Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
1 of 17
A-100 Start-Up Check List
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
2 of 17
CONTENTS
1. Purpose 2. Scope 3. Responsibility 4. Procedure 5. Records 6. Reference
Revision Date Prepared By Reviewed By Approved By
0 26-10-2009 Al-Hamadani, A.Aziz Abdullah Al-Farsi Abdullah Al-Farsi
Signature
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
3 of 17
1. Purpose 1.1. The purpose of this procedure is to provide a detailed steps in carrying out safely and at shortest time possible for CDU normal start-up
2. Scope 2.1. This procedure covers the Normal Start-up of CDU unit from cold circulation until the products are all on-specification
3. Responsibility 3.1. The Foreman shall be responsible for ensuring that: 3.1.1. 3.1.2. 3.1.3. 3.1.4. 3.1.5. 3.1.6. 3.1.7.
Adequately trained operator coverage is provided The procedures outlined are understood by all concerned and carried out to completion. A copy of this procedure will be placed in the control room and ensure the time is indicated as each step was carried out. All safety regulations are observed at all times. Accurate blind listing is maintained. Be responsible for the periodical review of this work instruction or when process modifications warrant the review, and for recommending appropriate changes. Appropriate actions are done to correct any deviation from the prescribed activities when this event occurs
3.2. The Lead Operator in charge shall be responsible for ensuring that the procedure outlined in this instruction is performed properly in coordination with the Shift Foreman and the Panel Operator. 3.3. The Control Operator and Field Operator are responsible for carrying out their prescribed activities within the safest and shortest time period possible. 3.4. The Shift Supervisor on duty is responsible for coordinating all activities of and interrelated with each Operating Section within the Refinery, and to ensure that all related documents/checklists are accomplished by the operators concerned after the units have been secured. 3.5. The CDU Area Manager and/or CDU Process Engineer are responsible for updating or revising this procedure.
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
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Date/Time
4. Procedures a. Preliminary Start-up checks and activities i. All equipment including instruments,electrical equipments, etc. is ready for use. ii. All utilities are available for all the equipment. iii. Ensure all feeds, products, chemicals and effluents are properly lined up and are ready to supply and receive materials. iv. All blinds or spectacle blinds have been placed in their respective operating positions. v. The line up for start-up has been completed vi. Make sure that all instruments are ready for operation. vii. Close all vents, drains and sample connection. viii. Make sure that all valves are open to level glasses and pressure gauge. ix. Ensure that the Flare is lined up and operable. x. All pumps are ready. xi. Commissioned steam tracing. xii. Leak checked all the equipments. xiii. Control valve stroke check is completed. xiv. PSV auditing is completed.ESD check completed. xv. Check pump freeness,utility connections and oil condition . xvi. Housekeeping of the plant is must before any startup.
Sign
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
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xvii. Readiness of ignitor for lighting the furnace. xviii. All safety equipment required for hydrocarbon entry to the unit must be on site and operable. Check that: 1. Emergency shower and eye wash are ready and operable. 2. All portable fire fighting equipments are in place. 3. The fire hydrant system is in service. 4. Miscellaneous safety equipments are available. 5. The area is reasonably free from obstructions. 6. Necessary warning signs are posted. xix. Utilities – use of instrument/plant air, electrical power, cooling water and potable water have been informed.
xx. Offsite – Ensure use of required slop tanks,offspec tanks and product tanks are ready and can be linedup as and when required,. Offsite operators must keep a constant watch on the tank level in order not to overfill the tank and flare system is ready and operating. 4.1. Preparation for Cold Oil Circulation
Before starting cold oil circulation the following preparations to be done;
4.1.1.
Ensure that all preliminary start-up activities/checks have been completed. Inform all other concerned units ,Area Manager,Shift supervisors about the crude unit start up.
4.1.2.
Ensure that the Crude Oil circulation line up is ready to receive crude oil.
4.1.3.
Advice Offsite personnel to line up mixed crude oil
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
6 of 17
tank (T-6101A-C) to the crude distillation unit.
4.1.4.
Line up tankage and heavy slop line for all products.
4.1.5.
Keep Desalters on-line with the power in OFF position
4.1.6.
Close atmospheric residue line block valves at battery limit to RFCC Unit (V-2101) and to storage (T-6102).
4.2. Cold Oil Circulation
4.2.1.
Line up Crude Oil Charge line at the battery limit in preparation for Crude Oil receiving and line filling.
4.2.2.
Ask Offsite personnel to start the one Crude Charge Pump (P-6101 A/B or C)
4.2.3.
Open FC-001 and FC-002 gradually by keeping a watch on Desalter Pressure and keep the crude oil flow rate at 60% of design (460 m3/hr). Maintain equal flow rate on E-1102 A/B and E-1103.
4.2.4.
Continue filling the system including Desalter A/B (V1101 A / B) to the Pre-Flash Drum (V-1102).
4.2.5.
Set Pre-Flash Drum pressure controller, PC-004 at 2.5 BarG
4.2.6.
When the level in the Pre-Flash Drum reached 60%, start P-1101 A or B.
4.2.7.
Set FC-051 to FC-058 with initial opening of 40% and put in CASCADE with 11-LC-008. Preflash Drum Level Control should be in MANUAL position at this stage.
4.2.8.
When C-1101 bottom level reached 60%, start P-1109 A or B going to the Heavy Slop Tank via FV-31 and FV-32.
4.2.9.
Establish or maintain flow rate for a once through operation for 1 hour and drain condensate from low
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
7 of 17
points.
4.2.10. Start closed loop circulation by opening the isolation valve of the jump over line and closing the slop line isolation valve and the crude charge isolation valve at the Battery Limit simultaneously. 4.2.11. After the circulation has continued for 2 hours, stop the circulation, hold for 30 minutes and drain water from all the lowest points including equipment pump casing other than Cold oil circulation loop. 4.2.12. The circulation will be as follows; E-1101A/B(S) E1102A/B (S) E1103 A/B(S) 1104A/B (S) E1105A/B (S) (V-1101A/B) E1106(T) E-1107 (T) E1108A/B (T) V1102 P1101A/B E1109A/B(S) F1101 C1101 P1109A/B E1109 (T) E1108 (S) E1105 (T) E1116 Start up bypass line E1101A/B (S). 4.3. Hot Oil Circulation 4.3.1.
Purge the furnace with steam and Lightup burners in furnace as per procedure. See attached Furnace Start-up Procedure and Checklist
4.3.2.
Maintain Crude Column Overhead Drum (V-1103) pressure approximately 0.385 barg using the over head pressure control valve (11-V-007A). 11-PCwith 11-PC007 B fully closed on ‘Manual” and 11-PC-007A on “AUTO” control.
NOTE: Start overhead fin fan coolers (E-1116) as required.
4.3.3.
Continue to check and drain water condense at all low points as the unit comes on line.
4.3.4.
Increase the crude heater F-1101 out let temperature at
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
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around 28oC /hr.
4.3.5.
Open Flushing Oil line at P-1108 A/B discharge to establish Bottom Pump Around (BPA) circulation
4.3.6.
Continue increasing the heater outlet temperature to 200oC. The level on the C-1101 bottom will drop due to vaporization while heating up the system.Ensure Hot bolting is done. Open the Mixed Crude Charge valve, and the Heavy Slop Tank at Battery Limit while closing the jump over line for a once-through operation.
4.3.7.
4.4. Crude Column Section Start-up 4.4.1.
Continue gradual increasing of Coil Outlet temperature to 250oC at 30 oC/hr rate.
4.4.2.
Introduce LLP Steam to F-1101 steam coil when 11-TI100 reached 185 oC, and open vent to atmosphere
4.4.3.
At 235 oC, Open the AR line to slop and Open fully the crude charge valve at battery limit. Close the circulation line isolation valve.
4.4.4.
Open all products, Naphtha, Kerosene, and Gas Oil rundown line at the battery limit to HSL.
4.4.5.
When the crude column bottoms temperature reaches 235oC, a small amount of stripping steam can be introduced in to the column.
NOTE: Before admitting stripping steam, make sure the steam is free from condensate At 300°C Hot bolting to be done.
4.4.6.
Continue increasing the Coil Outlet temperature to 340 C at the same 30 oC/hr rate.
o
4.4.7.
Monitor the Crude Column Overhead Receiver (V1103), Kerosene Stripper (C-1102) and Gas Oil Stripper
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
9 of 17
(C-1103) level.
4.4.8.
When hydrocarbon begins to accumulate in the crude column overhead receiver, start cold reflux to C-1101 by starting P-1102A/B
NOTE: All water must be drained from the pump casing before starting the overhead reflux pump.
4.4.9.
Monitor the water boot level of crude column overhead receiver (V-1103) and maintain the level at maximum 50%.
4.4.10. As the atmospheric residue product rate from C-1101 begins to decrease due to lowering of C-1101 bottom level, the crude charge can be increased to maintain the level of Pre-Flash Drum V-1102 and C-1101 bottom. 4.4.11. When level appears in gas oil and kerosene side strippers, start stripping steam, start the gas oil/kerosene product pumps and route rundown to Heavy Slop Tankage. 4.4.12. Line up the gas oil product rundown from the discharge of the gas oil pumps, P-1107A/B through the crude/gas oil heat exchangers with bypass closed, the gas oil rundown cooler E-1115 and through the flow control valve 11-FV-030A/B to the heavy slop header. 4.4.13. Line up from the discharge of the bottom pump around pumps P-1108A/B, through all exchangers and control valve back to the crude column. NOTE: Drain all low point bleeders and pump casing before starting the pump.
4.4.14. Line up middle pumparound pumps P-1106A/B through all exchangers and control valves back to the crude column. Drain all low point bleeds of free water. 4.4.15. Line up the top pumparound pumps P-1104A/B through all exchangers and control valves back to the crude column. Drain all low point bleeds of free water
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
10 of 17
4.4.16. When the Desalter inlet temperature reached 120oC, commission the Desalting water injection and put the power on the Desalter transformer. Start water injection to both Desalter at 5% of the Crude Charge rate. 4.4.17. As the crude heater transfer temperature increased, increase the crude charge to maintain approximately 60% of design atmospheric residue flow rate. When atmospheric residue meets specifications divert atmospheric residue to RFCC unit or RFCC Intermediate tank. 4.4.18. When gas oil meets the specifications, divert gas oil to DHDS unit or storage tank. 4.4.19. When kerosene meets the specifications divert kerosene to kerosene Merox unit or to intermediate storage tank. 4.4.20. The crude column overhead liquid sent to the stabilizer feed surge drum (V1121). The unstabilized naphtha is routed to Stabilizer (C-1121). [Stabilizer Stabilized naphtha to storage ] NOTE: Never route unstabilized naphtha alone to heavy slop.
4.4.21. After establishing reflux streams, the crude outlet temperatures should be increased as required. Continue to make needed adjustments on the side-cut stripper draw off rates and stripping steam injections to produce the desired products with the required unit charge rate. 4.4.22. Start all the required chemical injections to the crude column and desalters such as: 4.4.22.1.Ammonia 4.4.22.2.Corrosion inhibitor 4.4.22.3.Demulsifier. 4.5. Stabilizer Section Start-Up 4.5.1.
When V-1121 level reached 30%, start P-1121 A/B and circulate the bottoms using 11-FC-018 and establish minimum flow rate of 90 m3/hr
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
11 of 17
4.5.2.
Place 11-FC-026 on “CASCADE” control with LC-020 set at 50%
4.5.3.
When C-1121 level at 30%, gradually commission Stabilizer reboiler by opening 11-FC-036
NOTE: Ensure V-MOV-004 is fully opened
4.5.4.
Reset 11-UC-009, when LCV-024 reached 30%, place 11-FC-035 on “CASCADE” control with the 11-LC024 set at 60%.
4.5.5.
Heat up the system and build up pressure via 11-PC011 on Auto with a setting of at 12.9 BarG.
4.5.6.
Ensure 11-PC-011 B isolation valve is opened and lined up to Off Gas system and 11-HC-021 is lined up to Flare
4.5.7.
Increase gradually the Reboiler temperature 11-TI-088 up to 210 oC by increasing 11-FC-036 flow rate.
4.5.8.
Watch V-1122 level, when 11-LC-027 level is at 40%, start P-1122 A/B and establish reflux flow rate to C1121, maintaining top temperature of 70 oC.
NOTE: Ensure 11-MOV-005 is fully open
4.5.9.
Naphtha rundown will be on HSL or Off specification tank and routed to ON specification tank (T-6217 A/B/C when the required specifications was met
4.5.10. V-1122 excess level will go to C-1122 via P-1124 A/B
4.6. Deethanizer Section Start-Up Establish level in Deethanizer and route LPG to off spec tank. Start heating up Deethanizer reboiler (E-1129) gradually by increasing the LLP steam flow. When Deethanizer pressure starts to rise, increase it gradually up to 30.7 BarG and increase Reeboiler temperature, 11-TI097 gradually When level appears in the Deethanizer Overhead Receiver (V-1123)
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
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start top reflux, by starting P-1123 A/B. maintaining C-1122 top temperature of 45 oC. When the specification of LPG is met bottom product can be sent to CDU LPG Merox Unit.
4.7. Special Precautions The special precautions at the start-up are as follows:
4.7.1.
All start-up operation of heater should be performed by means of manual control until the heater is in normal and stable operation.
4.7.2.
Check no leakage of any fluid periodically during heating up
4.7.3.
Excess air normal conditions
4.7.4.
An online oxygen analyzer AI-001 is provided on the heater to check the fire-box atmosphere. And the firebox atmosphere is also checked by manual sampling with using portable vacuum pump through sampling points periodically.
5. Records 5.1. Start-Up Checklist
6. Reference 6.1. Circulation Loop Mark-Up Drawing 6.2. P&ID
See attached drawing for proper line-up
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist
Cold Oil Circulation
Doc. No.
OP-511-11014
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1
Date
1-NOV 2009
Page
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Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist
Hot Oil Circulation
Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
14 of 17
Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist
Crude Column Section Start-up
Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
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Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist
Stabilizer Start-up line-up
Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
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Procedure Title: Operation Procedures: A-100 Normal Start-up-Checklist
Deethanizer Line-up
Doc. No.
OP-511-11014
Rev.
1
Date
1-NOV 2009
Page
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