapour pressure @ 35 oC, mm Hg

< 1 mmHg @ 68oF

Odour

Pungent

Solubility in water @ 30 oC

Insoluble

Solubility in others

Vapour Density (Air = 1) Specific Gravity (Water = 1)

3.


0.83

pH

Not applicable

FIRE AND EXPLOSION HAZARD DATA Flammability

Moderate

TDG 3 Flammability Auto ignition Temperature oC

LEL (%V)

0.7

Flash Point (OC) oC

UEL (%V)

5.0

Flash Point, (CC) oC

37 – 66

228

Explosion Sensitivity to Impact Explosion Sensitivity to Static Electricity Hazardous Combustion products Hazardous Polymerization Combustible Yes Liquid Flammable Yes Material Pyrophoric No Material

CO, CO2

Explosive Material

No

Oxidiser

No

Organic Peroxide

No

Corrosive Material Others


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

No

Vol-I (Addendum)

Page 346


4.



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

REACTIVITY DATA Chemical Stability

Stable

Incompatibility with other material Reactivity

None

Hazardous Reaction Products

5.

HEALTH HAZARD DATA Routes of Entry Effects of Exposure/ Inhalation Symptoms

Inhalation, ingestion,

Ingestion

Emergency Treatment

Obtain immediate medical attention.

Inhalation

Remove affected person to fresh air. If respiratory problems develop. Do not induce vomiting.

Ingestion Skin : Apply a generous amount of waterless hand cleaner (such of GOOP, Gojo or similar product) to the affected area. Rub briskly onto the skin, on and around the affected area. Remove the mixture of cleaner-product with paper towels or clean dry rags. Repeat the entire procedure, then was the skin with a mild soap, rinsing with warm water. Eye : Flush with water for at least 15 mins. If irritation occurs.

LD50 (Oral-Rat),

mg/kg

LD50 ,

Permissible

mg/kg

Odor Threshold, ppm

ppm

mg/kg

Exposure Limit

mg/kg


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 347

. Indian Oil Gujarat Refinery TLV (ACGIH)

VOL-I: Addendum ppm mg/kg

NFPA Hazard Signals

6.

7.



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

STEL, Health

Flammability

ppm mg/kg

Reactivity/Stability

Special

PREVENTIVE MEASURES Personal Protective Equipment

Gloves, footwear, coveralls, and/or apron as necessary to prevent repeated or prolonged skin . Any clothing which becomes wet with product should be removed immediately and laundered before reuse. Chemical goggles or face shield as necessary to prevent eye .

Handling and Storage Precautions

Store in tightly closed, properly labeled containers in a cool, well ventilated area away from all ignition sources. Store out of direct sunlight. Wear appropriate personal protective equipment. Avoid inhalation of product vapors or mist. Never use a welding or cutting torch on or near a drum (even empty) because vapours from the material (even residue) can ignite explosively. Follow all MSDS/label precautions even after container is emptied because it may retain product residue.

EMERGENCY AND FIRST AID MEASURES FIRE

EXPOSURE

Fire Extinguishing Media

Use water fog, foam, dry chemical powder, CO2

Special Procedure Unusual Hazards First Aid Measures

Use water to cool fire exposed components. Obtain immediate medical attention. Inhalation : Remove affected person to fresh air. If respiratory problems develop. Ingestion : Do not induce vomiting. Skin : Apply a generous amount of waterless hand cleaner (such of GOOP, Gojo or similar product) to the affected area. Rub briskly onto the skin, on and around the affected area. Remove the mixture of cleanerproduct with paper towels or clean dry rags. Repeat the entire procedure, then was the skin with a mild soap,


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 348




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

rinsing with warm water. Eye : Flush with water for at least 15 mins. If irritation occurs. Antidotes/ Dosage Steps to be taken

SPILLS

Waste Disposal Method

Standard hydrocarbon spill procedures apply to this product. Remove all sources of ignition. Isolate the affected area. Confirne entry into the affected area to those persons properly protected. Stop leak at the source. Cut off and redirect surface runoff by trenching of diking. Spills should be contained through the use of commercial oil adsorbent, but other materials such as earth, sand or sawdust may be more expedient to limit the extent of the spill. Prevent the release of this product into the waterway or sewer. To prevent further losses, reposition, plug or place the leaking container into an oversized recovery drum/container. Wear protective equipment. Absorb spilled product using a commercial oil absorbent soaking up as much product as possible.

8.

ADDITIONAL INFORMATION/ REFERENCES

9.

MANUFACTURER/ SUPPLIERS DATA Name of firm : Mailing Address :

10.

DISCLAIMER Information contained in this material safety data sheet is believed to be reliable but no representation, guarantee or warranties of any kind are made as to its accuracy, suitability for a particular application or results to be obtained from them.


Ammonia


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 349


1



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHEMICAL IDENTITY Chemical Name : AMMONIA Inorganic Compound

Chemical Classification :

Synonyms: Liquid Ammonia, Ammonia Gas, Ammonia Ammonia Anhydrous.

Formula: NH3 NO. 1005


Trade Name:

C.A.S.NO: 7664-41-7

UN

Shipping Name : Ammonia Codes/Label : Non Flammable Gas, Class 2 Hazardous waste I.D. No: 17 Hazchem Code : 2 PE

2.

HAZARDOUS INGREDIENTS C.A.S.NO.

C.A.S.NO.


1. Ammonia

7664-41-7

2.


Boiling Point/Range Colourless

-33.4oC

Physical State : Liquefied Compr.Gas


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Appearance :

Vol-I (Addendum)

Page 350




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Vapour pressure

Odour : Strong

Pungent Odour @ 35oC

7600 mm Hg at 25.7oC

Melting / Freezing -77.77 C Point ___________________________________________________________________________________ __________________ Vapour Density 0.60 Solubility in water @ 30oC Others (Air = 1) Very soluble Moderately soluble in Alcohol o

Specific Gravity (Water = 1)

3.

0.771 @ 0oC

pH

: I N aq. Sol. 11.6

FIRE AND EXPLOSION HAZARD DATA Flammability Pertinent (OC)

No

LEL

16.0 %

TDG Flammability Pertinent (CC)

NA

UEL

25.0 %

Auto ignition Temperature

Flash Point oC

Flash Point oC

C

651.0

Explosion Sensitivity to Impact

Stable

Explosion Sensitivity to Static Electricity

Not available

o

Not

Hazardous Combustion products

Emits toxic fumes of NH3 & NOx

Hazardous Polymerization

Does not occur.

Not

Combustible Liquid No

Yes

Explosive Material

No

Corrosive Material

Flammable Material

No

Oxidiser

No

Others


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 351


VOL-I: Addendum

Pyrophoric Material

4.

No

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Organic Peroxide

No


Stable

Incompatibility with Silver, Halogens, Other material Reactivity

Strong Oxidisers, Calcium hypochlorite, Gold, Mercury, Acetaldehyde, Acrolein. Reacts with Silver chloride, Silver nitrate, Silver azide, chlorine, bromine,iodine, heavy metals and their compounds, Incandescent reaction when heated with Calcium.

Hazardous Reaction

5.



Reacts with Silver chloride, Silver nitrate, Silver Azide and Silver Oxide form explosive silver nitride.

HEALTH HAZARD DATA Routes of Entry

Inhalation, Skin or Eyes

Effects of Exposure/

700 ppm causes eye irritation and permanent injury may result if prompt medical remedial measures are not taken. 5000 ppm may cause death from spum inflammation, or edema of the larynx. of the liquid with skin freezes the tissues and causes the caustic burns.

Symptoms

Emergency Treatment artificial respiration

Inhalation: Remove the victim to fresh air and provide or oxygen, if needed. Skin and Eyes : Wash the affected

area with plenty of water for 15 mins. Seek Medical Aid. Permissible

25 ppm

18 mg/m3

Odour Threshold


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

46.8 ppm Vol-I (Addendum)

Page 352



VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

32.53 mg3 Exposure Limit L.D50 (Oral-Rat)

350 mg/kg

TLV (ACGIH) 27 mg/m3 NFPA Hazard Signals Special

25 ppm

18 mg/m3

Health

STEL

Flammability

2

6.

Reactivity 0

PREVENTIVE MEASURES

Personal Protective Equipment

Avoid with liquid or vapours Provide rubber boots, safety goggles, self-contained breathing apparatus, gas mask and protective clothing in case of liquid ammonia.

Handling and Storage precautions

7.

1

35 ppm

Avoid storing along with oxidizing materials and away from all possible sources of ignition. Store in well ventilated flame resistant locations.

EMERGENCY AND FIRST AID MEASURES FIRE fog.


Special Procedure

Stop flow of gas. Use water spray or

Keep the containers cool by spraying

water if exposed to heat or flame. Unusual Hazards EXPOSURE

First Aid Measures

Gas is suffocating. Inhalation : Remove the victim to fresh air area, provide artificial respiration or oxygen, if needed. Skin : Remove the contaminated clothes and wash the affected area with plenty of water and soap.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 353




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Eyes : Flush with plenty of water for 15 mins. Seek medical aid. Antidotes/Dosages

Not available.

SPILLS Steps to be taken

Contain leaking liquid on sand or earth, allow to evaporate. Dilute the vapours with plenty of water.


Put into a large vessel containing water, neutralise with

HCl And discharge into sewer with sufficient water.

8.

ADDITIONAL INFORMATION/REFERENCES A human poison by an unspecified route. Difficult to ignite. NH 3 and air in a fire, can detonate. Potentially violent or explosive reactions on with interhalogens. Forms sensitive explosive mixture with air and hydrocarbons. Those affected with eye and pulmonary diseases should avoid exposure to Ammonia.

9.

MANUFACTURER/SUPPLIERS DATA Name of firm : Mailing Address :

10.


MATERIAL SAFETY DATA SHEET Caustic Soda

1

CHEMICAL IDENTITY Chemical Name :

SODIUM HYDROXIDE

Chemical Classification : Alkaline Inorganic Compound

Synonyms: Caustic Soda, Soda Lye, Lye, Sodium Hydrate

Trade Name : Caustic soda


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 354


Formula



NaOH

C.A.S.NO. 1310-73-2


Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

UN. No. 1823 / 1824

Shipping Name : Sodium Hydroxide, Solid / Solution Codes/Label

: Corrosive, Class-8

Hazardous Waste I.D. No: 16 Hazchem Code : 2 R

2.


C.A.S.NO.

1.

1310-73-2

Sodium Hydroxide


C.A.S.NO.

PHYSICAL AND CHEMICAL DATA Boiling Point/Range

C 1390 - 1557 Physical State : Solid

Appearance : White Flakes / Pellets

o

oC 318.4 - 322 Melting / Freezing Vapour pressure Odour: Odourless Point @ 35 oC 1 mm Hg at 730 oC _________________________________________ ______________________________________________________

Vapour Density (Air = 1)


3.

Not Pertinent

Solubility in water @ 30 oC Soluble

2.12 at 24 oC/4 oC

pH

Others: Soluble in Alcohol, Methanol and Glycerol.

13 - 14


No

LEL Not pertinent

TDG Flammability N.A. Auto ignition Temperature

UEL Not pertinent C

Flash Point oC Flash Point oC

(OC) (CC)

Not Pertinent

o

Explosion Sensitivity to Impact

Stable

Explosion Sensitivity to Static Electricity

Stable


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 355


VOL-I: Addendum

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Emits toxic fumes of Na 2O.

Hazardous Polymerization

Will not occur

Combustible Liquid

No

Explosive Material

No

Corrosive Material

Flammable Material

No

Oxidiser

No

Others

No

Organic Peroxide

Yes

No


Stable

Incompatibility with other material. Reactivity

Water, Acids, Flammable Liquids, Organic halides, metals, A1, Sn, Zn, Nitromethane and Nitro Compounds. Vigorous reaction with Organic Halides, Metals, Nitro Compounds.

Hazardous Reaction Products

5.

Issue Date

Hazardous Combustion products

Pyrophoric Material

4.



Not available.

HEALTH HAZARD DATA Routes of Entry

Inhalation, Skin, Ingestion & Eyes.

Effects of Exposure/ Symptoms

Inhalation : Causes small burns to upper respiratory tract & lungs, mild nose irritation. Ingestion : Causes severe damage to mucous membrane, Severe scaring or perforation may occur. Eyes: Severe damage. Skin: Causes severe burns. Inhalation: Remove the victim from exposure. respiration, give oxygen, If necessary. Ingestion: Give water or milk followed by dilute vinegar or fruit juice. Do not Induce vomiting. Skin: Wash the affected area with plenty of water and soap. Eyes: Wash with plenty of water for 15 mins. Seek medical aid immediately. Not listed mg/Kg L.D 50

Emergency Treatment

L.D50 (Oral-Rat) Permissible Exposure Limit

-

ppm

TLV (ACGIH)

-

ppm 2 (Ceiling) mg/m3

NFPA Hazard Signals

2 (Ceiling) mg/m3 Odour Threshold Odourless ppm Odourless mg/m 3

Health 3

STEL

Not listed

Flammability 0

ppm

Not listed

Reactivity/Stability 1


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

mg/m 3

Special

Vol-I (Addendum)

Page 356



6.

7.

VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

PREVENTIVE MEASURES Personal Protective Equipment.

Avoid with solid or liquid. Provide side covered safety goggles, face shield, filter or dust-type respirator, rubber shoes and rubber hand gloves.

Handling and Storage Precautions

Keep in a cool, dry and well ventilated place.


Fire Extinguishing Media Special Procedure

EXPOSURE

Not Flammable Keep the containers cool by spraying water if exposed to heat or flame.

Unusual Hazards Toxic gases are produced. First Aid Measures If eyes are affected, flush with plenty of water for 15 mins. Skin: Remove contaminated clothes & shoes. Wash the affected area with plenty of water. If inhaled, remove the victim to fresh air area. respiration. Seek medical aid immediately for all types of exposures. Antidotes/Dosages

Not available.

SPILLS Steps to be taken


Sweep and collect without making dust. Wash the surface with plenty of water and soap. Put into a large vessel, neutralise with HCl and drain

into sewer with abundant water.

8.

ADDITIONAL INFORMATION/REFERENCES A strong base. Vigorous reaction with 1, 2, 4, 5-Tetrachlorobenzene has caused many industrial explosions & forms extremely toxic 2, 3, 7, 8 – Tetra-chloro-di-benzodioxin. Under proper conditions of temperature, pressure and state of dilution, it can react or ignite violently with Acetic Acid, Acetaldehyde, Acetic Anhydride, Acrolein, Acrylonitrile, Allyl Alcohol, Allyl Chloride.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 357


9.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

MANUFACTURER/SUPPLIERS DATA Name of firm : Mailing Address :

10.


MATERIAL SAFETY DATA SHEET Demulsifier

1.

CHEMICAL IDENTITY

Chemical Name

Synonyms

Demulsifier

Chemical Classification

Blend of Ethoxylated Block Co-Polymer, Resin, Wetting Agent and Surfactant in Aromatic Solvent

Mixture of organic compounds

Trade Name


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Demulsifier

Vol-I (Addendum)

Page 358




VOL-I: Addendum

Formula

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

C.A.S. NO.


Shipping Name

UN NO.

Demulsifier

Codes/Label Hazardous waste I.D. No. Hazchem Code


C.A.S. NO.


C.A.S. NO.

1. Petroleum solvent 2. Aromatics

2.


Boiling Point/ Range oC

Physical State

Melting/ Freezing Point oC

Vapour pressure @ 35 oC, mm Hg

Vapour Density (Air = 1)

Solubility in water @ 30 oC

Liquid

Appearance

Dark Brown

Odour

Dispersible

Solubility in others


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Aromatic solvent, kerosene

Vol-I (Addendum)

Page 359


3.

VOL-I: Addendum

0.92  0.02 at 25oC




pH

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

6.0 to 7.0


Yes

TDG 3 Flammability Auto ignition Temperature oC

LEL (%V)

Flash Point (OC) oC

UEL (%V)

Flash Point, (CC) oC

>93

Explosion Sensitivity to Impact Explosion Sensitivity to Static Electricity Hazardous Combustion products Hazardous Polymerization Combustible Yes Liquid Flammable Yes Material Pyrophoric No Material

4.

CO, CO2

Does not occur. Explosive Material No Oxidiser

No

Organic Peroxide

No

Corrosive Material Others

No


Stable

Incompatibility with other material Reactivity Hazardous Reaction Products

5.

HEALTH HAZARD DATA Routes of Entry Effects of Exposure/ Inhalation Symptoms

Inhalation, May cause headache and nausea.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 360




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Nausea, vomiting. If retained leads to symptoms of central nervous system depression. Skin : Dermatitis, Eyes : Irritation

Ingestion

Emergency Treatment

Medical attention is required.

Inhalation

Move to fresh air. If breathing is difficult give oxygen and call for physician.

Ingestion Skin : Flush with large amount of water for 15 minutes. Eyes : Immediately flush eyes with large quantities of water for at least 15 minutes.

LD50 (Oral-Rat),

mg/kg

Permissible Exposure Limit

mg/kg ppm

TLV (ACGIH)

ppm mg/kg

NFPA Hazard Signals

6.

LD50 , 50 mg/m3 10

mg/kg

Odor Threshold, ppm mg/kg STEL,

Health

Flammability

ppm mg/kg

Reactivity/Stability

15 75 mg/m3 Special

PREVENTIVE MEASURES Personal Protective Equipment Handling and Storage Precautions

Rubber or plastic gloves, solvent resistant, chemical safety goggles. Store between 5 oC and 49oC. May be stored in unlined Mild Steel Tanks


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 361


7.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



D, CO2

Special Procedure

Fire fighters must use SCBA.

Unusual Hazards EXPOSURE

First Aid Measures

SPILLS

Antidotes/ Dosage Steps to be taken

Medical attention is required. Move to fresh air. If breathing is difficult give oxygen and call for physician. Skin : Flush with large amount of water for 15 minutes. Eyes : Immediately flush eyes with large quantities of water for at least 15 minutes. Absorb with an inert material such as sand, soil or vermiculite.


8.

ADDITIONAL INFORMATION/ REFERENCES

9.

MANUFACTURER/ SUPPLIERS DATA Name of firm : Mailing Address :

10.



Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 362




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CONTROL OF HAZARDOUS CHEMICAL INVENTORY LEVEL

In atmospheric distillation unit main hazardous chemical, are ammonia & NaOH. Caustic solution is dozed at pre-desalter inlet to neutralize Naphthenic acid & at post desalter exchanger train to neutralize HCL generated by hydrolysis of salts of MgCl2. NH3 is injected in the over head of column to neutralize any HCL vapour which has remained unneutralized by caustic. NH3 is injected in some units as ammonia solution of 2-3% strength diluted with DM water & in some units as ammonical caustic solution where NH3 remains in solution with dilute caustic for neutralization purpose. NH3 is procured in cylinders of 40 Kg weight. Caustic is received from OMS & diluted to required strength with DM water. Caustic is also used for removing H2S from naphtha & LPG streams in naphtha & LPG Caustic & water wash system, where caustic of 10% strength is used. Inventory of this chemical is maintained for about 15 days of average daily consumption. Chemical

Unit

Average

Daily Requirement

consumption

for 15 days

Inventory level (requirement+ 10%)

NaOH

AU-3

200Kg

3.0 MT

3.3 MT

Ammonia

AU-3

13Kg

0.2MT

5 Cylinders

Demusifier AU-3

65Kg

1.0MT

5 drums

Ahuralan

7Kg

0.1MT

1 drum

AU-3


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 363



VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER-19 AU 3 CONTROLVALVE DATA

SIZE 1" SR. TAG NO. &

SERVICE

OLD TAG NO.

1

3FV 3509

SIZE &

RATING

AIR SPRI. CV MAKE ACTION POSITIONER/ SUPPLY RANGE I/P CONVERTOR

LIFT STEAM TO HY.NAP STRIPPER

1''-0.812''

300

12 =%

MIL

FO A/C MIL

2

3PV 3005

F-3 F.O. PRESSURE

1''

300

16=%

MIL

FC A/O

19.05 MM

3

F-3 F.G TO PILOT 3PCV 3001 BURNER

1''

150

1.7

MIL

(410HV2002)

1''

PLANT AIR TO F3 For Decocking 1" (3FC3001)

30 PSI

200

0.2-1 Kg/cm2

3 21

6-30 PSI 200

0.2-1 3 KG/CM2 211

992

open

ATOMISING 3DPV 3006 STEAM TO F-3

3HV3002

MIL

3-15PSI

Normal

150

12

MIL

FO A/C

19.05 MM

5

25 PSI

I/P watson smith

(SELF ACTUATING VALVE) 4

& MO SIGNAL NO

I/p Rosemount

19.08

SL. &

MIL I/P watson smith

300RF

12 Liner

MIL

FC A/O

50 PSI

3-15 PSI 991 0.2-1 KG/CM2

3 21

6-30PSI

991

.23 1KG/CM2 211

19.05mm

SIZE -1.5" Gujarat Refinery- Eco-friendly Refinery Prepared By

Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 364



1

3FV3211

VOL-I: Addendum

CR-I ( KERO-I ) TO K-1 1.5"

300RF 35 =%

MIL


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

FO A/C

19.05 MM STRIPING STEAM TO K 3A 1.5"-1.5"

2 3FV3517

3 3FV 3206

300RF 25 =%

MIL

FO A/C

25 =%

MIL

FO A/C

19.05 MM 4 3FV 3508

K-1 TOP PRESSURE

300

25 =%

MIL

FO A/C

MIL

ATF TO KERO

F3 FO SDV RETUN

410XV2003

1.5"

300

(410HV2003)

30 PSI

MIL

25 =%

MIL

FO A/C

MIL

35

MIL

2

3-15 PSI 991

2

25 PSI 11-30 PSI 200 3-15 PSI

FC A/O

2

11-30PSI 991

19.05MM

(3FC3008)

2

3-15PSI 200 0.2-1 Kg/cm2

20 PSI

2

3-15PSI 200 0.2-1 Kg/cm2

I/P Rosemount 300RF

F3 Decocking Steam To 1 1.5"

8 3HV3003

30 PSI

I/P watson smith

19.05 MM 7 3SDV3003

MIL

FO A/C

19.05 6 3TV 3506

MIL

2

3-15PSI 200 .21kg/cm2

I/p Rosemount

1.5''-1.5'' 300 RF 25=%

1.5''1.25''

30PSI

I/p Rosemount

19.8 5 3PV3201

MIL

3-15PSI 991 3-15PSI

I/p Rosemount

300

STEAM TO 1.5''HSD STRIPPER 1.25''

25PSI

I/P watson smith

19.5 MM STRIPING STEAM TO K- 1.5''6B 1.25''

MIL

21 300RF

35

MIL

FC A/O

11-30PSI 991

19.05MM

21

SIZE-2" 1

3FV3208

KERO-I FLOW 2"- 2"

300RF 46 =%

MIL

FO A/C MIL


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

25PSI

3-15PSI 991

Vol-I (Addendum)

Page 365



VOL-I: Addendum


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

TO KERO R/D 19.05 MM

2

3FV 3207

STRIPING STEAM TO K6A 2''-1.625''

I/P watson smith

300

46= %

MIL

FO A/C MIL

19.05 MM 3

3FV3210

HY.NAPTHA R/D(TO HSD)

2''-2''

I/p Rosemount 300

46=%

MIL

FC A/O MIL

4

3FV3209

2''

300

46=%

MIL

5

3LV3203

2"-2"

MIL

3LV3602

E-4 LEVEL

2"-2"

7

3SDV3002 410XV2002

SR. TAG NO. &

2"

200

0.2-1 Kg/cm2

2

6-30 PSI 991

6-30 PSI

I/P Rosemount 26 300RF linear

MIL

FC A/O MIL

35PSI

6-31PSI

OLD TAG NO.

46

MIL

FC A/O

11-30PSI 991

21 RATING

AIR SPRI. CV MAKE ACTION POSITIONER/ SUPPLY RANGE I/P CONVERTOR

LIFT

K-4 TOP REFLUX

3" - 3"

300RF

65 =%


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

SL. &

& MO SIGNAL NO

SIZE-3" 1 3FV3601

911

3-15PSI 300RF

SIZE &

2

2

19.05 SERVICE

2

20 PSI 3 -15PSI 911

19.5MM F3 FO SUPPLY

3-15PSI

0.2-1 Kg/cm2

FO A/O MIL

19.5MM 6

35 PSI

I/p Rosemount 15 300RF Linear

2

0.2-1 Kg/cm2

FC A/O MIL

19.05 E-1 WATER BOOT LEVEL

35 PSI

I/p Rosemount

19.05 SIDE CUT NAPTH TO HSD

30 PSI

3-15PSI

MIL FO A/C MIL

Vol-I (Addendum)

Page 366




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

38.1 MM 2 3FV3201

K-1 TOP TEMP. CONT.(REFLUX)

3" - 3"

I/P Rosemo 300RF

110 =%

MIL FO A/C MIL

I/P Rosemo 3 3FV 3005

F-3 CRUDE -2

3''

600

110=%

MIL

FO A/C MIL I/P watson smith

38.1 MM 4 3FV 3003

F-3 CRUDE -1

3''

600

110=%

MIL

FO A/C MIL I/P watson smith

38.1 MM 5 3LV3206

3"K-6B BOTTOM LEVEL 2.62MM

300RF

110 =%

MIL

FO A/O

38.1MM 6 3LV3205

K-6A BOTTOM LEVEL

I/P Rosemo

3"2.62MM

300RF

110 =%

MIL

FO A/O

38.1MM 7

3PV 3205

STRIPPING STEAM TO K-1

MIL

MIL

I/P Rosemo

3''-2.625''

75 Linear

300

MIL

FO A/C

MIL

I/P Rosemo 8

3 TV3129

CR-I TEMP. CONTROL

3''-3''

75 LINEAR MIL

300

Combing 3-way valve 38.1 MM 9 3HV3004 (410HV2004)

F3 Decocking Steam To 2 3" (3FC3009)

300RF

75 Liner mil

F to U port

MIL

Closed

I/p watso smith

FC A/O

38.1MM

SIZE-4" 1

3FV3111

KERO -2 TO KERO R/D

4"

300RF

225 =%

MIL FO A/C MIL

I/P Rosemo 2

3LV3516

K-3C BOTTOM LEVEL

4"-3.5"

300RF

195 =%


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

FO MIL A/O

MIL

Vol-I (Addendum)

Page 367




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

38.1MM 3

3PV 3003

F-3 F.G. PRESSURE

4''

I/P Rosemo 150

1.95=%

MIL FC A/O

MIL

I/P watso smith

38.1 MM 4

3SDV3005(3001)

FG TO F3

410XV2001 5

3FV3203

4"

150RF

195

300RF

195 =%

FC MIL A/O

38.1MM E-1 NAPHTHA TO K4

4"

MIL FC A/O MIL I/P watson smith

38.1 MM 6

3LV3601

K-4 BOTTOM LEVEL

4"

300RF

195 Liner

300

400 =%

MIL FC A/O MIL

38.1MM

SIZE-6" 1

3FV 3501

STRIPING STEAM TO K-2 6''-5''

MIL FO A/C

MIL

I/p Rosemo 2

3FV 3205

STRIPING STEAM TO K-1 BOTM 6''-4''

300

275 =%

MIL FO A/C

50 MM 3

3LV3503

MIL

I/p Rosemo

K-3B BOTTOM LEVEL 6"-6"

300RF

360 =%

MIL FC A/O

MIL

300

575=%

MIL

MIL

50.8MM 4

3TV 3125B

TEMP. CONT. OF E305

6''-6''

FO A/C

I/p watso smith

(3DTC 3125) 76.2 MM 5

3TV 3131

K-4 FEED TEMP. CONTROL

6''-6''

300

270 Linear

Combing 3-way valve


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

MIL

F to U port

MIL

Closed

I/p watso

Vol-I (Addendum)

Page 368




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

smith 6

3TV 3505

SRGO EX. K-2 TO K3B

6''-5''

300

400 =%

MIL

FO A/C

50.8 MM

SR. TAG NO. &

SERVICE

OLD TAG NO.

SIZE &

MIL

I/P Rosemo

RATING

CV

MAKE ACTION POSITION

I/P CONVERT

LIFT

SIZE- 8" 1 3FV3519

CR -III TO K -2

8" - 8"

300RF

640 =%

MIL FO A/C MIL I/P watson smith

50.8 MM 2

3TV 3102A

TEMP.CONT. E308A/B/C TO K-2

8''

300

575=%

MIL

FO A/C

MIL

I/p watso smith

76.2 MM 3

3TV 3135

CR-III TEMP. CONTROL Combing 3-way valve

4

3TV 3130

CR-II Return Temp.Cotrol Combing 3-way valve

5

3TV 3605

6 3FV5903

8''-8''

300

480 Linear

MIL

63.5 MM 8''-8''

300

480 Linear

MIL

63.5 MM

K-4 BOTTOM TEMP. CONTORL

8''

Diverting 3-way valve

63.5 MM

IMPORTED CRUDE TO

8"

300

150RF

480 Linear

640 =%

MIL

MIL

F to U port

MIL

Closed

I/p watso smith

F to U port

MIL

Closed

I/p watso smith

F to U port

MIL

Closed

I/p watso smith

A/O

MIL I/P watson smith

(15FV5902)


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 369




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

SIZE - 10 " 1

3FV3110

CRUDE TO K -1

10"

300RF 900 = %

MIL FO A/C MIL I/P watson smith

76.2 MM 2

3TV 3125A

TEMP. CONT. OF T-19 A/B 10''-10''

300

900=%

MIL

FO A/C

MIL

I/p watso smith

(3DTC 3125) 76.2 MM 3

4

3TV 040

3TV 3102B

K-1 FEED TEMP. CONTROL

10''-10''

Diverting 3-way valve

63.5 MM

TEMP. CONT.OF T2-C

10''

300

300

750 Linear

900=%

F to U port

VALTEK

Closed

I/p watso smith

FO A/C

MIL

MIL

MIL

I/p watso smith

76.2 MM

SIZE - 12" 1

3LV3501

RCO TO RUN DOWN 12"-12" K-2 BOTTOM

2

3PV 3101

300RF 1260 =% MIL FC A/O MIL

95.25MM

DESALTER COMMON PRESS.

12''

I/P Rosemo 300

1260=%

MIL

FO A/C

95.25 MM

MIL

I/p watso smith

CHAPTER-20 NORMAL LIST OF INTERLOCKS AU-III F1/F2/F3

TRIP SETTING AU-III UNIT( updated in Aug13) Gujarat Refinery- Eco-friendly Refinery Prepared By

Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 370




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

RUDE CHARGE HEATER F-02

.No. TAG NO.

Service

1 2 3

F-1 FG PRESSURE-A F-1 FG PRESSURE-A F-1 FG PRESSURE-A

PT3304A PT3304B PT3304C

PT3303A PT3303B PT3303C

F-1 FO Low Pressure Switch F-1 FO PRESSURE-A F-1 FO PRESSURE-B F-1 FO PRESSURE-C

PT3412A PT3412B PT3412C

F-2 FG PRESSURE-A F-2 FG PRESSURE-B F-2 FG PRESSURE-C

PL3303B

4 5 6

PL3411B PT3411A PT3411B PT3411C

F-2 FO Low Pressure Switch F-2 FO PRESSURE-A F-2 FO PRESSURE-B F-2 FO PRESSURE-C

Type of IP AI AI AI

TX Range

TRIP SETTING

0-5 Kg/cm2 0-5 Kg/cm2 0-5 Kg/cm2

DI

AI AI AI

0-5 Kg/cm2 0-5 Kg/cm2 0-5 Kg/cm2

DI

0.1 KG/CM2 0.1 KG/CM2 0.1 KG/CM2

F-1 CL

1 Kg/cm2

F-1 CL

0.1 KG/CM2 0.1 KG/CM2 0.1 KG/CM2

F-2 CL

1 KG/CM2

F-2 CL

7

PT3811

FD DISCHARGE PRESS LOW

0-400 MMWC

+20 MMWC

8

PT3819

ID SUCTION PRESS

-180 to +20 MMWC

-20 MMWC

9

PT3802A

F-1 ARCH PRESS-A

AI

10

PT3802B

F-1 ARCH PRESS-B

AI

11

PT3802C

F-1 ARCH PRESS-C

AI

-50 to +50 MMWC -50 to +50 MMWC -50 to +50 MMWC

+5 MMWC +5 MMWC +5 MMWC


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

AC

Vol-I (Addendum)

Page 371



PT3821A

F-2 ARCH PRESS-A

AI

13

PT3821B

F-2 ARCH PRESS-B

AI

14

PT3821C

F-2 ARCH PRESS-C

AI

15

FT3307

F-1 FLOW

AI

16

TT3317

F-1 COT HIGH

AI

17

FT3402B

F-2 -1 FLOW

AI

2500 MMWC/0200 M3/HR

18

TT3422

F-2 -1 COT HIGH

AI

0-500 DEGC

19

FT3403B

F-2 -2 FLOW

AI

2500 MMWC/0200 M3/HR

AI

0-500 DEGC

Type of IP

TX Range

AI

0-150 MMWC

F-2 -2 COT HIGH RUDE CHARGE HEATER F-03 TTT3413

.No. TAG NO.

21

22 23 24 25

Service

Combustion Air Press Low Combustion Air Press 3PT3015B Low-B Combustion Air Press 3PT3015C Low-B 3PT3015

3FT3002 3FT3004 3TT3023A 3TT3023B

Low Feed Flow -1 Low Feed Flow -2 -1 COT High -2 COT High

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


12

20


+5 MMWC +5 MMWC +5 MMWC

2500 MMWC/0200 M3/HR 0-500 DEGC

60 M3/HR 390 Deg 90 M3/HR 390 Deg

90 M3/HR 390 Deg

TRIP SETTING 16 MMWC 16 MMWC 16 MMWC

AI

0-100 TPH 0-100 TPH 0-500 DEGC 0-500 DEGC

10 T/Hr 10 T/Hr 400 DEG C 400 DEG C


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 372

AC

. Indian Oil Gujarat Refinery FD-A Suction Flow Low FD-B Suction Flow Low



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

26

3FT3011A

27

3FT3011B

28

3PT3004 F-03 FG Press. Low 3PT3004B F-03 FG Press. Low 3PT3004C F-03 FG Press. Low

AI AI AI

0-6 Kg/cm2 0-5 Kg/cm2 0-5 Kg/cm2

0.2 Kg/cm2

29

3PT3013 Fuel Oil Pressure Low 3PT3013B Fuel Oil Pressure Low 3PT3013C Fuel Oil Pressure Low

AI

0-10 Kg/cm2

0.96 Kg/cm2

30

3PT3011

AI

-300 to 0

-60 MMWC

34

3TT3027

AI

0-300 DEGC

31

3PT3016A Arch Press. High

AI

32

3PT3016B

Arch Press. High

AI

33

3PT3016C Arch Press. High

AI

35 36 37

IT3001A IT3001B IT3003

ID Suction Pressure ID Suction Temperature

AI

/ 0-33400

6680

AI

/ 0-33400

6680

285 DegC


10 MMWC 10 MMWC 10 MMWC

FD-A Current Low FD-B Current Low ID Fan Current Low

1474 Count 1474 Count 1474 Count


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 373




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER-21

HSD COALESCER

OPERATION AND MANTENANCE MANUAL: CLIENT: M/S INDIAN OIL CORPORATION LIMITED PROJECT: IOCL GUJARAT REFINERY (UNIT-AU3) INSPECTION: M/S LRIS ITEM: DIESEL COALESCER TAG NO. / QTY: 03-V-301 / ONE PO NO: RJRMM 44119/17150951 DTD 08-10-2004 MULTITEX DRG NO. – WD-869-PV-10-04-02-A1-01 DESCRIPTION: MULTITEX DIESEL COALESCER is a compactly made mechanical device manufactured to a high degree of accuracy. If complete instructions regarding installation, operation and maintenance of these units are observed carefully, the coalescer should give trouble free service for a very long period. THE DIESEL COALESCER in its simplest form, designed and manufactured as per ASME Section VIII Div. I. It consists of a horizontal shell having dished end at its both ends and one manhole connection at the middle to facilitate the easy removal of coalescer and separator elements for cleaning and replacement. INSTALLATION The Coalescer is a precision product and requires extremely careful handling during transportation, fitting and installation. The coalescer is thus normally dispatched in well-packed installation. It should be unpacked just before installation only and the whole coalescer may be checked for any damage.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 374




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The coalescer should be fitted in position taking care of the orientation of nozzles etc. the coalescer should be rigidly hooked upto various piping connection and base to avoid any vibration due to flow. Ensure sufficient empty space on the front of the Manhole opening to facilitate the element removal without tilting. IMPORTANT: To avoid damage to the element by any leftover material in the piping system, up-stream of the element should be flushed thoroughly before the fitment of coalescer/separator element in the housing. METHOD OF WORKING The Diesel Coalescer housing is provided with the inlet and outlet nozzles of suitable sizes at the front end on dish and at far end on dish of housing respectively. Connection for safety relief valve has been provided. The water droplets coalesced through the element gets collected in the horizontal sump provided below main vessel and thereafter drained through the drain nozzle provided at its bottom. Horizontal sump with dished end on its both end has been provided. Connections for Level Transmitter and Level Gauge have also been provided to mount instruments on the horizontal sump. The Diesel coalescer consists: (a) 1st stage: Coalescer element to coalesce fine mist of water and to retain dust particle (b) 2nd Stage: Separator element to separate out water droplets (At outlet < 20 ppm) All the solid particles 10 microns (98%) are trapped in the element. In addition liquid droplets do not wet the fibres but remain attached to them as beads of liquid. As more liquid droplets are separated, more they agglomerated and coalesced into large drops due to their surface attraction to each other. When the coalesced liquid drops attains a sufficient size from 100 to 200 times their initial size, the force of gravity and frictional drag of the fluid causes them to drain out the element and they are carried into sump of the vessel. Due to their size, they are readily stripped out in the horizontal sump through downcomers. OPERATION The coalescer has been thoroughly subjected to inspection and testing at our works before dispatch, but to check the leak proofness of matching flanged connections, the coalescer along with the up-stream and downstream piping should be subjected to hydrostatic testing. After satisfying that there is no leaking t causing spillage and wastage of service fluid, the coalescer should be put to the operation as follows :


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 375




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

1. Supply of stream (at required temperature) should be started before putting the coalescer into operating 2. Provide all instrument / isolation valves at per drawing & P&ID 3. Close all valves including inlet, outlet and drain plug. Open air vent. 4. Open inlet valves slowly so that coalescer is in operation. 5. Open drain plug and flush out any debris. 6. Close drain plug. 7. Allow coalescer to fill in with liquid and when the liquid starts coming out of the air vent, close the air vent again. 8. Open coalescer outlet valve. 9. If there is a by- valve, close it slowly. The fluid enters through the inlet to the coalescer. In the process of ing through the elements, the entrained particles (Liquid+Dust) are caught through the depth of the element and clean fluid es out through the outlet.

MAINTENANCE AND CLEANING / REPLACEMENT The element of the coalescer supplied has been designed for the following pressure drop: Pressure Drop (clean): - 0.75 kg/cm2 MULTITEX coalescer will give satisfactory service if it is ensured that the element is replaced on attaining the maximum permissible pressure drop as indicated above. The following procedure should be adopted for replacement of the element: Whenever the pressure drop reaches the maximum permissible pressure drop the element should be replaced by new element. Close inlet and outlet valves and open the drain plug and flush out the fluid in the housing. Take out the dirty element from the shell and replace it. The element can be taken out by opening Manhole cover. Enter into the housing, unscrew the tie rod nuts, remove the spider plate and then pull the element on the tie road. Revolve the element and take out from housing through manhole. After replacement of element, the system can be now put into operation.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 376




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

CHAPTER-22

ANNEXURES

Annexures-1: Equipment Handing over/ Taking over Procedures 1. 2. 3. 4.

Check list for handing over of Pump/motor to (M/M / E/M) Check list for handing over of Heat Exchanger to (M/M) Check list for handing over of Column to (M/M) Check list for handing over of Tank/Vessel to (M/M / C/M)

Chapter 5 5. Check list for taking over of Pump/motor from (M/M / E/M) 6. Check list for taking over of Heat Exchanger from (M/M) 7. Check list for taking over of Column to (M/M) 8. Check list for taking over of Tank/Vessel from (M/M / C/M)

Abbreviations:


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 377




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

M/M – Mechanical Maintenance E/M – Electrical Maintenance C/M – Civil Maintenance


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 378




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

PRODUCTION DEPARTMENT ( GR- II )

Check list for handing over of Pump/motor to (M/M / E/M) UNIT: OPERATOR:

DATE: TIME:

PUMP /MOTOR NO:______________________ SR DESCRIPTION STATUS NO 1 Pump/motor status. ON/OFF Motor electrically isolated? Yes / No Ensure that “ DO NOT OPERATE/MAN AT WORK “ board is put on switch. LOTO to be followed in TOTO. 2 Suction/discharge valves are closed? Yes / No 3 Warm up valve closed? Yes / No / N.A 4 Quench steam/water valve closed? Yes / No / N.A 5 AOP stopped after pump cooling and Yes / No / NA electrically isolated? 6 M/seal-flushing line valve/ bearing Yes / No / N.A cooling water valve closed? 7 Material drained / depressurized to Yes / No / NA CBD / ABD/ OWS / Flare? Heavy material pump should be flushed with FLO and then drained. 8 Ensure complete depressurization. Yes / No / N.A 9 Positive isolation done by blinding? Yes / No / NA (Suction/discharge/warm-up/flare CBD/ABD line). 10 Area cleaning done? Yes / No 11 Motor decoupled? Yes / No / NA 12 Junction box disconnected? Yes / No /N A 13 Ready for issue clearance. Yes / No


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

REMARKS

Vol-I (Addendum)

Page 379




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

REMARKS: SIGN:

DATE: PRODUCTION DEPARTMENT ( GR-II )

Check list for handing over of Heat Exchanger to (M/M) UNIT: OPERATOR:

DATE: TIME:

EQUIPMENT: EXCHANGER /COOLER / CONDENSER /REBOILER EQUIPMENT NO: __________________________ SR DESCRIPTION STATUS NO 1 After Exchanger Bying. Yes / No Tube side inlet valve closed? 2 Tube side outlet valve closed? Yes / No 3 Shell side inlet valve closed? Yes / No 4 Shell side outlet valve closed? Yes / No 5 Tube/shell side HPV open? Yes / No 6 Material completely drained out to ABD Yes / No / CBD /OWS? Take FLO in tube/shell sides for handling heavy material and drain to CBD/OWS. 7 Ensure complete drain out. Yes / No 8 Steam / water flushing connection to Yes / No tube/shell side done? (2-hrs) 9 Primary steam / water flushing to Yes / No tube/shell side done? 10 Tube and Shell both the sides B/W and Yes / No final steaming done? (4-hrs) 11 Required insulation removed? Yes / No 12 Ready for issue clearance? Yes / No 13 If HOT job planned/required gas test Yes / No / NA


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

REMARKS

Vol-I (Addendum)

Page 380




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

done? REMARKS: SIGN:

DATE :

PRODUCTION DEPARTMENT ( GR-II )

Check list for handing over of Column to (M/M) UNIT: OPERATOR:

DATE: TIME:

COLUMN NO: _________________________ SR DESCRIPTION NO Pump out /empty out column completely 1 2 3 4 5

6

7

STATUS Yes

/ No

Column isolated by feed inlet and product outlet valve?

Yes

/ No

Complete drain out remaining material to CBD/OWS. Utility column bottom steam and top vent line de-blinded? Keep vent and drain open and do primary steaming at least for 6 Hrs. Inlet/outlet and other lines B/ W/ O as per scheme except steam and reflux line done? (Keep min. purge steam charge during B/WO to avoid vacuum in column) Do full blast steaming for min. 24 hrs. keeping column vent & drain open .Observe column press. It should be maintained below operating pressure.

Yes

/ No

Yes

/ No

Yes

/ No

Yes

/ No

Yes

/ No


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

REMARKS

Vol-I (Addendum)

Page 381


8

9

9 10


(Ensure that bottom drains & vents are open and steam/water coming from all w/o flanges) Do hot water washing for min 8-12 hrs.


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Yes / No

Stop steam and start water washing for 6 hrs Yes till clean & cold water observed ex bottom drain. Done? (Ensure for drain valve fully open) Positive isolation of column as per scheme Yes including utility steam and reflux line done? Opening of top / bottom and middle Manhole Yes done?

/ No

Gas test done from all opened manholes? H/C : _________

/ No

Yes

/ No / No

OK/not OK 11

12 13 14

O2 : _________ (If H/Cs are positive. Box up Man hole and repeat steaming/water washing till OK gas test.) Exhaust fan boxed up & started at top & bottom manholes for air circulation? Water hose provided near manhole to avoid any possibilities of pyrophoric iron? Flood light and hand lamps provided near manholes? Further gas test done for man entry?

OK/not OK

Yes

/ No

Yes

/ No

Yes

/ No

Yes

/ No

15 16

Gas test for H/C& O2. Ready for man entry clearance?

OK/ not OK Yes / No

REMARKS:

SIGN:

DATE:


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 382




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 383




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Check list for handing over of Tank/Vessel to (M/M / C/M) UNIT: DATE: OPERATOR: TIME: TANK /VESSEL NO: __________________________ SR NO 1

2

3

4 5

6

7

8

DESCRIPTION Vessel empty out by pumping to system? Vessel isolated by inlet, out let and inter connection valves except flare and drain valve? Vessel completely drains out to CBD / OWS keeping flare or vent valve open? Vessel depressurized to flare/atmosphere? Utility steam hose connection given/exist? Primary steaming done to flare or vent for B/WO for about 4 hrs? Vessel B/WO done as per scheme? Further steaming done for 24 hrs keeping drain and vent valve open including instrument tapping open? Vessel positive isolation by blinding as per scheme done? Steam connection removed and line got blinded? Top manhole opened? Water connection provided to vessel? Water over flowing from top manhole done for 24 hrs or till clean water observed from

STATUS Yes

/ No

Yes

/ No

Yes

/ No

Yes Yes

/ No / No

Yes Yes Yes

/ No / No / No

Yes

/ No

Yes Yes

/ No / No

Yes Yes

/ No / No


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

REMARKS

Vol-I (Addendum)

Page 384


9

10 11


drain? Stop water washing to vessel and blind water line. Done? Vessels completely drain out keeping vent valve open. Done? Side manhole got opened?

13 14

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Yes

/ No

Yes

/ No

Yes

/ No

Vessel gas test done for H/C : ________ O2 : ________ ( IF not OK repeat sr no 5&7activities till gas test OK)

12


Provide flood light and hand lamp near manhole. Done? Provide air hose & water hose near manhole. Done? Vessel ready for man entry clearance?

Yes/ No/OK/ not OK Yes/ No/OK/ not OK Yes / No Yes

/ No

Yes

/ No

REMARKS: SIGN:

DATE:


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 385




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Check list for taking over of Pump /motor from ( M/M / E/M ) UNIT: OPERATOR:

DATE: TIME:

PUMP/MOTOR NO: ______________________ SR DESCRIPTION NO 1 Motor electrical and earthing connection completed? 2 Motor checked for correct rotation? Motor canopy boxed up? 3 Mechanical maint. Job completed? 4 Coupling guard provided? 5 Ensure pump-cooling water and steam quenching system are healthy?

STATUS Yes

/ No

Yes Yes Yes Yes Yes

/ No / No / No / No / No

Yes Yes Yes

/ No / No / No

Yes

/ No

10

Lube oil level and lube oil cup are OK? Pressure gauges are in position? Check pump & motor shaft free rotation. Done? Check that associated lines are de blinded? (Suction, discharge,warmup,ABD, CBD,OWS) Suction B/V Discharge B/V Warm-up B/V Drain line B/V Vent line B/V M/seal sealing system is OK?

11

Pump M/seal checked for leak?

Yes / No/OK/not OK

6 7 8

9

REMARKS

Open / Close Open / Close Open / Close Open / Close Open / Close Yes / No


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 386




12 Area cleaning done? REMARKS: SIGN:

Yes

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

/ No

DATE:


Check list for taking over of Heat Exchanger from (M/M) UNIT: OPERATOR:

DATE: TIME:

EQUIPMENT: HEAT EXCHANGER /COOLER /CONDENSER /REBOILER EQUIPMENT NO: _______________________________ SR DESCRIPTION STATUS REMARKS NO 1 Tubes and shell cleaning done properly? Yes / No 2

Leaky tubes if any are plugged / replaced? Shell is painted as per inspection?

Yes

/ No

Yes

/ No

Exchanger is boxed up with proper size gaskets? Whether any short bolting are there?

Yes

/ No

Yes

/ No

Yes

/ No

7

Bull plugs, thermo-wells, pressure gauges, PSV / TSV are boxed up properly? FLO lines are blinded.

Yes

/ No

8

Shell side Inlet / outlet are de-blinded?

Yes

/ No

9

Tube side Inlet / outlet are de-blinded?

Yes

/ No

9

CBD/OWS drains are de-blinded?

Yes

/ No

10

HPV, LPD Closed & capped?

Yes

/ No

11

Ear thing connections are completed?

Yes / No

12

Insulation is completed?

Yes / No

3 4 5 6


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 387




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

13

Area cleaning done?

Yes / No

14

Ready for commissioning

Yes / No

REMARKS: SIGN:

DATE: PRODUCTION DEPARTMENT ( GR-II )

Check list for taking over of Column to (M/M) UNIT: OPERATOR:

DATE: TIME:

COLUMN NO: ________________________ SR DESCRIPTION NO 1 Start boxing up from the top 2 3 4

5 6

7 8 9 10 11 12 13

The tray decks below the manhole are clean and free of foreign materials Temporary connections are removed All instruments tapping, drain points, distributors, downcomers, inlet and outlet nozzles are clear All internals as fitted properly All inside fittings like distributors, thermowells, flats of level indicators etc are in position. Tray manway covers are boxed up Manholes are boxed up on 4 bolts while insuring that nobody is left inside Tray manway and manholes should be boxed up in presence of production staff All manway covers are boxed upas above Blinding/ deblinding is complete as per Master blind list NRVs are installed in their proper direction Column bottom drains are connected

STATUS Yes

/ No

Yes

/ No

Yes Yes

/ No / No

Yes Yes

/ No / No

Yes Yes

/ No / No

Yes

/ No

Yes

/ No

REMARKS

Yes/ No Yes

/ No

Yes

/ No


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 388




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

properly 14 Safety valves are installed and lined up Yes / No 15 The instruments are in their respective Yes / No positions 16 The column is ready for service Yes / No REMARKS: SIGN: PRODUCTION DEPARTMENT ( GR-II )

DATE:

Check list for taking over of Tank/Vessel from (M/M) UNIT: OPERATOR:

DATE: TIME:

TANK /VESSEL NO: _______________________________

SR NO 1

2

3 4 5 6 7 8 9 10

DESCRIPTION

STATUS

Tank inside C/M & M/M job is over? Tank inside thoroughly cleaned? (In/out/drain nozzles to be checked for any foreign materials) Instrumentation job over? a) Level Indicator b) Press. Indicator c) Temp. Indicator Top/Bottom Manholes ready for boxed Up? Tank hydro test done? Breather valve/vent boxed up? Tank siphon drain line and valve boxed up properly? Tank top/bottom/clean out all manholes got boxed Up? Tank Inlet, Outlet, circulation, nitrogen, steam coil, and drain lines are de-blinded? Tank shell earthing is properly provided? Area cleaning done?

Yes Yes

REMARKS

/ No / No

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

Yes

/ No

Yes / No Yes / No


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 389



Tank ready for commission?


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Yes

/ No

REMARKS: SIGN:

DATE:


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 390




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Annexure-2 AU-3 M&I-2009 jobs 1.

CRITICAL JOB K-2 column shell replacement (Flash zone)

2.

OTHER MAJOR JOBS a. Heat Exchangers 

Complete re-tubing of following exchangers (07 nos.) carried out T-8C (B),

25 X 2X 6000, 372 tubes

T-2E,

20 X 2 X 6000, 372 tubes

T-2D (T),

20 X 2 X 6000, 372 tubes

T-2B (B)

20 X 2 X 6000, 372 tubes

T-19(T) E-313 A/B,



25 X 2 X 6000, 208 tubes 19.05 X 2 X 4000, 180 tubes each

Shell replacement was done for following (05 nos.) of heat Exchangers. T-8 A/B/C/D (04 No.), E-318 (01 No.)

b. Furnaces: 0410-F-01 / 02/03 

M&I jobs including replacement of sidewall tube hanger,18 nos, locking bars 28 nos, hip arch tube hangers 03 nos.



Repair of intermediate tube sheet of F-1, 2



Replacement of bottom most glass module of F-3, APH



Repair/repln. of Floor/sidewall casing plates, (30 M2 approx.in F-1, 45M2 approx in F-2)


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 391




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016



Castable refractory repair



coil replacement (02 nos) in F-3 furnace.

c. Columns: 0410-K-01/03ABC/04/06AB K-1 column: 

Replacement of bulged CS strips lining (05 locations in top dome and shell) with 5mm thick CS plate.



SS316L strip Weld build up done at 8 locations.

K-2 column: 

Replacement of top three Monel Trays.



Replacement and testing of SS, Monel strip lining at approximately 550 locations.



CS, Monel and SS weld buildup at various locations

d. Vessels/Tanks 19 nos. 

M&I Jobs



Epoxy painting of internal surface, after blast cleaning done in E-2



Provided conventional, 60 mm thk. Calundum in E-1/4

e. Safety valves: 43 nos. PSV/TSV  f.

Revisioning and testing of all safety valves

Modification Jobs 

Provision of Temperature indicator for RCO cooler.



Replacement of DM water with sour water for Desalter.



Resizing of cooling water return header of New CBD system with slop – elevation adjustment to enable water flow to tank by gravity.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 392




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

g. Piping jobs and Tag Jobs

h. RUP hookup jobs

Annexure-3 K-2 Column Flashzone replacement In AU-3 Unit, column K-2 is main fractionator which is the heart of any atmospheric unit. since this unit has been more than 45 years old and processing high chloride North Gujarat crude, metallurgy also get affected of erosion and corrosion, in turn leading to subsequent failures like pin hole leaks. To cope up with the problem of leakage, flash zone of nearly 6 meters height was to be replaced with cladded plate during M&I of june-2009. Before taking safe shutdown of unit, concrete structure with platform was prepared opposite of furnace F-3 to keep TOP PORTION of column - nearly 25 meters. 600 MT capacity giant crane was also brought in different parts and was assembled by using small cranes and hydras. This crane was to be used for holding and shifting of column. flashzone section to be replaced was prefabricated “20mm thick plate integraly cladded with 4mm SS317L plate” metallurgy. After shutdown of unit and completion of handing over the unit to mechanical maintenance, they started executing their plans. All attached pipings, instrumentation, electrical cables, column platform including ladders were detached from column safely. HIGH TECH tools (digital theodolite) and laser alignment instruments were used to benchmark column position and allied pipelines. 60 mm thick plates were used to fabricate the lifting lugs – 2 nos which were welded to column top to hold it. first the column was cut circumferentially from above flashzone while being hold by crane.then it was shifted to predesigned structure and placed there vertically. After that second cut was made and flashzone section of nearly 6 meters was removed. A new prefabricated portion was kelp on the place. After dimensional check and necessary alignment correction, bottom portion was welded.6 nos of trays were fixed in flashzone section and then column top was shifted to its original


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 393




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

position. After alignment and dimensional corrections, it was welded to flashzone section. all allied nozzles, pipelines, instrumentation and platforms were fixed as before. Unit reliability was enhanced by this critical job.

Annexure-4 RUP Hookup jobs There are 13 PTPs executed in AU-3 UNIT. 1. PTP-25 : Tapping taken just D/S of Hot RCO to GHP C/V FV-3115B. The RCO from this point will go to DCU FEED Tks 1510 / 1511. 2. PTP-18 : Tapping taken from the line ‘COLD RCO to VBU’ to the same destination as the same PTP-25. 3. PTP-166 : Tapping taken from the line ‘COLD RCO TO OM&S’; the RCO from this line will go to IFO TK 93/94 [RUP Names Tk-108A/B]. 4. PTP-303/304 : Represents new control valve PV-5903 in existing SKO line. 5. PTP-084 : The U/S line of new C/V PV-5903 will be going to HSD Coalescer along with Diesel of AU-3. 6. PTP-222 : The D/S line of NEW C/V PV-5903 will be going to DHDT feed tanks 1501 / 1502. 7. PTP-347B : SKO Ex PTP-84 WILL this PTP and go to HSD Coalescer in AU-3. 8. PTP-347C/D : represents the coalesce by line points. 9. PTP-80 : HSD Coalescer outlet line PTP-80 via new pumps [to be installed in AU-3 Chemical dosing area near old Desalter] 2115-P-119A/B will go to EURO-III HSD Header.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 394




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Annexure-5 Procedure for dechocking of equipment drain line 1. Ensure the first block valve from the equipment is closed. 2. Heat the line with steam lancers from drain point to first block valve, in case of heavy oil. 3. Connect LP/MP steam hose at drain point, provided the equipment pressure is less than LP/MP steam header pressure. Ensure proper hose connection (flange / clamp type) to avoid removal of hose during pressurization by steam. 4. Open the first block valve from the equipment and pressurize with steam for dechocking. Ensure positioning of manpower at both locations (i.e. near equipment and steam charging point). Confirm dechocking of drain line by touching the equipment valve / line. 5. In case the above procedures fail, isolate the equipment, pump out the material from the equipment to maximum possible extent (till the pump looses suction) and depressurize. Ensure no fresh material is entered into the equipment. Hand over the equipment to Maintenance for dechocking the line. 6. Ensure proper PPE is used during decoking operation. 7. Risk assessment to be done by shift officer & maintenance engineer before executing the dechocking activity.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 395




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Annexure-6 FLARE KOD DRUM / VESSEL DRAINING SR. NO. 1

DESCRIPTION



STATUS Yes/No

Remarks

Inform S/I, operator. Ensure steam in coil inside drum is ON for Flare KOD.



Carry personal gas Detectors and Walkie-Talkie

2



Get confirmation of the vessel level from Stand Up-stream of the Wind direction Follow the following procedure: o Crack Open 2nd Isolation valve o Crack Open Root Valve o Close Root valve as soon as gas/ vapours are noticed o Close the 2nd isolation valve Drain to CBD. If draining is required to

 

3



be done in OWS, keep running water hose on it. 4



Do not leave the place. In case of any abnormality, stop draining and inform Shift-In-Charge

5

After draining is over, isolate the drain valves. Ensure that the valves are holding, leave the place. Inform operator


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 396




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Don’ts      

Don’t leave the drain valve open – unattended Don’t close the 2nd isolation valve before the root valve Don’t stand in the Downstream of the wind direction Don’t open the drain valve wide open Don’t deviate from the standard procedure for draining Don’t start draining if ‘hot job’ is in progress in the unit


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 397




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Annexure-7 GENERAL SAFETY INSTRUCTIONS 

All safety valves must be kept in line with both sides isolation valves car sealed/ wire sealed in wide open condition. If any of the safety valves isolated due to ing or leak, ensure that it is attended on priority. Every shift to highlight the isolated safety valve in the logbook.



While handling chemicals, use safety wears. Shift PNE/SPNE should satisfy themselves regarding the adequacy of protection (use of PVC hand gloves, apron, face shield, safety goggle, hand gloves or gas mask etc.,) required to carry out the job.



All drains and vents on lines and equipments handling hydrocarbons and dangerous chemicals are to be kept properly capped or blinded. Sample points from where regular samples are collected should be kept hand tight.



Draining of oils from system should be done to CBD system. If draining is required to be done to OWS for any reason, ensure that the material being drained is sufficiently cold enough or put a running water hose as to avoid vapor cloud formation/ auto-ignition.



Light hydrocarbons are NOT to be drained into OWS as it may create vapor cloud at other places leading to fire and explosion.



All sewage manholes must always be kept covered.



Any line/ equipment which has been under hydrocarbon service, should not be exposed to atmosphere/ air unless it is made free of hydrocarbons either by steaming or by water flushing or ivation/washing procedure as applicable to that equipment.Similarly when


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 398




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

any equipment is exposed to air, it is to be made free of air before putting it into hydrocarbon service. 

Rotary equipment is to be handed over to maintenance only after proper isolation (process isolation, draining and electrical de-energisation (including LOCK OUT AND TAG OUT LOTO). Confirm the de-energisation by pressing the start button in the field.



Any excavated area or opening at higher altitude must be properly barricaded to eliminate chances of anybody falling down.



Wooden planks, bamboo’s, ropes, oil soaked cotton wastes or any other combustible material must not be allowed to remain in the unit area specially near hot equipments as it can result in fire.



First-Aid box must be available in ONE/SPNE office. Ensure refill of the box as and when required. Record in the logbook for any deficiency.



Constant watch to be kept on firebox conditions. Boxes must be clear and there should be no flame impingement on the tubes.



Naphtha is not to be given to any person/section for washing or cleaning purpose.



Scales/ mucks taken out from equipments under lighter hydrocarbon service (e.g. fuel gas, LPG and naphtha) are to be kept wet and carefully removed to a safer place and buried. This is to prevent fire due to presence of pyrophoric iron.



In certain abnormal circumstances wherein maintenance activity is required to be carried out (without complete hydrocarbon freeing) wherein sufficient risk exists from upstream/ downstream of equipments/ pipelines (to be taken under maintenance), Job Safety Analysis (JSA) is to be performed by GSI and approved by unit in-charge before giving clearance.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 399




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ANNEXURE 8

ROUTINE CHECKS BY OPERATOR

ROUTINE CHECK OF DESALTERS :

       

Try point checking for interphase level and cross check with . Check Brine colour Check Amperage & volts Check desalter outlet pressure and cross check with . Check whether demulsifier injection is normal Check whether pre-/ post desalter caustic dosing is proper. Desludging to be done as per schedule Check for leaks in connected flanges /nozzles

ROUTINE CHECKING OF LPG QUALITY  Mainly two quality checks to be done by field operators namely o Weathering- this is done to determine the volatility of LPG. The specification is +2°C O Pb-acetate paper test- this is done to have an idea of corrosivity of LPG. A

WEATHERING TEST o Take a clean and empty weathering pot


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 400

. Indian Oil Gujarat Refinery o o o o o o B



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Open the second isolation valve of the sample point first and then the first isolation valve slowly. Drain the hold up material and collect the LPG in weathering pot up to 100 ml. Dip the thermometer inside the pot and allow the LPG to evaporate. The temperature shown when 5 ml of the liquid is remaining in the tube is the weathering temperature. Report the above to . Above job to be done at least 4 times in a shift.

Pb-ACETATE PAPER TEST o o

Soak a filter paper with Pb-acetate solution Hold the paper in front of LPG from the sample point. Observe the colour change of the paper. If there is no change in colour LPG is OK. If there is change in colour report to pane/ shift in-charge.

Above job to be done atleast twice a shift. In case of some reasons stabiliser column is upset, then after stabilisation weathering test to be done by taking sample from LPG pump discharge to have an idea that the corrective actions taken has been effective.

ROUTINE CHECKS OF PUMPS

          

Check for temp. around bearing housing, stuffing box, and motor side by touching hand. Check the lube oil level in bearing housing- top up if required. Steam quench to be just puffing. Check the discharge pressure and amperage. Check for any leakage from any flange- report to shift I/C in case of any leakage. All stand by pumps to be in warm up condition and its steam and water lines to be isolated. Also check the power supply with a kick. Check all the oil cups for proper level & appearance of oil. Oil quality to be checked by removing the oil cup & check the oil by hand. Check for abnormal vibration. Check pressure for unusual pulsation. Check cooling water supply to stuffing box, bearing cooling, etc.


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 401




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

ANNEXURE 9 List of Major jobs carried out during this M&I in ’2013 1. Installation of MOV in K1 bottom (pre fractionator) 2. Installation of MOV in K2 bottom (Main fractionator) 3. Installation of MOV in E1 bottom (Pre fractionator overhead receiver) 4. Installation of MOV in E2 bottom (Main fractionator overhead receiver) 5. Installation of Hand controlled valves (2 no) in RCO outlet of E-302A/B and E103A/B 6. Replacement of Pre desalter heat exchangers T19A/B with HM3A/B/C


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 402




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

7. Replacement of post desalter heat exchangers T2A/B/C/D and T3 with HM1A/B/C/D/E/F 8. modification in E309A/B/C tube side 9. Replacement of existing gate valves with globe valves in Ex E309A/B/C RCO lines 10. Installation of strainers in fuel gas to 410-F1/410-F2 11. Replacement of 3 burners in 410F1(one to one& out of 6) 12. Replacement of 5 burners in 410F1 (one to one & out of 10) 13. Control routing of Kero to LABFS line 14. Routing of FGH off gas to gas away line 15. Providing additional level in K2 bottom 16. Routing of AU3 slop to GRE slop tank 17. Replacement of APH module in F1/F2 APH 18. Additional skin thermocouples installed 4 number each in 410F01 and 410F-02 19. Emergency shutdown switch provided in field for 410F01 and 410F02 20. 2oo3 logic implemented in following trip settings 1. Fuel gas to 410F01/410F02/410F03( low pressure ) 2. Low combustion air pressure in 410F03 3. Arch pressure high of 410F01 and 410F02


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 403




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

4. Fuel oil to 410F01/410F02/410F03( low pressure ) stub taken for 2oo3 logic implementation

Excerpts from PDEC cell report (Dec’2010)on “ AU3 preheat improvement and decongestion” Proposed modifications to improve Temperature control: • Installation of globe valves in RCO split line downstream to E-309 in place of existing block valves, • Two hand control valves to be provided on the RCO lines downstream of heat exchangers HM-3 A/B/C & E-302 A/B/C to ensure flow balance of RCO • Installation of globe valves in RCO split line upstream of E-103A/B in place of existing block valves, Conclusion:


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 404




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

The redundant exchangers after implementation of this project will be: 1) T-19 A/B - 2 bundles (Non TEMA Exchangers) 2) T-2 A/B/C/D/E & T-3 - 12 bundles (Non TEMA Exchangers) 3) E-309 A/B/C - 3 bundles (refer Note 1 below) New Heat exchangers installed under this project will be: 1. HM-1 A/B/C/D/E/F - 6 Bundles (refer Note 2 below) 2. HM-3 A/B/C - 3 Bundles 3. HM-2 A/B - 2 bundles (refer Note 1 below)

Note:1) PDEC recommends to retain the existing heat exchanger E-309A/B/C in PHT-3 with tube side modification from 6 to 4 instead of procuring 2 new bundles to contain the project cost. The executability of the same was discussed and confirmed with JR during the PDEC team visit in October 2010. Revised datasheets for both E-309 A/B/C (with change) and HM-2A/B are incorporated in this report. 2) Replacement of T-2A/B/CD/E and T3 is done with 3 twin exchangers (6 bundles) HM-1 A/B/C/D/E/F. 2 Exchangers HM-1 A/B (Both Shell and tube) are of alloy steel (5 Cr , 0.5 Mo) metallurgy and 4 exchangers HM-1 C/D/E/F (Both Shell and tube) are of CS metallurgy. All the 6 bundles are connected in series. 2 bundles HM-1 A/B of alloy steel are required to address the case of crude mix (NG 55% Wt + Imported HS (Kuwait) 45% Wt) for negotiating high crude/RCO temperature. 3) To improve present preheat attempt can be made in the Unit operation to Close the by around E-309 A/B/C as much as possible and introduce Stripping steam to K1 at prescribed design rate.

AU3


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 405




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

PREHEAT TRAIN DATA AFTER MODIFICATON


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 406




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 407




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 408




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 409




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 410




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 411




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 412




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 413




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Annexure 10 AU3 column and furnaces blind list K1 column Sl N

Blind poisition

Size

o

Blinded on

Deblinded On

Remarks

Sign 1. K1 Vent 2. Ka vapour overhead line

2 16

To be deblinded

3. Top reflux at column top u/s of

4

Blinding to be done after

NRV 4. K6A vap return, at K1 column body 4

water wash Blinding to be done after

flange 5. K6A draw, at K1 column body

water wash 3

flange

Blinding to be done after water wash

K-6B vap return, at K1 column 6. body

4

flange 7. CR-1 return, at K1 column body

3

flange K6B draw, at K1 column body 8. flange

4

9. Feed inlet, at K1 column

14

10. Strip steam to K1

3


Blinding to be done after water wash To be blinded after water wash

Overflash, at K1 column body 11. flange

6*2

Stripping Steamline of 12. K6A

3

Stripping Steamline of 13. K6B

3

14. Steam out

3

To be blinded after water wash

15. K1 Level troll

1.5*2


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 414



16. H41A/B/C suction

16*3

17. Ahuralan injectio

1

18. Ammonia injection

1

19. PSV to flare

8*2

20. PSV by line

2*2

21. Condenser by

2

22. Condenser inlet

10*2


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Size(inch)

No of blinds

Size(inch)

No of blinds

1

2

8

2

1.5

2

10

2

2

5

6

2

3

6

14

1

4

4

16

4

K6A Sl N

Blind poisition

Size

o 1. K6A feed inlet

Blinded on

Deblinded

Sign

On

3

Remarks Blinding to be done after water wash

2. K6A level troll

1.5*2

3. K6A bottom , d/s of b/v

4

Blinding to be done

4. K6A vapour

4

after water wash Blinding to be done

5. Stripping steam , at d/s of

3


NRV

after water wash


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 415




VOL-I: Addendum

Size

No of blinds

1.5

2

3

2

4

2

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

K6B Sl N

Blind poisition

Size

1.

K6B feed inlet

4

2.

K6B level troll

1.5*2

3.

K6B bottom , d/s 4

Blinding to be done after water

4.

of b/v K6B vapour

4

wash Blinding to be done after water

5.

outlet Stripping steam , 3

wash Blinding to be done after water

at d/s of NRV

wash

o

Blinded on

Deblinded

Sign

On

Remarks Blinding to be done after water wash

Siz e

No of blinds

1.5

2

3

4

4

3

K2 column including K3A K3B and K3C Sl No

Blind poisition

Size

1.

K2 Vent

2

2.

PSV

10

3.

K2 vapor lines

12*2

Blinded on Sign

Deblinded On

Remarks To be deblinded


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 416



Top reflux


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

4

Blinding to be done

5.

K3A vap return at column

6


6.

body flange H Naphtha withdraw at

6


7.

column body flange CR2 return at column body

12

8.

flange K3C vap outlet

8

Blinding to be done

9.

Kero withdrawal

14*2


10.

8

11.

K3B vap return at column body flange CR3 return

12.

Disel withdrawal

12*2

after water wash

after water wash Blinding to be done after water wash

8*2 Blinding to be done after water wash

13.

Feed inlet

22

14.

Overflash outlet

6

15.

Overflash inlet

6

16.

Stripping Steamline of K2

3

To be blinded after

17.

Steam out point of K2

3

water wash To be blinded after water wash

18.

Level troll

1.5*2

19.

K2 bottom

12

20.

Ahuralan and ammonia injection

1*4

21.

PSV to flare

10*2

22.

PSV by line

2

23.

Condenser inlet

8*4



Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 417




Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Size

No of blinds

Size

No of blinds

Size

No of blinds

Size

No of blinds

1

4

3

2

10

2

14

2

1.5

2

4

1

8

8

22

1

2

2

6

4

12

6


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 418




VOL-I: Addendum

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

K3A Sl N

Blind poisition

Size

o

Blinded on

Deblinded On

Remarks

Sign 1.

K3a feed inlet

8


2.

K3A level troll

1.5*2

3.

K3A bottom , d/s of b/v

4


4.

K3A vapour outlet

6


5.

Stripping stea3m , at d/s

2

water wash Blinding to be done after

of NRV

water wash

Size

No of blinds

1.5

2

2

1


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 419


1

6

1

8

1



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

K3B

Sl N

Blind poisition

Size

K3B feed inlet

8

o

Blinded on

Deblinded On

Remarks

Sign 1.


2.

K3B level troll

1.5*2

3.

K3B bottom , d/s of b/v

4


4.

K3B vapour outlet

6



Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 420


Stripping stea3m , at d/s



2

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


of NRV

water wash

Size

No of blinds

1.5

2

2

1

4

3

6

1

8

1

12

1

K4 Sl N

Blind poisition

Size

K4 PSV line at column

4

o

Blinded on

Deblinded On

Remarks

Sign 1.

nozzle

2.

K4 overhead line at

8


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 421


3.



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

column nozzle Reflux line , u/s of nozzle 4 at column

4.

K4 feed inlet

6*3

5.

K4 level troll

1.5*2

6.

Reboiler outlet nozzle at 12 column

7.

K4 bottom at d/s of b/v

8.

K4 vent

8 To be deblinded

Size

No of blinds

1.5

2

2

1

4

2

6

3

8

2


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 422




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

BLIND LIST FOR MAN ENTRY IN F1/F2/F3 OF AU3 BLIND LIST FOR MAN ENTRY IN F1 Deblinded


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 423

. Indian Oil Gujarat Refinery Description

Operating Manual for JR AU-III VOL-I: Addendum Size Running

S/D


Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Type

1

F-1 FC3301

6 OUT

IN

SPECT

2

F-1 FC3301 EXIT

6 OUT

IN

SPECT

3

F-1 STEAM HEADER

6 OUT

IN

TAIL

4

FO SUPPLY TO F-1

2 OUT

IN

TAIL

5

FO RETURN EX F-1

2 OUT

IN

SPECT

6

FG TO F-1 F1 SOOT BLOWER LC/IGNTOTOR LC

4 OUT

IN

SPECT

7

blinded on/Sign

on/Sign

BLIND LIST FOR MAN ENTRY IN F2 OF AU3 1

F-2 STEAM HEADER

6 OUT

IN

SPECT

2

FG TO F-2

4 OUT

IN

SPECT

3

FUEL OIL SUPPLY TO F-2

2 OUT

IN

SPECT

4

FUEL OIL RETURN EX F-2

2 OUT

IN

SPECT

5

F2 1 FC3402

6 OUT

IN

SPECT

6

F2 2 FC340

6 OUT

IN

SPECT

7

F2 1 FC3402 EXIT

6 OUT

IN

SPECT

8

F2 2 FC340 EXIT

6 OUT

IN

SPECT


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 424




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

9

N2/ IVATION TO FC3402

2 IN

IN

TAIL

10

N2/ IVATION TO FC3403 F2 SOOT BLOWER /IGNOTOR LC

2 IN

IN

TAIL

11

BLIND LIST FOR MAN ENTRY IN F2 OF AU3 1

STEAM HEADER TO F3

6 OUT

IN

TAIL

2

FUEL GAS TO F3

4 OUT

IN

SPECT

3

FUEL OIL SUPPLY TO F-3

2 OUT

IN

SPECT

4

F3 1 FC3003

6 OUT

IN

TAIL

5

F3 2 FC3005

6 OUT

IN

TAIL

6

F3 1 FC3003 EXIT

6 OUT

IN

TAIL

7

6 OUT

IN

TAIL

8

F3 2 FC3005 EXIT ivation to C/V FC3003& FC3005

1 IN

IN

SPECT

9

N2 to C/V FC3003&FC3005

1 IN

IN

SPECT

10

Fuel oil return Ex F3

11

F3 soot blower and igniter LC


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 425




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 426




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

Annexure 11 Limit for Skin thermocouples in AU3

TAG WISE DETAIL OF SKIN THERMOCOUPLES

Sno. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Tag No. 3TI 3309A 3TI 3309B 3TI3309C 3TI3309D 3TI3309E 3TI3309F 3TI3408A 3TI3408B 3TI3408C 3TI3408D 3TI 3409A 3TI 3409B 3TI3409C 3TI3409D 3TI 3002A 3T I3001 3TI 3003 3TI 3004 3TI 3005 3 TI 3006 3 TI 3008 3 TI 3007 3 TI 3012 3 TI 3011

Description F-01 Skin temperature F-01 Skin temperature F-01 7TH Tube Skin North Side F-01 16th Tube Skin North Side F-01 7th Tube Skin South Side F-01 16th Tube Skin South Side F-02 -I tube Skin F-02 -I tube Skin F-02 23th Tube Skin -I F-02 7th Tube Skin -I F-02 -II tube skin F-02 -II tube skin F-02 23th Tube Skin -II F-02 7th Tube Skin -II F-03 -I tube skin F-03 -I tube skin F-03 -I tube skin F-03 -I tube skin F-03 -I tube skin F-03 -I tube skin F-03 -II tube skin F-03 -II tube skin F-03 -II tube skin F-03 -II tube skin


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Max operating limit 450 450 450 450 450 450 450 450 450 450 450 450 450 450 475 475 475 475 475 475 475 475 475 475 Vol-I (Addendum)

Page 427



Operating Manual for JR AU-III VOL-I: Addendum 3 TI 3010 3 TI 3009

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

F-03 -II tube skin F-03 -II tube skin

475 475

Annexure 12

List of work instructions Following work instructions mentioned in detail in SEQMS manual. Kindly do refer

SEQ / PN

(GR-II) / R / 4.2.4 / 1


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 428


Chapter 6



Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

NORMAL OPERATIONS OF CENTRIFUGAL PUMPS FOR GR-II UNITS

SEQ / PN (GR-II)/WI/7.5.1 / 2

NORMAL OPERATIONS OF HEAT EXCHANGERS FOR GR-II UNITS

Chapter 7 SEQ / PN (GR-II)/WI/7.5.1 / 3

NORMAL OPERATIONS OF COOLERS FOR GR-II UNITS


NORMAL OPERATIONS OF CONDENSERS


NORMAL OPERATION OF RECIPROCATING PUMPS FOR GR-II UNITS


NORMAL OPERATIONS OF IFO/VR PUMPS FOR GR-II UNITS


NORMAL OPERATION OF REFLUX DRUMS FOR GR-II UNITS


NORMAL OPERATION OF FURNACES FOR GR-II UNITS


NORMAL OPERATION OF CHEMICAL/SOLUTION/ WATER/IFO TANKS FOR GR-II UNITS

Chapter 14 SEQ / PN (GR-II)/WI/7.5.1 /


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 429




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

10



Chapter 17 SEQ / PN (GR-II)/WI/7.5.1 / 13 SEQ / PN (GR-II)/WI/7.5.1 / 14

NORMAL ROUTING OF PRODUCTS FOR GR-II UNITS

NORMAL OPERATION OF DESALTER IN AU-III

NORMAL OPERATION OF FRACTIONATING COLUMNS IN AU-III

NORMAL OPERATION OF VR BURNING FACILITY IN AU III


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 430



Chapter 19



Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

QUALITY CONTROL OF AU III PRODUCTS

PREPARATION OF CHEMICAL SOLUTION IN AU-III

SEQ / PN (GR-II)/WI/7.5.1 / 16


Chapter 21

SEQ / PN (GR-

NORMAL OPERATION OF UDEX

NORMAL OPERATION OF FGH

II)/WI/7.5.1 / 18

Chapter 22 SEQ / PN (GR-

NORMAL OPERATION OF MTBE / BUTENE-I

II)/WI/7.5.1 / 19

CHAPTER-23

DRAWINGS


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 431




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 432




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 433




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 434




Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

Vol-I (Addendum)

Page 435




VOL-I: Addendum

1'’

Blinding Scheme for mathballing K6A/K6B

Issue Date

Rev. No.

Rev. Date

1st Sep,2016

0

1st Sep,2016

1'’

10'’ flare line

8'’ 2'’

8'’

2'’

16'’ vent 10'’ 6'’

10'’

2'’

2'’ vent 6'’

6'’

T-7A

T-7B Condensor by

4'’

2'’

B

2'’

2'’

OPEN

Ex new desalter B

4'’

Ex old desalter

B

OPEN

B

K6A

CR-1 to K1 Ex 3FV3211

3'’ 4'’

LPD OPEN

K1

1.5'’

B

Reflux

3'’ stripping steam

1.5'’

OPEN

E-2

OPEN

4'’ 14'’

From E313

6'’ Feed Open

K6B To E313 B

1.5'’

OPEN

6'’

1.5'’ open

1.5'’

Drain

4'’

P301A/B


B 1.5'’

OPEN

B


B

B

3'’ utility steam line

2'’

B

16'’

B

H41A/B/C


Approved By

Issued By

Deepak Kewlani AMPN

Kalyan Sarma NM

Bhaskar Sen SPNM

P305A/B

B

B

B

Vol-I P304A/B/C (Addendum) Blinding for mathballing of K6A/B Date:01-08-2013

Page 436

Document No:

Operating Manual of GR-II Block – AU-III

SEQ/PN(GR)/SI/7.5.1/3

Gujarat Refinery

ATF TO AU4

ATF to JOB50/AU1AU2 ATF to JOB50& OMS TANK

TO LAB FS

To tank 213/214

KERO TO OMS TO LAB FS (B/V OPERATION WITH OMS) TO ATF

ATF to AU4 MEROX

EX PDF SLOP

ATF TO AU4

(B/V OPERATION WITH OMS)

B/V INFRONT OF QC LAB (OPERATED BY OMS)

KERO ex T14A

ATF receiving line Ex Au3 to GRE AU4

TO LAB FS

Kero to RCO 3FV3208 KERO to EURO 3 diesel

LABFS receving line ex au3 to oms

TO DHDT FEED TANK To TK 212

3PC5905R 3PV5903R

To TK 213/214

EX AU1/AU2 DISEL TO GRE

DIESEL TO OMS

Diesel Ex E-315

DIESEL TO AU4 COALESCER

3FC5911R 2115P119A/B

3FC5905R

SALT DRIER

KERO & DIESEL CIRCUIT

TO EURO 3 diesel pool

Document No:



Gujarat Refinery

B/L

Hot RCO EX AU1/AU2/AU3 to FPU1

Towards AU1/AU2 From FCC COB B/L LSHS header Ex AU4 RCO Cold RCO ex AU1/AU2 B/L

B/L

3FV3119(HV) KERO EX T14A

B/V at AU4 712P10A

3FV3114 (LV)

FO Ex JOB 50 to AU4 (3'’) FLO

EX AU1/AU2/AU3 cold RCO To FCC offsite tanks Tk-801/802

To OMS

VB FO to AU3 line LSHS (8'’) LV AU3 R/D to OMS line FO to AU4

To OMS RCO to RUNDOWN

3LV3507

HV grade RCO

3FC3118

To VR vessel

3FI3104

3FV3104

T16 A/B/C/D/E/F

FLO

RCO to VBU(2'’)

CBD pump discharge FLO

3LHV3501

Cold RCO to GRE VBU (B/L)

3FV3117

Hot RCO EX AU1/AU2

12'’ Cold RCO ex AU4 to GHP Cold RCO to GHP 3FV3120 Cold RCO to GHP

3FV3115A Hot RCO to FPU1

FLO

3FC3116 3FV3116 DCU feed tanks Tk1510 and 1511(B/L)

3FC3115A B/L

KERO TO VR

3FV5904 Hot RCO to GHP

TO RUP IFO tanks

3FV3115B HOT RCO TO R/D

H4/H5A

B/L 3FC3115B Hot RCO Ex AU4

RCO R/D

FLO

Page - 438

E103A

E320A/B

HV1001A

T-19A/B

E309A/B/C HM1A/B

HM1C/D

HME/F

3TC040

E103B

HV1001B H42/H11/H11A

E308A/B/C

E302A/B/C

RCO RUNDOWN CIRCUIT

Document No:



Gujarat Refinery

45-VV-004

RCO RUNDOWN IFO return

IFO receiving FLO

45-VV-004

Inst VR SURGE DRUM 45-VV-003

3LV390 FLO

FLO

AU3 RCO to VR

FLO TO F2

TO F1

To Job 50

TO F3

3PV3005

3PV3301

3PV3417

VR receiving

FLO 45P2A/B

E-03A/B

Ex H20/E20A

BPC

F3 c/v

FLO

E-03C/D

FLO

FLO

TO VR drum area

FLO

410H41A/B/C

To E6/E7 VR return line

To E309A/B/C

To E317A/B

IFO supply line

Hot oil return

Hot oil return from udex

VR/IFO CIRCUIT IN AU3

Page - 439

Au3.pdf 2v3iw

Overview 3e4r5l

More details w3441

More Documents from "Amit Singh" x4y3m

Discovery Of India.pdf 1y42t

Locomotive Frame 1s4c6y

Multiple Choice Questions (mcq) With Answers On Industrial Safety - Scholarexpress 2g2a66

Investigatory Project On Ldr 376653

Au3.pdf 2v3iw

Komplett Preisliste Allstar En-de 2017 6g55j